JP7235755B2 - Process for making articles of manufacture - Google Patents

Description

The present invention relates to a process, e.g., a continuous process, for making articles of manufacture comprising fibrous structures, and more particularly to fabricating fibrous structures, such as soluble fibrous structures, including soluble filaments, e.g., water-soluble filaments. Processes for making articles of manufacture comprising:

Processes for making fibrous structures, eg, soluble fibrous structures, and/or components thereof, such as soluble filaments, are known in the art. Additionally, the fibrous structure and/or components thereof have ultimately been incorporated into consumer products, such as product articles such as fabric care products, hair care products, dental care products, and the like. However, such known processes to date have been discontinuous. In other words, such known processes involve at least two or more discrete (discontinuous) steps or unit operations that interrupt the process of making an article of manufacture, e.g. , has one or more steps of making released and/or discrete fiber structures from one or more steps of conversion into a consumer product. Such discontinuous/discontinuous processes include the following steps: 1) a filament-forming composition making step, such as a batch process for making the filament-forming composition; and 2) spinning the filament-forming composition to produce filaments. 3) optionally a mixing (coforming) step to mix solid additives, e.g. particles with the filaments; 4) filaments and/or mixed filaments; a recovery step to recover the solid additive to form a fibrous structure, e.g., a soluble fibrous structure; (e.g., slitting and/or lamination and/or calendering and/or processing with minor ingredients such as perfumes, enzymes, bleaching agents, flavoring agents, blowing agents, die cutting, and printing). 6) and optionally a packaging step for packaging the article of manufacture.

One problem faced by formulators is how to make such articles of manufacture containing fibrous structures, such as soluble fibrous structures, in a continuous or more continuous than known discontinuous process. In other words, one problem faced by formulators is how to combine multiple process steps from the above into a continuous process such that they are not discrete discontinuous process steps.

Accordingly, there is a need for a process for making articles of manufacture, eg, consumer products, comprising fibrous structures, eg, soluble fibrous structures, in a continuous or at least partially continuous process.

The present invention provides a continuous process and/or continuous process step within a process for making an article of manufacture, e.g., a fibrous structure, e.g., a soluble fibrous structure, including a fibrous structure, e.g., a consumer product. , fulfills the needs described above.

One solution to the problems identified above is to implement a process for making articles of manufacture, e.g., consumer products, comprising fibrous structures, e.g., soluble fibrous structures, in a continuous or more continuous process. to provide. Such a continuous process comprises at least the steps of: 1) a filament-forming composition-making step to make a filament-forming composition; and 2) spinning the filament-forming composition to make filaments, e.g., soluble filaments. 3) optionally a mixing (coforming) step to mix solid additives, e.g. particles, with the filaments; and 4) recovering the filaments and/or mixed filaments and solid additives. , a recovery step to form a fibrous structure, e.g., a soluble fibrous structure, and, if present, steps (1-4) make a filament-forming composition to convert the filament-forming composition into filaments. (optionally mixing the solid additive with the filament), collecting the filament (and/or the mixed filament and solid additive) in a collection device, and forming a fibrous structure, any interruptions or One after the other without interruption or interruption, in a continuous fashion, which can then be converted into an article of manufacture and finally packaged, for example, in consumer packaging. The continuous process includes 5) converting operations (converting the fibrous structure into one or more articles of manufacture, e.g., consumer products (e.g., slitting and/or lamination and/or calendering and/or fragrance, enzyme, bleaching, etc.). 6) optionally, a packaging step for packaging the article of manufacture; can further include

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

In one embodiment of the invention, a process for making a fibrous structure comprises:
a. providing one or more soluble filament-forming materials;
b. forming an aqueous composition comprising one or more soluble filament-forming materials;
c. processing the aqueous composition to produce a filament-forming composition;
d. delivering a filament-forming composition to one or more dies;
e. spinning a filament-forming composition to form a plurality of soluble filaments;
f. collecting the soluble filaments on a collection device to form a fibrous structure. In one embodiment, one or more activators may be added to the process in at least one of steps b, c and d.

1 is a schematic diagram of an embodiment of a process according to the invention; FIG. 1 is a schematic diagram of an example of a process according to the invention; FIG. 1 is a schematic diagram of an example of an extruder screw suitable for use in the process according to the invention; FIG. 1 is a schematic diagram of an embodiment of part of a process according to the invention; FIG. 1 is a top plan view of a die suitable for use in the process of the present invention; FIG. 1 is a schematic diagram of an embodiment of part of a process according to the invention; FIG. 1 is a schematic diagram of an example of a recovery zone on a recovery device suitable for use in a process according to the invention; FIG.

DEFINITIONS As used herein, "fibrous structure" means a structure comprising one or more filaments and optionally one or more particles. In one embodiment, a fibrous structure according to the invention means a combination of filaments and optionally particles together forming a structure, such as a monolithic structure, capable of performing a function.

The fibrous structure of the present invention may be a single layer or multiple layers. When multi-layered, the fibrous structure comprises at least 2, and/or at least 3, and/or at least 4, and/or at least 5, and/or at least 6, such as one or more filaments. It may include one or more composite structures having layers, one or more particle layers, and/or one or more mixed layers of filaments and particles. The layers may include particulate layers within the fibrous structure or between filament layers within the fibrous structure. A layer containing filaments may sometimes be referred to as a ply. A ply, as described herein, may be a fibrous structure that may be a single layer or multiple layers. In one example, the layer may be formed by a single spinning die and/or particle delivery source, or in the case of a composite structure layer, by a single spinning die and particle delivery source.

In one embodiment, the fibrous structure of the present invention may comprise single or multiple layers, at least one of which must comprise fibers. Layers may include additives (eg, pastes or sprays) applied to the fibers and/or particles co-mixed with the fibers within the composite structure.

In one embodiment, a single-ply fibrous structure according to the present invention, or a multi-ply fibrous structure comprising one or more fibrous structure plies according to the present invention, is measured according to the basis weight test method described herein. When made, it can exhibit a basis weight of less than 5000 g/m ² . In one embodiment, a single-ply or multi-ply fibrous structure according to the present invention has a weight of greater than 10 g/m ² to about 5000 g/m ² , and/or greater than 10 g/m ² to about 3000 g/m ² , and/or greater than 10 g/m ² to about 2000 g/m ² , and/or greater than 10 g/m ² to about 1000 g/m ² , and/or greater than 20 g/m ² to about 800 g/m ² , and/or greater than 30 g/m ² to about 600 g/m ² , and/or greater than 50 g/m ² to about 500 g/m ² , and/or greater than 300 g/m ² to about 3000 g/m ² , and/or 500 g /m ² to about 2000 g/m ² .

In one example, a single ply comprising a multi-layer fibrous structure comprises a plurality of filaments present at a basis weight of from about 10 to about 200 gsm, and/or from about 30 to about 100 gsm, and/or from about 50 to about 75 gsm. A plurality of filaments present in a first layer, such as a scrim layer, and a second layer, for example, at a basis weight of from about 400 to about 3000 gsm, and/or from about 600 to about 1500 gsm, and/or from about 800 to about 1200 gsm. alone or as a composite structure layer containing filaments and solid additives, such as particles.

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

As used herein, an "integral fibrous structure" means two or more and/or three fibrous structures that are intertwined or otherwise bonded together to form a fibrous structure and/or fibrous structure plies. An arrangement that includes more than one filament. A unitary fibrous structure of the present invention can be one or more plies in a multi-ply fibrous structure. In one embodiment, the monolithic fibrous structure of the present invention can include three or more different filaments. In another example, the monolithic fibrous structure of the present invention may comprise two or more different filaments.

As used herein, "article" includes a consumer unit, consumer unit dose unit, consumer salable unit, single dose unit, or monolithic fibrous structure and/or Refers to other forms of use involving one or more fibrous structures of the invention.

As used herein, "fibrous element" means an elongated particle having a length that greatly exceeds its average diameter, ie, a ratio of length to average diameter of at least about 10. The fibrous elements can be filaments or fibers. In one embodiment, the fiber element is a single filament rather than a yarn comprising multiple filaments.

The fiber elements of the present invention can be spun from fiber element-forming compositions, also referred to as filament-forming compositions, via suitable spinning process operations such as meltblowing, spunbonding, electrospinning, and/or rotary spinning. .

The fibrous elements of the present invention can be monocomponent (a single unitary solid piece rather than two different parts such as a core/sheath bicomponent) and/or multicomponent. For example, the fibrous element may comprise bicomponent fibers and/or filaments. The bicomponent fibers and/or filaments can be of any form such as side-by-side, sheath-core, islands-in-the-sea type.

As used herein, a "filament" is 5.08 cm (2 inches) or greater, and/or 7.62 cm (3 inches) or greater, and/or 10.16 cm (4 inches) or greater, and/or 15 Elongated particles as described above exhibiting a length of 0.24 cm (6 inches) or greater.

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

As used herein, a "fiber" is less than 5.08 cm (2 inches) and/or less than 3.81 cm (1.5 inches) and/or less than 2.54 cm (1 inch) in length means an elongated particle as described above that exhibits a

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

In one example, one or more fibers can be formed from the filaments of the present invention, such as when the filaments are cut into shorter lengths (such as lengths less than 5.08 cm). Thus, in one embodiment, the invention also includes fibers made from filaments of the invention, such as fibers comprising one or more filament-forming materials and one or more fiber additives, such as active agents. Accordingly, references herein to filaments of the present invention also include fibers made from such filaments, unless otherwise specified. Fibers are typically considered to be discontinuous in nature, whereas filaments are typically considered to be continuous in nature.

As used herein, "fibrous element-forming composition" and/or "filament-forming composition" means a composition suitable for making the filaments of the present invention, such as meltblowing and/or spunbonding. do. A filament-forming composition comprises one or more filament-forming materials, which exhibit properties that make them suitable for spinning into filaments. In one example, the filament-forming material comprises a polymer. In addition to one or more filament-forming materials, the filament-forming composition may include one or more fiber additives, such as one or more active agents. Additionally, the filament-forming composition may comprise one or more polar solvents, such as water, in which one or more, such as all filament-forming materials and/or one or more, such as all The active agent is dissolved and/or dispersed prior to spinning filaments, such as filaments derived from the filament-forming composition.

In one embodiment, filaments made from the filament-forming compositions of the present invention have one or more fiber additives, e.g., one or more active agents, that are the same as the active agents in the filaments and/or particles. may be present within the filament rather than on the filament, such as a coating composition comprising one or more active agents which may be different or may be different. The total concentration of filament-forming materials, and the total concentration of active agents present in the filament-forming composition, can be any suitable amount so long as the filaments of the present invention can be produced therefrom.

In one example, one or more fiber additives, such as active agents, may be present in the filaments, and one or more additional fiber additives, such as active agents, are present on the surface of the filaments. good too. In other examples, the filaments of the present invention may include one or more fiber additives, such as active agents, which are originally present in the filament when made but are Blooms on the surface of the filament prior to and/or upon exposure to the intended service conditions.

As used herein, "fibrous element-forming material" and/or "filament-forming material" are polymers that exhibit properties suitable for making filaments, or monomers, etc., capable of producing such polymers. means the material of In one example, the filament-forming material comprises one or more substituted polymers, such as anionic, cationic, zwitterionic and/or nonionic polymers. In another example, the polymer is a hydroxyl polymer such as polyvinyl alcohol (“PVOH”), partially hydrolyzed polyvinyl acetate, and/or starch and/or starch derivatives such as ethoxylated starch and/or acid diluted starch. polysaccharides, carboxymethylcellulose, hydroxypropylcellulose, hydroxyethylcellulose, and methylcellulose. In another example, the polymer can include polyethylene and/or terephthalate. In yet another embodiment, the filament forming material is a polar solvent soluble material.

As used herein, "particles" means solid excipients such as powders, granules, agglomerates, encapsulations, microcapsules, and/or prills. The shape of the particles can be spherical, rod-like, dish-like, tubular, square, rectangular, disk-like, star-like, fiber-like, and can have regular or irregular random shapes. Particles of the invention, at least those particles of at least 44 μm, can be measured by the particle size distribution test method described herein. For particles less than 44 μm, a different test method, e.g. Capsules can be determined.

In one aspect, the particles may comprise a recycled fibrous structural material, in particular, the fibrous material is obtained by grinding fibers into finely divided solids, and converting the finely divided solids into agglomerates, granules, or other particles. Recycled by reincorporating into form. In another aspect, the particles may comprise recycled fibrous structural material, specifically, the fibrous material is incorporated into a fluid paste, suspension, or solution and then processed to form agglomerates. , granules, or other particle morphology. In another aspect, the fluid paste, suspension, or solution containing regenerated fibrous material may be applied directly to the fibrous layer in the process of making a new fibrous article.

As used herein, "active agent-containing particles" means solid additives, eg, particles, containing one or more active agents. In one example, the active agent-containing particles are active agents in the form of particles (in other words, the particles contain 100% active agent). The active agent-containing particles can exhibit a particle size of 5000 μm or less when measured according to the Particle Size Distribution Test Method described herein.

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

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

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

In another example, the fibrous structure of the present invention has a weight of greater than 1 g/ ^m2 , and/or greater than 10 g/ ^m2 , and/or 20 g/m2, as measured according to the Basis Weight Test Method described herein. more than 30 g/m ² and/or more than 40 g ^/ m ² and/or from about 1 g/m ² to about 5000 g/m ² and/or to about 3500 g/m ² and/or or up to about 2000 g/m ² , and/or from about 1 g/m ² to about 2000 g/m ² , and/or from about 10 g/m ² to about 1000 g/m ² , and/or from about 10 g/m ² to about 500 g/m 2 . basis weight of m ² , and/or from about 20 g/m ² to about 400 g/m ² , and/or from about 30 g/m ² to about 300 g/m ² , and/or from about 40 g/m ² to about 200 g/m ² includes a plurality of particles, eg, active agent-containing particles.

In another example, the fibrous structure of the present invention has a weight of greater than 1 g/ ^m2 , and/or greater than 10 g/ ^m2 , and/or 20 g/m2, as measured according to the Basis Weight Test Method described herein. more than 30 g/ ^{m 2 and} /or more than 40 g/m ² and/or from about 1 g/m ² to about 3000 g/m ² and/or from about 10 g/m ² to about 5000 g/m ² and/or about 3000 g/m ² and/or about 2000 g/m ² and/or about 20 g/m ² to about 2000 g/m ² and/or about 30 g/m ² to about 1000 g/m ² and/or or about 30 g/m ² to about 500 g/m ² , and/or about 30 g/m ² to about 300 g/m 2 , and/or about 40 g/m ² to about 100 g/ ^{m 2 ,} and/or about 40 g/m ² to about 80 g/m ² basis weight, comprising a plurality of filaments. In one example, the fibrous structure includes two or more layers, and filaments are present in at least one of the layers at a basis weight of from about 1 g/m ² to about 500 g/m ² .

As used herein, "mixed" and/or "mixed" means the state or form in which particles are mixed with fibrous elements, eg, filaments. The mixture of filaments and particles may be throughout the composite structure or within a plane or region of the composite structure. In one example, the mixed filaments and particles can form at least the surface of the composite structure. In one example, the particles may be uniformly distributed throughout the composite structure and/or planes and/or regions of the composite structure. In one example, the particles may be evenly distributed throughout the composite structure, thereby preventing sag and/or free movement and/or movement of the particles within the composite structure to other regions within the composite structure. Avoid and/or prevent, thus resulting in zones of higher concentration of particles and zones of lower or zero concentration of particles within the composite structure. In one example, a μCT cross-section of a composite structure can indicate whether the particles are evenly distributed throughout the composite structure.

As used herein, "fiber additive" means any material present in the filaments of the present invention that is not a filament-forming material. In one example, the fiber additive includes an active agent. In another example, the fiber additive comprises a processing aid. In yet another embodiment, the fiber additive comprises a filler. In one embodiment, the fiber additive includes any material present in the filament that does not result in the filament losing its filament structure due to the material not being present in the filament. not, in other words, the absence of the material does not result in the filament losing its solid form. In another example, the fiber additive, eg, active agent, comprises a non-polymeric material.

In another example, fiber additives may include plasticizers for filaments. Non-limiting examples of suitable plasticizers for the present invention include polyols, copolyols, polycarboxylic acids, polyesters, and dimethicone copolyols. Examples of useful polyols include glycerin, diglycerin, propylene glycol, ethylene glycol, butylene glycol, pentylene glycol, cyclohexanedimethanol, hexanediol, 2,2,4-trimethylpentane-1,3-diol, polyethylene glycol. (200-600), pentaerythritol, sugar alcohols such as sorbitol, mannitol, lactitol, and other monohydric and polyhydric low molecular weight alcohols (such as C2-C8 alcohols); monosaccharides, disaccharides, and oligosaccharides such as , fructose, glucose, sucrose, maltose, lactose, high fructose corn syrup solids, and dextrin, and ascorbic acid.

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

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

In yet another embodiment, the fiber additive is added when the filament is exposed to the intended use conditions and/or when the active agent is released from the filament and/or when the filament changes morphology. , may include one or more colors and/or dyes incorporated within the filaments of the present invention to provide a visual signal.

In yet another example, the fiber additive can include one or more release agents and/or lubricants. Non-limiting examples of suitable release agents and/or lubricants include fatty acids, fatty acid salts, fatty alcohols, fatty esters, sulfonated fatty acid esters, fatty amine acetates, fatty amides, silicones, aminosilicones, Fluoropolymers, and mixtures thereof. In one embodiment, the release agent and/or lubricant may be applied to the filaments, in other words, after the filaments are formed. In one example, one or more release agents/lubricants may be applied to the filaments prior to collecting the filaments with a collection device to form a fibrous structure. In another embodiment, one or more release agents/lubricants are applied to a fibrous structure formed from filaments of the present invention prior to contacting one or more fibrous structures, such as a stack of fibrous structures. may apply. In yet another example, to facilitate filament and/or fibrous structure removal and/or to prevent plies of filament and/or fibrous structures of the present invention from sticking together and even unintentionally. In addition, the filaments and/or fibrous structures containing filaments of the present invention are subjected to one or more mold releases before the filaments and/or fibrous structures contact a surface, such as a surface of equipment used in a processing system. Agents/lubricants may be applied. In one example, the release agent/lubricant includes particulates.

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

As used herein, "intended conditions of use" means that the filaments, and/or particles, and/or fibrous structures of the present invention are used under one of the purposes for which the filaments and/or fibrous structures are designed. means the temperature, physical, chemical, and/or mechanical conditions to which it is subjected in use for one or more purposes. For example, if the filaments and/or particles and/or fibrous structures containing filaments are designed to be used in laundry machines for laundry care purposes, the intended conditions of use are: The temperature, chemical, physical and/or mechanical conditions present in the washing machine, including any wash water in the washing machine. In another example, when the filaments and/or particles and/or fibrous structures comprising filaments are designed to be used by humans as a shampoo for hair care purposes, the intended conditions of use are , includes thermal, chemical, physical and/or mechanical conditions present in shampooing human hair. Similarly, when the filaments and/or particles and/or fibrous structures containing filaments are designed for use in hand or dishwasher warewashing operations, the intended conditions of use are Including temperature, chemical, physical and/or mechanical conditions present in the dishwashing water and/or dishwasher during the washing operation.

As used herein, "active agent" refers to the intended use of filaments and/or particles and/or fibrous structures comprising filaments and/or particles and/or filaments. means a fiber additive that produces its intended effect in the environment outside of the filaments and/or particles and/or fibrous structure containing the filaments of the present invention, such as when exposed to conditions. In one embodiment, the active agent is used on hard surfaces (i.e. kitchen counters, bathtubs, toilets, urinals, sinks, floors, walls, teeth, cars, windows, mirrors, dishes) and/or soft surfaces (i.e. fabrics, hair). , skin, carpets, crops, plants) and other surface-treating textile additives. In another embodiment, the active agent undergoes a chemical reaction (i.e., foaming, foaming, effervescing, coloring, warming, cooling, foaming, disinfecting, and/or purifying, and/or chlorinating, For example, added fiber additives to create purified water and/or disinfected water and/or chlorinated water). In yet another embodiment, the active agents include textile additives that treat the environment (ie, deodorize, purify, or perfume the air). In one example, the active agent is formed in situ, such as during the formation of filaments and/or particles comprising the active agent, e.g. It may include water-soluble polymers (eg, starch) and surfactants (eg, anionic surfactants) that can form polymer complexes or coacervates that function as agents.

"Treat", as used herein with respect to treating a surface, means that the active agent provides a benefit to the surface or environment. Treatments include modulating and/or immediately improving the appearance, cleanliness, odor, purity, and/or feel of a surface or environment. In one embodiment, treating with respect to treating a keratinous tissue (eg, skin and/or hair) surface means modulating and/or improving the cosmetic appearance and/or feel of keratinous tissue. For example, "regulating the condition of the skin, hair, or nails (keratinous tissue)" includes thickening of the skin, hair, or nails (e.g., skin, hair, or nail thickening to reduce skin, hair, or nail atrophy). structure of the epidermis and/or dermis and/or subcutaneous (e.g. subcutaneous fat or muscle) layers and, where applicable, the stratum corneum of the nail and hair shaft), dermal-epidermal boundary (also as interpapillae) loss of skin or hair elasticity (loss, damage, and/or inactivation of functional dermal elastin), such as increased torsion, elastosis, sagging, loss of recovery from skin or hair deformation prevention of dark circles under the eyes, blemishes (such as uneven redness due to rosacea) (hereinafter referred to as "red spots"), poor complexion (pale color), telangiectasias or spider vessels and prevention of melanotic or non-melanotic changes in skin, hair, or nail color, such as discoloration caused by dermatitis, and gray hair. Treatments may provide benefits to fabrics during washing or softening in a washing machine, to provide benefits to hair during shampooing, conditioning, or coloring hair, or to benefits environments such as toilet bowls by cleaning or disinfecting. may include providing

In another example, the treatment is to remove stains and/or odors from fabric articles (e.g., clothing, towels, linens) and/or hard surfaces (e.g., counters and/or tableware such as pots and pans). means.

As used herein, "fabric care active" means an active that, when applied to fabrics, provides benefits and/or improvements to the fabrics. Non-limiting examples of benefits and/or improvements to fabrics include cleaning (e.g., by surfactants), stain removal, stain reduction, wrinkle removal, color restoration, static control, wrinkle resistance, permanent pressing, abrasion reduction, Abrasion resistance, anti-pilling, anti-pilling, soil removal, soil resistance (including soil release), shape retention, shrinkage reduction, softness, fragrance, antibacterial, antiviral, deodorant, and odor removal.

As used herein, "dishwashing active" means when applied to dishware, glassware, pots, pans, kitchen utensils, and/or cooking sheets, a dishwashing, glassware, plastic article, deep It means an active agent that provides benefits and/or improvements to the pot, pan, and/or cookie sheet. Non-limiting examples of benefits and/or improvements to tableware, glassware, plastic articles, pots, pans, kitchen utensils, and/or cooking sheets include food and/or stain removal, cleaning (e.g., interfacial active agents) stain removal, stain reduction, grease removal, water stain removal and/or water stain prevention, glass and metal care, sanitization, shine, and polishing.

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

As used herein, "keratinous tissue active agent" means an active agent that may be useful in treating keratinous tissue (eg, hair, skin, or nails) conditions. In the case of hair care actives, "treating" or "treatment" or "treat" means modulating the cosmetic appearance and/or feel of keratinous tissue and/or Including immediate improvement. For example, "regulation of skin, hair, or nail condition" includes thickening of the skin, hair, or nails (e.g., skin epidermis and/or dermis) to reduce atrophy of the skin, hair, or nails. and/or construction of the subcutaneous (e.g., subcutaneous fat or muscle) layer and, where applicable, the stratum corneum of the nail and hair shaft), rotation of the dermal-epidermal junction (also known as the interpapillae). Prevention of loss of skin or hair elasticity (loss, damage and/or deactivation of functional dermal elastin), such as increase, elastosis, sagging, loss of recovery from skin or hair deformation, under the eyes dark circles, blemishes (e.g. uneven redness due to rosacea, etc.) (hereinafter referred to as "red spots"), pale complexion (pale color), discoloration caused by telangiectasias or spider vessels; and prevention of melanotic or non-melanotic changes in skin, hair, or nail color, such as gray hair. Another example of a keratinous tissue active agent can be an active agent used to shampoo, condition, or dye hair.

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

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

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

As used herein, "weight average molecular weight" refers to Colloids and Surfaces A.M. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. Means weight average molecular weight determined using gel permeation chromatography according to the protocol found in 107-121.

As used herein with respect to a filament, "length" means the length along the longest axis of the filament from one end to the other end. If the filament has a twist, curl or bend in it, the length is the length along the entire path of the filament from one end to the other end.

As used herein with respect to filaments, "diameter" is measured according to the Diameter Test Method described herein. In one embodiment, the filaments of the present invention have a and/or exhibit a diameter of less than 10 μm, and/or less than 6 μm, and/or more than 1 μm, and/or more than 3 μm.

As used herein, a "triggering condition," in one embodiment, functions as a stimulus to change (e.g., filamentary and / or as an action or event that initiates or causes a loss or change in the physical structure of the fiber structure and/or release of fiber additives, such as active agents, therefrom. In another example, the triggering condition may be present in an environment such as water when the filaments and/or particles and/or fibrous structures of the present invention are added to the water. In other words, nothing changes in the water except for the fact that the filaments and/or fibrous structures of the invention are added to the water.

As used herein with respect to morphological change of filaments and/or particles, "morphological change" means that the filament undergoes a change in its physical structure. Non-limiting examples of morphological changes in filaments and/or particles of the present invention include dissolving, melting, swelling, contracting, crushing, rupturing, lengthening, shortening, and combinations thereof. The filaments and/or particles of the present invention may completely or substantially lose their physical structure, or may have their physical structure altered, when exposed to the conditions of intended use. or may retain or substantially retain the physical structure of their filaments or particles.

"Weight on a dry filament basis" and/or "Weight on a dry particle basis" and/or "Weight on a dry fibrous structure basis" refer to filaments and/or particles and/or fibrous structures. Filaments and/or particles and/or fibers respectively measured immediately after the weight has been conditioned for 2 hours in a conditioned room at a temperature of 23°C ± 1.0°C and a relative humidity of 50% ± 10% respectively Means the weight of the structure. In one example, the weight on a dry filament basis and/or a dry particle basis and/or a dry fibrous structure is the weight of filaments and/or particles when measured by the Moisture Content Test Method described herein. and/or the fibrous structure is less than 20 wt%, and/or less than 15 wt%, and/or less than 10 wt%, based on the dry weight of the filaments and/or particles and/or fibrous structure; and/or less than 7% by weight, and/or less than 5% by weight, and/or less than 3% by weight, and/or 0% by weight, and/or more than 0% by weight of moisture, such as water, e.g., free water. means to contain

For example, when used herein in reference to the total concentration of one or more active agents present in a filament and/or particle and/or fibrous structure, "total concentration" refers to the material of interest, e.g. means the sum of all weights or weight percentages of In other words, the filaments and/or particles and/or fibrous structures are such that the total concentration of active agents present in the filaments and/or particles and/or fibrous structures is 50% by weight, i.e. dry 25% by weight on a dry filament basis and/or dry particle basis and/or dry fibrous structure basis to be greater than 55% on a filament basis and/or dry particle basis and/or dry fibrous structure basis of anionic surfactant and 15% by weight on dry filament basis and/or dry particle basis and/or dry fibrous structure basis nonionic surfactant and dry filament basis and/or dry particle basis and/or 10% by weight of dry fibrous structure chelating agent and 5% by weight of dry filament basis and/or dry particle basis and/or dry fibrous structure perfume.

As used herein, a "fibrous structure product" is a solid product that includes one or more actives (e.g., fabric care actives, dishwashing actives, hard surface actives, and combinations thereof). It refers to a form (eg, a rectangular solid sometimes referred to as a sheet). In one embodiment, the fibrous structure product of the present invention comprises one or more surfactants, one or more enzymes (such as in the form of granular enzymes and/or liquid enzymes), one or more fragrances, and/or one Contains one or more antifoam agents.

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

In another embodiment, the fibrous structure product of the present invention includes builders and/or chelating agents. In another embodiment, the fibrous structure product of the present invention includes bleaching agents (such as encapsulated bleaching agents).

As used herein, "different morphology" or "different" refers to materials such as filament-forming materials within filaments as a whole and/or filaments within filaments and/or active agents within filaments. one material, such as the forming material and/or the active agent, is chemically, physically, and/or structurally different from another material, such as the filament and/or the filament-forming material and/or the active agent means For example, a filament-forming material in filament form is different than the same filament-forming material in fiber form. Similarly, starch polymers are different from cellulose polymers. However, different molecular weights of the same substance, such as different molecular weight starches, are not different substances from each other for the purposes of the present invention.

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

As used herein with respect to filaments and/or particles, "Associate", "Associated", "Association" and/or "Associating" "" means to combine filaments and/or particles by either direct or indirect contact such that a fibrous structure is formed. In one example, the filaments and/or particles to be bonded may be adhered together by, for example, an adhesive and/or thermal bond. In another example, the filaments and/or particles can be bonded together by being deposited on the same fibrous structure that makes up the belt and/or the patterned belt.

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

As used herein, "cross-machine direction" or "CD" means the direction that is perpendicular to the machine direction on the same plane of the fibrous structure and/or fibrous structure product containing the fibrous structure. .

As used herein, "ply" or "multi-ply" refers to individual fibrous structures arbitrarily arranged in a substantially continuous face-to-face relationship with other plies to form a multi-ply fibrous structure. means body. It is also contemplated that a single fiber structure can effectively form two "plies" or multiple "plies", eg, by folding onto itself. A ply may include layers of filaments, filament/particle blends, and/or particles. In another embodiment, there may be layers of filaments or particles between the plies.

As used herein, the articles "a" and "an" as used herein, e.g., "an anionic surfactant" or "a fiber," refer to the or one or more of the materials described.

All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.

Unless otherwise specified, all ingredient or composition concentrations are for the active concentration of that ingredient or composition and exclude impurities that may be present in the commercial source, such as residual solvents or by-products. be done.

Process for Making Articles of Manufacture In one embodiment of the present invention, as shown in FIG. The process 10 for forming comprises at least the following steps: 1) one or more steps for making the filament-forming composition 18 which is later sent to the next operation, i.e. the spinning operation 20, for example via a pipe; 2) spinning the filament-forming composition, e.g., filament-forming composition 18 produced in filament-forming composition-making operation 16, to make filaments 22, e.g., soluble filaments; 3) a mixing operation, optionally comprising one or more steps of mixing, e.g. co-forming, a plurality of solid additives, e.g. particles 26, with the filaments 22; 24, and 4) collect filaments 22 and/or mixed filaments 22 and solid additives, e.g. a recovery operation 28 comprising one or more recovery steps to form, e.g., a fibrous structure 14 comprising particles 26, e.g., a soluble fibrous structure; From making the forming composition 18, the filament-forming composition 18 is spun into filaments 22 (optionally, solid additives such as particles 26 are mixed with the filaments 22), and the filaments 22 (and/or or any interruption or stoppage or interruption in the process of recovering the mixed filaments 22 and solid additives, e.g. It is done in a continuous fashion, one after the other.

Once the fibrous structure 14 is formed, the fibrous structure 14 is then sold, consumable via a conversion operation 30 that includes one or more steps for converting the fibrous structure 14 into an article of manufacture 12. One or more of the conversion steps may be continuous with the previous operations (1-4) of process 10. Once the fibrous structure 14 is converted into an article of manufacture 12 comprising the fibrous structure 14, e.g., one or more, two or more, three or more, four or more, five or more plies of the fibrous structure 14, Articles of manufacture 12 may be packaged via packaging operation 36 into packages 32 that include external packaging materials 34 such as packaging films, cardboard boxes, and the like.

In one embodiment, the articles of manufacture and/or process steps of the invention, such as spinning operations, coforming operations, recovery operations, converting operations, and packaging operations, independently from about 20% to about 75%, and/or at a relative humidity of from about 30% to about 65%, and/or from about 35% to about 60%.

Conversion operation 30 converts fibrous structure 14 into one or more articles of manufacture 12, e.g., consumer products (e.g., slitting and/or lamination and/or calendering and/or fragrance, enzyme, bleach , flavoring agents, foaming agents, etc. (such as adding optional ingredients to the fibrous structure 14, e.g., the surface of the fibrous structure 14), die-cutting, as well as printing). and 6) optionally, one or more steps for packaging one or more articles of manufacture 12, e.g., consumer products such as soluble consumer products, into package 32. Operation 36 may be included.

In one embodiment, conversion operations include, for example, die cutting to desired shapes, printing, optional ingredients (minor ingredients) to maximize the number of manufactured articles produced from a fibrous structure or multiple desired shapes. may include rolling up the fibrous structure on rolls as a converting line step, including when all of this is done in a single process or single converting line. For example, the process of the present invention is selected from the group consisting of slitting, laminating, calendering, treating with optional ingredients, die cutting, printing, packaging, mechanical ply bonding, chemical ply bonding, and/or combinations thereof. may include one or more transformation operations and/or steps performed. In one embodiment, one or more or all of these converting operations and/or steps are performed in a single converting line, which is a fiber structure production line (e.g. spinning/mixing/recovery operations). and can be directly linked to filament-forming composition-making operations. In one embodiment, as discussed herein, the entire process from filament-forming composition operations to conversion operations and, optionally, packaging operations to make articles of manufacture according to the present invention can be performed in a single It can be performed on one production line, for example a single continuous production line. The conversion operation can ultimately result in salable units that can be used by consumers.

In one embodiment, the process is such that the fibrous structure, e.g., composite structure, formed in the recovery operation is processed on a single manufacturing line, e.g., any single-ply, multi-ply, or single-ply or multi-ply article. Slitting, lamination, and lamination into consumer-usable salable units on a surface, on a single production line, e.g., single-ply, multi-ply, or any surface of a single-ply or multi-ply article. as further converted using converting operations and/or processes selected from calendering, treatment with optional ingredients, die cutting, printing, packaging, mechanical plywood, chemical plywood, and/or combinations thereof It's a process.

a. Filament-forming composition preparation operation (16)
As shown in FIG. 2, in one embodiment, the filament-forming composition 18 is added with one or more filament-forming materials 38, such as one or more soluble filament-forming materials, such as water or another polar solvent. are made by providing one or more hydroxyl polymers, such as polyvinyl alcohol, resulting in an aqueous or polar solvent composition comprising a water-soluble filament-forming material and water or a polar solvent. The aqueous or polar solvent composition is then processed, e.g., polymer processed, in an extruder to form filament-forming composition 18, which is then processed into a plurality of filaments 22 in spinning operation 20. Suitable for sending to above die. In one example, the aqueous or polar solvent composition may be processed in a batch tank (not shown).

In one embodiment, filament-forming material 38 is sufficiently cooked to form a homogeneous aqueous or polar solvent composition of filament-forming material 38 .

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

In one embodiment, filament-forming material 38 is greater than 40%, and/or greater than 50%, and/or greater than 60%, and/or from about 60% to about 80%, and/or from about 60% to about 70% may be added at a solids concentration of

In one example, filament-forming material 38 is greater than 5%, and/or greater than 10%, and/or greater than 13%, and/or less than 50%, and/or less than 40%, and/or less than 30%, and/or may be present at levels of less than 25%.

In one example, the filament-forming material 38 is greater than 10%, and/or greater than 20%, and/or greater than 30%, and/or less than 90%, and/or less than 80%, and/or less than 70%, and/or may be present in the extruder at levels of less than 65%.

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

When the filament-forming material 38 is in solid form, the solid filament-forming material, e.g., one or more hydroxyl polymers such as polyvinyl alcohol, is extruded from a hopper 44, e.g., in a continuous process, into an extruder 42, e.g., a single screw extruder. or a twin-screw extruder, for example a Coperion ZSK 26 twin-screw extruder (maximum speed 1200 rpm, maximum torque per helical axis 106 Nm, screw diameter 25.5 mm, screw length 900 mm, number of barrel sections 9, each zone Heating and cooling, screw height 4.55 mm, estimated throughput 20-60 kg/hr), etc. are added to the twin screw extruder. In this embodiment, the addition of solid filament-forming material to extruder 42 occurs in zone 1 of extruder 42, as shown in FIG. The purpose of adding filament-forming material 38 to extruder 42 is to achieve hydration of filament-forming material 38 and to solubilize filament-forming material 38, particularly when it is originally in solid form.

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

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

In one embodiment, filament-forming material 38 includes polyvinyl alcohol.

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

extruder 42 may be at least about 5, and/or at least about 10, and/or at least about 15, and/or at least about 20, and/or at least about 40, at least about 80, and/or from about 5 to about 200; and/or to exhibit a wet throughput of about 80 to about 135 kg/hr, and in one example a complete filamentation material flow rate of about 100 to about 700 kg/hr, and/or about 345 to about 575 kg/hr. , at least about 2, and/or at least about 4, and/or at least about 6, and/or at least about 10, and/or at least about 15, and/or at least about 20, and/or from about 2 to about 120, and Dry throughput of about 10 to about 85, and/or about 20 to about 85 kg/hr, and/or about 50 to about 85 kg/hr, less than about 1600 rpm, and/or less than about 1400 rpm, and/or less than about 1200 rpm and/or a maximum screw speed of about 200 to about 1600 rpm, and/or about 400 to about 1400 rpm, and/or about 600 to about 1200 rpm, about 20 to about 95%, and/or about 30 to about 85%, and/ or about 40 to about 70% solids % (filament-forming material 38), and an exit pressure of about 10 to about 80, and/or about 15 to about 75, and/or about 20 to about 65 bar set points. , the filament-forming composition has an SME (solids minutes throughput basis), and the extruder is allowed to bring the filament-forming composition to a temperature of at least 49° C. at an exemplary barrel temperature of the extruder performed as shown in Table 1 below. expose.

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

In one embodiment, the surfactant and/or surfactant blend comprises one or more anionic surfactants selected from the group consisting of linear alkylbenzene sulfonates (LAS), alkyl sulfates (AS) and mixtures thereof. containing agents. Surfactants may be blended or co-neutralized with sodium hydroxide to form a low water content paste. In addition, other surfactants such as alkyl ethoxylate sulfates (AES), co-surfactants such as amine oxides, linear alcohol ethoxylates, glucamide surfactants, and alkyl chain branching such as MLAS and HSAS. letter version.

In one example, in addition to one or more surfactants, a structuring agent such as polyethylene oxide such as PEO 100K and/or PEO N60K and/or polyvinylpyrrolidone is mixed with the surfactant to improve phase stability. can provide. Optionally, other ingredients may also be mixed with salts, for example surfactants such as sodium sulfate.

In one embodiment, the filament-forming composition 18, and thus at least one filament 22 produced from spinning the filament-forming composition 18, is a filament 22 with one or more active agents 48 present within the filament 22. In some cases, one or more active agents 48 are included.

In one embodiment, active agent 48 is selected from the group consisting of anionic surfactants, cationic surfactants, nonionic surfactants, zwitterionic surfactants, amphoteric surfactants and mixtures thereof. containing surfactants.

In one embodiment, one or more actives 48 include fabric care actives, dishwashing actives, carpet care actives, surface care actives, air care actives, oral care actives (e.g., tooth cleaners, tooth whitening agents, tooth care agents, periodontal gum care agents, mouth rinses, denture cleansers, tongue cleansers, breath fresheners, fluoride agents, mouth rinses, anti-caries agents, fragrances), hair care actives agents (shampoos and/or conditioners), keratinous tissue care agents, toilet bowl cleaners, skin care actives and mixtures thereof.

In one embodiment, at least one of active agents 48 includes one or more blowing agents.

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

Filament-Forming Material A filament-forming material is any suitable material, such as a polymer or a monomer from which such a polymer can be made, that exhibits properties suitable for making fibrous elements, such as by a spinning process.

In one example, the filament-forming material can include polar solvent soluble materials, such as alcohol soluble materials and/or water soluble materials.

In another example, the filament forming material may comprise a non-polar solvent soluble material.

In yet another example, the filament-forming material comprises polar solvent soluble materials and may be free of non-polar solvent soluble materials (less than 5% by weight, based on dry fibrous elements and/or dry soluble fibrous structures, and/or less than 3 wt%, and/or less than 1 wt%, and/or 0 wt%).

In yet another example, the filament-forming material can be a film-forming material. In yet another example, the filament-forming material can be synthetic or naturally derived, and the material can be chemically, enzymatically, and/or physically modified.

In yet another embodiment of the present invention, the filament-forming material includes polymers derived from acrylic monomers such as ethylenically unsaturated carboxylic acid monomers and ethylenically unsaturated monomers, polyvinyl alcohols, polyacrylates, polymethacrylates, acrylic acid and It may include polymers selected from the group consisting of copolymers of methyl acrylate, polyvinylpyrrolidone, polyalkylene oxides, starch and starch derivatives, pullulan, gelatin, hydroxypropylmethylcellulose, methylcellulose, and carboxymethylcellulose.

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

In another example, the filament-forming material is pullulan, hydroxypropylmethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, methylcellulose, polyvinylpyrrolidone, carboxymethylcellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum, acacia gum, gum arabic, polyacrylic acid. , methyl methacrylate copolymer, carboxyvinyl polymer, dextrin, pectin, chitin, levan, erucinan, collagen, gelatin, zein, gluten, soy protein, casein, polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, protein, chitosan, chitosan polymers selected from the group consisting of derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethylcellulose and mixtures thereof.

Polar Solvent Soluble Materials Non-limiting examples of polar solvent soluble materials include polar solvent soluble polymers. Polar solvent soluble polymers may be of synthetic or natural origin and may be chemically and/or physically modified. In one example, the polar solvent soluble polymer has at least 10,000 g/mol, and/or at least 20,000 g/mol, and/or at least 40 g/mol, as determined according to the weight average molecular weight test method described herein. ,000 g/mol, and/or at least 80,000 g/mol, and/or at least 100,000 g/mol, and/or at least 1,000,000 g/mol, and/or at least 3,000,000 g/mol, and /or a weight of at least 10,000,000 g/mol, and/or at least 20,000,000 g/mol, and/or up to about 40,000,000 g/mol, and/or up to about 30,000,000 g/mol It exhibits an average molecular weight.

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

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

In one embodiment, water-soluble hydroxyl polymers of the present invention comprise polysaccharides.

As used herein, "polysaccharide" means natural polysaccharides and polysaccharide derivatives and/or modified polysaccharides. Suitable water-soluble polysaccharides include, but are not limited to, starches, starch derivatives, chitosans, chitosan derivatives, cellulose derivatives, hemicelluloses, hemicellulose derivatives, gums, arabinans, galactans, and mixtures thereof. The water-soluble polysaccharide is from about 10,000 to about 40,000,000 g/mol, and/or greater than 100,000 g/mol, and/or It can exhibit a weight average molecular weight of greater than 1,000,000 g/mol, and/or greater than 3,000,000 g/mol, and/or greater than 3,000,000 to about 40,000,000 g/mol.

The water-soluble polysaccharides may include non-cellulose, and/or non-cellulose derivatives, and/or non-cellulose copolymer water-soluble polysaccharides. Such non-cellulose water-soluble polysaccharides may be selected from the group consisting of starches, starch derivatives, chitosans, chitosan derivatives, hemicelluloses, hemicellulose derivatives, gums, arabinans, galactans, and mixtures thereof.

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

The water-soluble hydroxyl polymer is from about 10,000 g/mol to about 40,000,000 g/mol, and/or greater than 100,000 g/mol, and /or having a weight average molecular weight of greater than 1,000,000 g/mol, and/or greater than 3,000,000 g/mol, and/or greater than 3,000,000 g/mol to about 40,000,000 g/mol obtain. Higher and lower molecular weight water-soluble hydroxyl polymers may be used in combination with a hydroxyl polymer having a particular desired weight average molecular weight.

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

Naturally occurring starch is generally a mixture of linear amylose of D-glucose units and branched amylopectin polymers. Amylose is a substantially linear polymer of D-glucose units joined by (1,4)-α-D bonds. Amylopectin is a highly branched polymer of D-glucose units linked by (1,4)-α-D and (1,6)-α-D bonds at the branch points. Naturally occurring starches such as cornstarch (64-80% amylopectin), waxy maize (93-100% amylopectin), rice (83-84% amylopectin), potato (about 78% amylopectin), and wheat ( 73-83% amylopectin) typically contain relatively high concentrations of amylopectin. Although all starches are potentially useful herein, the present invention most generally focuses on agricultural resources that take advantage of being abundantly available, easily replenishable, and inexpensive. with a high amylopectin native starch derived from

As used herein, "starch" includes any naturally occurring unmodified starch, modified starch, synthetic starch and mixtures thereof, as well as mixtures of amylose or amylopectin fractions; modified by biological processes, or biological processes, or a combination thereof. The choice of unmodified or modified starch for the present invention may depend on the desired end product. In one embodiment of the present invention, the starch or starch mixture useful in the present invention comprises from about 20% to about 100%, more typically from about 40% to about 90%, by weight of the starch or mixture thereof; typically have an amylopectin content of about 60% to about 85% by weight.

Suitable naturally occurring starches include corn starch, potato starch, sweet potato starch, wheat starch, sago starch, tapioca starch, rice starch, soybean starch, arrowroot starch, amioca starch, bracken starch, lotus starch, Non-limiting examples include waxy corn starch, and high amylose corn starch. Naturally occurring starches, particularly corn starch and wheat starch, are preferred starch polymers due to their economics and availability.

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

In one embodiment, the water soluble hydroxyl polymer is selected from the group consisting of polyvinyl alcohol, hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose and mixtures thereof. Non-limiting examples of suitable polyvinyl alcohols include those commercially available under the trade name CELVOL® from Sekisui Specialty Chemicals America, LLC (Dallas, Tex.). Non-limiting examples of suitable hydroxypropylmethylcellulose include those commercially available under the trade name METHOCEL® from The Dow Chemical Company (Midland, Mich.), including combinations with hydroxypropylmethylcellulose as described above. .

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

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

Water-soluble thermoplastic polymers may include biodegradable polymers.

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

Non-Polar Solvent Soluble Materials Non-limiting examples of non-polar solvent soluble materials include non-polar solvent soluble polymers. Non-limiting examples of suitable non-polar solvent soluble materials include cellulose, chitin, chitin derivatives, polyolefins, polyesters, copolymers thereof, and mixtures thereof. Non-limiting examples of polyolefins include polypropylene, polyethylene, and mixtures thereof. Non-limiting examples of polyesters include polyethylene terephthalate.

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

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

Active Agent An active agent is anything other than the fibrous elements and/or particles and/or soluble fiber structures themselves, such as, for example, providing a benefit to the environment external to the fibrous elements and/or particles and/or soluble fiber structures. A class of fiber additives designed and intended to provide benefits to The active agent can be any suitable fiber additive that produces the intended effect under the conditions of intended use of the fiber element. For example, the active agent may be selected from the group consisting of: personal cleansing and/or conditioning agents such as hair care agents (e.g. shampoos and/or hair dyes), hair conditioning agents, skin care agents, sunscreens. and skin conditioning agents; laundry care and/or conditioning agents such as fabric care agents, fabric conditioning agents, fabric softeners, fabric anti-wrinkle agents, fabric care antistatic agents, fabric care stain removers, soil release agents. , dispersants, foam control agents, foam boosters, defoamers and fabric refreshing agents; liquid and/or powder dishwashing agents (for hand and/or automatic dishwashing), hard surface care agents and/or conditioning agents. agents and/or abrasives; other cleaning and/or conditioning agents such as antimicrobial agents, antibacterial agents, antifungal agents, fabric toning agents, fragrances, bleaching agents (e.g. oxygen bleach, hydrogen peroxide, percarbonate salt bleaches, perborate bleaches, chlorine bleaches), bleach activators, chelating agents, builders, lotions, brighteners, air care agents, carpet care agents, anti-migration agents, clay stain removers, Anti-redeposition agents, polymer soil release agents, polymer dispersants, alkoxylated polyamine polymers, alkoxylated polycarboxylate polymers, amphiphilic graft copolymers, solubilizers, buffer systems, water softeners, water hardeners, pH adjusters , enzymes, flocculants, foaming agents, preservatives, cosmetics, make-up removers, foaming agents, deposition aids, coacervate formers, clays, thickeners, latexes, silica, desiccants, odor control agents, inhibitors sweating agents, cooling agents, warming agents, absorbent gels, anti-inflammatory agents, dyes, pigments, acids and bases; liquid treatment actives; agricultural actives; industrial actives; Pharmaceutical agents, tooth whitening agents, tooth care agents, mouthwashes, periodontal gum care agents, edible agents, edible agents, vitamins, minerals; water treatment agents such as water clarifiers and/or disinfectants, and these a mixture of

Non-limiting examples of suitable cosmetics, skin care agents, skin conditioning agents, hair care agents, and hair conditioning agents can be found in the CTFA Cosmetic Ingredient Handbook, Second Edition, The Cosmetic, Toiletries, and Fragrance Association, Inc. 1988, 1992.

One or more classes of chemicals may be useful for one or more of the active agents listed above. For example, surfactants may be used for any number of the above active agents. Similarly, bleaching agents may be used for fabric care, hard surface cleaning, dishwashing, and even dental whitening. Accordingly, those skilled in the art will appreciate that the active agent is selected based on the desired and intended use of the fibrous elements and/or particles and/or soluble fibrous structures made therefrom.

For example, when the fibrous elements and/or particles and/or the soluble fibrous structures made therefrom are used for hair care and/or conditioning, the fibrous elements and/or particles and/or the fibrous elements and/or particles are incorporated. One or more suitable surfactants, such as lathering surfactants, can be selected to provide the desired consumer benefit when the soluble fibrous structure is exposed to the intended conditions of use. can.

In one example, if the fibrous elements and/or particles and/or soluble fibrous structures made therefrom are designed or intended for use in laundering clothes in a laundering operation, the fibrous elements and/or particles , and/or one or more suitable surfactants to provide the desired consumer benefit when the soluble fibrous structure in which the fibrous elements and/or particles are incorporated is exposed to the intended conditions of use. , and/or enzymes, and/or builders, and/or fragrances, and/or antifoaming agents, and/or bleaching agents. In another embodiment, the fibrous elements and/or particles and/or soluble fibrous structures made therefrom are designed or intended for use in washing clothes in laundering operations and/or cleaning dishes in dishwashing operations. If so, the fibrous elements and/or particles and/or soluble fibrous structures may comprise laundry detergent compositions or dishwashing detergent compositions or active agents used in such compositions. In yet another embodiment, if the fibrous elements and/or particles and/or soluble fibrous structures made therefrom are designed for use in cleaning and/or sanitizing toilet bowls, the fibrous elements and/or Or the particles and/or soluble fibrous structures made therefrom may comprise toilet bowl cleaning compositions and/or foaming compositions and/or active agents used in such compositions.

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

In one embodiment, at least one of the active agents is a skin treatment agent, drug, lotion, fabric care agent, dishwashing agent, carpet care agent, surface care agent, hair care agent, air care agent, and mixtures thereof. selected from the group consisting of

The filament forming composition 18 is then passed to the spinning operation 20 via a pipe and/or a pump 46 such as a booster pump through a static mixer 50 such as a jacketed or unjacketed and/or pumped SMX mixer. can be mixed via Filament-forming composition 18 produced from filament-forming composition-making operation 16 may be delivered to one or more dies and/or one or more beams of dies via one or more pumps 46 . Prior to delivery to spinning operation 20 , the rheology of filament-forming composition 18 is measured off-line or on-line, for example, using on-line rheometer 52 , to measure rheology of filament-forming composition 18 through spinning operation 20 . It can be ensured that it is suitable for spinning into filaments 22 .

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

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

Filament formation and/or attenuation requires a delicate balance of forces to succeed. First, filament-forming composition 18 must form stable filaments 20 as it exits the die. If the viscosity of the filament-forming composition 18 is too high, complete damping cannot be achieved. If the viscosity of filament-forming composition 18 is too low, filaments 20 will break under damping forces. In addition, stabilization follows after the filament 20 has decayed to a diameter of approximately 20um. The stabilization process can be accomplished in several ways, most notably drying and/or crystallization. The rheological properties of filaments 20 as they transition from liquid (filament-forming composition 18) to solid (filaments 20) are of paramount importance in the successful spinning of filaments. In one example, the filament-forming composition 18 of the present invention exhibits a capillary number greater than 1, and/or greater than 2, and/or greater than 3, and/or greater than 4, and/or greater than 5. In the fiber element spinning process, the fiber element should have initial stability as it exits the spinning die. In one embodiment, the filament-forming composition 18 has at least 1 to about 50, and/or at least 3 to about 50, and/or /or exhibits a capillary number of at least 5 to about 30.

The capillary number is a dimensionless number used to characterize this droplet breakup probability. A higher capillary number indicates higher fluid stability upon exiting the die. The capillary number is defined as follows.

Ｖは、ダイ出口における流体速度であり（時間当たりの長さの単位）、
ηは、ダイの条件における流体粘度（長さ×時間当たりの質量の単位）であり、
σは、流体の表面張力（時間の二乗当たりの質量の単位）である。速度、粘度、及び表面張力が一連の一貫した単位で表されるとき、得られる毛管数は、それ自体の単位を有しないことになる。個別単位は打ち消すことになる。

V is the fluid velocity at the die exit (in units of length per time);
η is the fluid viscosity (in units of length times mass per time) at the die conditions,
σ is the surface tension of the fluid (units of mass per square of time). When velocity, viscosity, and surface tension are expressed in a consistent set of units, the resulting capillary number will not have units of its own. Individual units will cancel out.

The capillary number is defined for conditions at the exit of the die. Fluid velocity is the average velocity of the fluid through the holes of the die. Average velocity is defined as follows:

Ｖｏｌ’＝体積流量（時間当たりの長さの三乗の単位）であり、
Ａｒｅａ＝ダイ出口の断面積（長さの二乗の単位）である。

Vol' = volumetric flow rate (units of length cubed per time),
Area = the cross-sectional area of the die exit (in units of length squared).

If the die holes are circular holes, the fluid velocity can be defined as follows:

Ｒは、円形の穴の半径（長さの単位）である。

R is the radius (in units of length) of the circular hole.

The shear viscosity of filament-forming composition 18 is from about 0.1 Pa-s to about 50 Pa-s, and/or from about 0.3 Pa-s to about 40 Pa-s at 3000 s ⁻¹ over the operating temperature range of spinning operation 20 . , and/or can range from about 0.5 Pa-s to about 35 Pa-s. The extensional viscosity of the filament-forming composition 18 is from about 50 Pa-s to about 200 Pa-s at a strain rate of 700 s ⁻¹ as measured by an e-VROC device from RheoSense (San Ramon, Calif.) or equivalent, and/or from about 60 Pa-s to about 180 Pa-s, and/or from about 70 Pa-s to about 150 Pa-s, and/or from about 75 Pa-s to about 125 Pa-s, and/or from about 75 Pa-s to about 100 Pa-s s. The ratio of pressures P23/P14 on SSEVR should be greater than 0.8 and/or greater than 0.9 and/or greater than 1.

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

In one embodiment, the non-volatile component of the filament-forming composition is from about 20%, and/or from about 30%, and/or from 40%, and/or by weight based on the total weight of the filament-forming composition. It may comprise from 45% and/or from 50% to about 75% and/or up to 80% and/or up to 85% and/or up to 90%. The non-volatile component may consist of filament-forming compositions such as backbone polymers, active agents, and combinations thereof. Non-volatile components of the filament-forming composition can comprise the remaining percentage and range from 10% to 80% by weight based on the total weight of the filament-forming composition.

Successful fiber spinning of complex mixtures such as molten fatty alcohols or aqueous surfactant solutions requires the addition of polymeric components commonly referred to as structurants. The purpose of the structurant is to increase the shear and extensional viscosities to enable fiber formation. Structuring agents are generally high molecular weight species, usually in the range of 100,000 to 6,000,000 g/mol. However, the balance between concentration and molecular weight is often a trade-off, such that using lower molecular weight species requires higher levels to function properly. Similarly, when higher molecular species are used, higher levels can be used to enable fiber spinning. An important aspect of the structurant is its solubility in the spin fluid to allow viscosity increase for fiber formation. The structurants polyvinylpyrrolidone and polyethylene oxide have been found to be two such polymers that meet the solubility criteria in the spin fluid and can be produced at high molecular weights.

b. spinning operation (20)
A filament 22 of the present invention comprising one or more filament-forming materials 18 and optionally one or more active agents 48 present within the filament 22 can be made as shown in FIGS. . As shown in FIGS. 4 and 5, a spinning operation 20 for making filaments 22 from a filament-forming composition 18 in a continuous process according to the present invention comprises:
a. providing filament-forming composition 18 delivered from filament-forming composition making operation 16 to spinning operation 20, wherein filament-forming composition 18 comprises one or more filament-forming materials 38 and, optionally, comprising one or more active agents 48 and/or one or more polar solvents (such as water), and optionally one or more inhibitors;
b. one or more filament-forming materials 38, and optionally spinning the filament-forming composition 18 into one or more filaments 22 comprising one or more activators 48 and one or more inhibitors.

In one example, spinning further includes providing a filament-forming composition comprising one or more filament-forming materials to one or more dies, such as one or more spinning dies 54 .

The filament-forming composition 18 is used at temperatures of from about 20° C. to about 100° C., and/or from about 30° C. to about 90° C., and/or from about 35° C. to about 70° C. when making the filaments 22 from the filament-forming composition 18. , and/or can be processed (spun) from the spinning die 54 at a temperature of about 40°C to about 60°C.

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

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

In one example, the process spins a plurality of filaments from a first die, e.g., a first spinning die, and then separates the mixed filaments and solid additives, e.g. The step of collecting the first filament on a collecting device prior to collecting on the second filament may further include collecting the first filament on the collecting device.

the total concentration of the one or more filament-forming materials present in the fibrous element 10, if active agents are present therein, is less than 80% by weight, based on the dry fibrous element and/or the dry soluble fibrous structure; and and/or may be less than 70% by weight, and/or less than 65% by weight, and/or no more than 50% by weight, the total concentration of one or more active agents, when present in the fiber element, based on the dry fiber element. and/or may be greater than 20 wt%, and/or greater than 35 wt%, and/or 50 wt% or more, 65 wt% or more, and/or 80 wt% or more, based on the dry soluble fibrous structure.

4 and 5, the spinning die 54 passes a fluid, such as air, through it as it exits the filament-forming holes 32 to attenuate the filament-forming composition 22 into the fiber elements 10. may include a plurality of filament formation holes including melt capillaries 34 surrounded by concentric damping fluid holes 36 that promote

In one embodiment, the spinning die 54 shown in FIG. 5 includes two or more circular extrusion nozzles (filament forming holes 60) spaced from each other with a pitch P of about 0.060 inch. has columns. The nozzles have individual inner diameters of about 0.012 inches and individual outer diameters of about 0.032 inches. Each individual nozzle includes a melt capillary 62 surrounded by an annular and diverging flared orifice (concentric damping fluid hole 64) for supplying damping air to each individual melt capillary 62. As shown in FIG. Filament-forming composition 18 extruded through the extrusion nozzle (filament-forming holes 60 ) is surrounded and dampened by a generally cylindrical stream of moist air fed through the orifice to produce filaments 22 .

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

The initial filament 22 has a temperature of about 149° C. (about 300° F.) to about 315° C. (about 600° F.) by an electrical resistance heater and/or gas burner (direct or indirect) (not shown) and dried. It is dried by a stream of drying air fed through the nozzle and exiting at an angle of about 90° to the overall orientation of the initial filaments 22 being spun. The dried filaments 22 may be applied to a belt or fabric, in one embodiment, a pattern, e.g., a non-random repeating pattern, to the fibrous structure 14, such as a soluble fibrous structure formed as a result of collecting the filaments 22 on the belt or fabric. can be collected on a collection device 58 such as a belt or fabric that can be applied to the The addition of a vacuum source 66 directly below the forming zone 68 , which is the area of the collecting device 58 where the filaments 22 contact the collecting device 58 , can be used to aid in the collection of the filaments 22 on the collecting device 58 . Spinning and collecting the filaments 22 produces a fibrous structure 14 comprising entangled filaments, eg, a soluble fibrous structure.

In one embodiment, the collection device 58 and the fiber structure 14 carried on the collection device 58 are free to move under the spinning enclosure 70 and the filaments 22 pass from the spinning die 54 to the collection device 58 . Spinning enclosure 70, which is a housing that at least partially encloses, and in one embodiment fully encloses, the extent to which it is spun. The spinning enclosure 70 at least partially controls the environment in which the filaments 22 are exposed down the spinline from the spinning die 54 to the collection device 58 .

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

In one embodiment, the filaments 22 are spun from one die, such as one spinning die 54, such as a multi-row capillary die.

In one embodiment, two or more different filaments 22 are spun from at least one die, eg, one spinning die 54 (same spinning die 54).

In one embodiment, filaments 22 are spun from two or more dies, such as two or more spinning dies 54 .

In one embodiment, the process of the present invention may include two or more spinning operations 20. In one embodiment, first spinning operation 20 mixes to produce fiber structure 14 on recovery device 58, which can be the same recovery device 58 from which filaments 22 from second spinning operation 20 are recovered. Via operation 24, spinning filaments 22 from a filament-forming composition 18 comprising one or more filament-forming materials 38 with or without an active agent 48 and without the inclusion of solid additives, e.g., particles 26. include. A second spinning operation 20 downstream of the first spinning operation 20 applies solids, with or without an active agent 48 , to the fibrous structure 14 formed by the first spinning operation 20 via a mixing operation 24 . Spinning filaments 22 from a filament-forming composition 18 comprising one or more filament-forming materials 38 with the inclusion of additives such as particles 26 .

filament 22 produced from filament-forming composition 18 having a total concentration of filament-forming material 38 of about 5% to 100% or less by weight in filament 22, on a dry filament basis and/or dry soluble fibrous structure basis; Filament-forming composition 18 may include any suitable total concentration of active agents 48, on a dry filament basis and/or dry soluble fibrous structure basis, from 0% to about 95% by weight in filaments 22. A concentration of filament-forming material 38 and any suitable concentration of active agent 48 may be included.

c. Mixing operation (24)
In one example, as shown in FIG. 6, particles 26 may be added to filaments 22 spun from one die, for example, spinning die 54, within spinning enclosure 70. FIG. Addition of particles 26 may be accomplished during formation of filaments 22 and/or after collection of filaments 22 at collection device 58 . Particles 26 may be added to fibrous structure 14 and/or filaments 22 from particle source 72 . Particles 26 may be added such that particles 26 are collected on surfaces of collection device 58 within spinning enclosure 70 . Collection device 58 may be operable within forming zone 68 , which may be inside spinning enclosure 70 . A spinning enclosure 70 may be positioned above the collection device 58 and may encompass the forming zone 68 on the collection device 58 .

Addition of particles 26 may result in such particles 26 becoming entrapped and/or entrapped within filaments 22 and/or fibrous structures 14 collected on collection device 58 .

A particle source 72, eg, a feeder, suitable for supplying a stream of particles is positioned directly above the dry area of the fibrous element, as shown in FIG. In this case, for example, vibrating feeders from Retsch® (Haan, Germany) are used. To aid in consistent distribution of the particles in the transverse direction, the particles are fed into trays (not shown) starting at the width of the particle source 72 and ending at the same width as the face of the spinning die 54 to produce the particles 26 . is delivered to all areas of filament 22 formation. The tray is completely enclosed except for the exit to minimize disruption of the particle feed.

In one embodiment, a split particle source, or two or more separate particle sources capable of delivering two or more different (e.g., different types, compositions, sizes, properties, etc.) particles are obtained. The fibrous structure may contain different zones and/or regions containing different particles, thereby resulting in a final layered fibrous structure having different particles in each layer after the initially formed fibrous structure is slit and laminated. can be used as a source of particles in mixing operations so that

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

Particles 26 may be spun between spinning die 54 and recovery device 58 at any angle so long as at least a portion of particles 26 contact filaments 22 in forming zone 68, as shown in FIGS. It can be introduced into enclosure 70 . As shown in FIG. 6, if the introduction of particles 26 into the stream of filaments 22 is not regulated, resulting in particles 26 contacting filaments 22 within forming zone 68, the particles will follow particle trajectory line A in FIG. Downstream of the forming zone 68 as shown (a point in the process closer to the finished article of manufacture and/or the packaged article of manufacture relative to the reference point, e.g., if the reference point is a spinning or recovery operation, the downstream is and/or upstream of forming zone 68 as indicated by particle trajectory line B in FIG. It may lead to a point in the process further from the article of manufacture 32, for example, if the reference point is a spinning or recovery operation, upstream may mean, for example, the filament-forming composition making operation 16).

In one embodiment, solid additive, eg, particles 26 , contact filaments 22 (“upstream filaments”) on the upstream side of spinning enclosure 70 .

In another embodiment, solid additive, eg, particles 26 , contact filaments 22 downstream of spinning enclosure 70 (“downstream of filaments”).

In another embodiment, solid additives, eg, particles 26, contact filaments 22 on both the upstream and downstream sides of spinning enclosure 70 (“upstream and downstream filaments”).

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

The solid additive, e.g., particles 26, is at least about 0° but not more than about 90°, and/or at least about 10° but not more than about 90°, and/or at least about 20° but not more than about 90°. and/or greater than or equal to about 30° but less than or equal to about 90°, and/or a contact angle of at least about 40° but less than about 90° (the contact angle is the direction of flow of the filaments flowing in and out of the spinning die 54). ), and/or with a contact angle of at least about 45° but less than about 90°.

Solid additives, eg, particles 26, are less than 40.0%, and/or less than 30.0%, and/or 25.0%, and/or less than 30.0%, as measured according to the CD and MD Basis Weight Variation Test Methods described herein. Less than 0%, and/or less than 20.0%, and/or less than 15.0%, and/or less than 10.0%, and/or less than 5.0%, and/or about 0% overall MD basis It can be dispersed throughout the fibrous structure 14 with an amount variation RSD%.

Solid additives, eg, particles 26, are less than 40.0%, and/or less than 30.0%, and/or 25.0%, and/or less than 30.0%, as measured according to the CD and MD Basis Weight Variation Test Methods described herein. Less than 0%, and/or less than 20.0%, and/or less than 15.0%, and/or less than 10.0%, and/or less than 5.0%, and/or about 0% overall CD tsubo It can be dispersed throughout the fibrous structure 14 with an amount variation RSD%.

solid additive, e.g., particles 26 greater than 1 m/s, and/or at least 2 m/s, and/or at least 2.5 m/s, and/or less than 10 m/s, and/or less than 8 m/s, and /or may contact the filament at a speed of 6 m/sec or less, and/or from about 1 m/sec to about 20 m/sec.

Solid additives, e.g., particles 26, are greater than 40%, and/or at least 42%, and/or at least 45%, and/or at least 50%, as measured according to the Content Efficiency Test Method described herein. , and/or at least 54%, and/or at least 65%, and/or at least 75%, and/or at least 85%, and/or at least 90%, and/or at least 95%, and/or at least 98% It can be mixed with filaments 22 for solid additive loading efficiency (eg, particle loading efficiency).

In one embodiment, the step of mixing includes mixing the solid additive, e.g., particles 26 into a plurality of filaments 22, e.g., soluble filaments, between at least one of the dies, e.g., spinning die 54, and collection device 58. Including introducing. In one embodiment, solid additive, eg, particles 26 , is introduced proximally by spinning die 54 than at least one die, eg, recovery device 58 . In another embodiment, solid additive, eg, particles 26 , is introduced proximally by collection device 58 to at least one die, eg, spinning die 54 .

In one embodiment, the mixing operation (step) includes introducing a solid additive, eg, particles 26 to filaments 22, eg, soluble filaments, spun from two different spinning dies 54.

Solid additive, eg, particles 26 may include more than one type or different types of particles 26 . In one embodiment, solid additive, eg, particles 26, comprises a mixture of particles 26 of different compositions. In another embodiment, solid additive, eg, particles 26, comprises a blend of particles of different compositions. In another embodiment, solid additive, eg, particles 26, comprise water-soluble and/or water-insoluble particles, which may include water-swellable particles. Additionally, in one embodiment, particles 26 may be in the form of aggregates, eg, aggregates comprising water-soluble and/or water-insoluble materials.

In one example, the solid additive, eg, particles 26, are about 100 μm to about 5000 μm, and/or about 100 μm to about 2000 μm, and/or about It can exhibit a D50 particle size of 250 μm to about 1200 μm, and/or about 250 μm to about 850 μm.

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

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

In one example, the solid additive, e.g., particles 26, are greater than 44 μm, and/or greater than 90 μm, and/or greater than 150 μm, and/or 212 μm, as measured according to the Particle Size Distribution Test Method described herein. and/or may exhibit a D10 of greater than 300 μm.

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

In one embodiment, the solid additives, e.g., particles 26, are identified above as long as D50 if present is greater than D10 if present and D90 if present is greater than D10 and D50 if present. can exhibit any combination of D10, D50, and/or D90.

In one example, the solid additive, eg, particles 26, can exhibit any combination of D10 and D90 identified above, so long as D90 is greater than D10.

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

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

In one embodiment, spinning operation 20 may include two or more spinning dies 54 positioned adjacent to each other in the machine direction and/or cross-machine direction. In one example, if spinning operation 20 includes two or more dies positioned adjacent to each other in the machine direction, mixing operation 24 includes two adjacent (machine direction) dies, e.g., two adjacent dies. It may be arranged between the spinning dies 54 that are connected.

Particles 26 used in the present invention to mix with filaments 22 may be active agent-containing particles.

d. recovery operation (28)
As shown in FIGS. 1, 4 and 6, filaments 22 from spinning operation 20 and, optionally, solid additives, e.g., particles 26, from mixing operation 24 are passed through a recovery device during recovery operation 28 . 58 to form the fibrous structure 14, which may be a composite structure (mixed filaments 22 and particles 26).

In one example, the collection device 58 may be a belt, such as a patterned belt, that imparts texture, such as a three-dimensional texture, to at least one surface of the fibrous structure 14 and/or rotating drum. Collection device 58 may impart a pattern that may be continuous, discontinuous, and/or semi-continuous in nature, eg, a non-random, repeating pattern. The collection device 58 can create different regions within the fibrous structure 14, eg, different average densities.

TEST METHODS Unless otherwise specified, all tests described herein, including those described in the Definitions section, and the following test methods were performed at a temperature of 23°C ± 1.0°C and 50% Conducted on conditioned samples for a minimum of 2 hours in a room conditioned at ±2% relative humidity. The samples tested are "usable units". As used herein, "usable unit" means a sheet, a flat portion obtained from roll stock, a pre-converted flat portion, a sheet, and/or a single-ply or multi-ply product. All tests are carried out under the same environmental conditions and in a room so arranged. Samples with wrinkles, tears, holes, or other defects are not tested. Samples conditioned as described herein are considered dry samples (eg, "dry filaments") for testing purposes. All instruments are calibrated according to manufacturer's specifications.

Basis Weight Test Method Basis weight is defined as the weight in g/m ² of the sample tested. This involves accurately weighing a known area of the conditioned sample using a suitable balance, recording the weight and area of the sample tested, applying the appropriate conversion factor, and finally g/g of the sample. Determined by calculating the basis weight of ^m2 .

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

For each sample, weigh the sample mass using the die cutter described above to cut the sample and record the mass result to the nearest 0.001 g.

Calculate basis weight in g/m2 as follows:
Basis weight = (mass of sample)/(area of sample).

or specifically,
Basis weight (g/m2) = (mass of sample (g))/(0.001704 m2).

Results are reported in units of 0.1 g/m2. Sample dimensions can be modified or varied using similar precision cutters as described above. If the sample dimensions are reduced, several samples should be measured and the average value should be reported as its basis weight.

Particle Size Distribution Test Method A particle size distribution test is performed to determine the characteristic size of the solid additive, eg, particles. This follows ASTM D 502-89, "Standard Test Method for Particle Size of Soaps and Other Detergents," approved May 26, 1989, along with further specifications for sieve size and sieving time used in the analysis. carried out using According to Section 7, "Procedure using machine-sieving method," US Standard (ASTM E 11) sieves #4 (4.75 mm), #6 (3 .35mm), #8 (2.36mm), #12 (1.7mm), #16 (1.18mm), #20 (850 micrometers), #30 (600 micrometers), #40 (425 micrometers ), #50 (300 micrometers), #70 (212 micrometers), #100 (150 micrometers), #170 (90 micrometers), #325 (44 micrometers) and clean dry sieves containing bread requires nesting of A defined mechanical sieving method is used with the nested sieves described above. A suitable sieve shaker is available from W.W. S. available from Tyler Company (Ohio, USA). A sieve shake test sample is approximately 100 grams and is shaken for 5 minutes.

Data are plotted on a semilogarithmic plot with the micrometer-sized openings of each sieve plotted on the logarithmic abscissa and the cumulative mass percent finer (CMPF) plotted on the linear ordinate. be. Examples of such data representations are shown in ISO 92761:1998, "Representation of results of particle size analysis--Part 1: Graphical Representation", figure A. 4. A characteristic particle size (Dx, x=10, 50, 90) is defined for the purposes of this invention as the abscissa value at the point where the cumulative mass percent equals x percent, and the x value is calculated by linear interpolation between the data points immediately above (a) and below (b)
Dx = 10 ^ [Log (Da) - (Log (Da) - Log (Db)) x (Qa - x%) / (Qa - Qb)]
where Log is the base 10 logarithm, Qa and Qb are the cumulative mass percentile values of the measured data immediately above and below the x-percentile, respectively, and Da and Db are Micrometer sieve size values corresponding to these data.

Example data and calculations:

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

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

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

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

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

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

Procedure for Measuring Transverse Variation at a Fixed Machine Direction Position Select the machine direction position of the web for the sample.

Measure the basis weight of all samples according to the basis weight test method described herein.

Cut as many samples as needed to sample the entire web width at a given MD location.

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

Discard samples at the edges of the complete web that do not completely fill the sampling die when cut.

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

Calculate the average sample basis weight for this fixed MD position.

Calculate the standard deviation of the samples at the fixed MD position.

Calculate the % RSD (Relative Standard Deviation) of the samples at this MD position by dividing the standard deviation by the average sample basis weight and multiplying by 100 to get the % value.

Repeat the above for a total of 10 rows or 10 MD locations, sampling at approximately 1 meter intervals of the web from the process.

Average the average RSD for all 10 rows and report it as the overall CD basis weight variation RSD%. This value is reported to the nearest 0.1%.

Procedure for Measuring Machine Direction Variation at a Fixed Transverse Position Sample the web at its transverse centerline position.

Measure the basis weight of all samples according to the basis weight test method described herein.

Cut 10 samples along the transverse centerline location of the web at approximately 1 m intervals in the MD direction of the web from the process.

Calculate the basis weight of each sample.

Calculate the average sample basis weight at the CD centerline location.

Calculate the standard deviation of the same sample set.

Calculate the MD basis weight variation RSD % for CD centerline location by dividing the standard deviation by the average sample basis weight and multiplying by 100 to get the % value. This value is reported to the nearest 0.1%.

Repeat the above transverse centerline location measurements by performing the same sampling and measurements along the midline on the left half of the CD centerline and then along the midline on the right half of the CD centerline.

From the above analysis three values are generated.
% RSD for CD centerline position
RSD% of midline above left half of CD centerline
RSD% of midline above right half of CD centerline
Average the RSD% for these three CD locations and report it as the overall MD basis weight variation RSD%. This value is reported to the nearest 0.1%.

Containment Efficiency Test Method Containment efficiency is the introduction (feed) into the mixing (coforming) operation of solid additives, solid additives entrapped and retained in the fibrous structure during the mixing (coforming) operation, e.g., particles. It is a measure of the percentage of the number of solid additives, eg, particles, added. A higher percentage of loading efficiency indicates a better solid additive, e.g., particles, that the entrainment operates during the mixing (coforming) operation and/or the coforming device and/or the mixing (coforming) operation. Realized by possible process conditions.

In general, the inclusion efficiency is as follows.

これは、以下のようにより良好に計算される。

This is better calculated as follows.

Procedure A mixing (coforming) operation is performed at steady state conditions to create a particle-free base fiber structure (filaments only).

Measure the basis weight of a cut sample of the base fibrous structure, as defined by the basis weight method defined herein.

Sample from the transverse center of the base fibrous structure or at the CD centerline of the base fibrous structure.

This is recorded as the base fibrous structure basis weight (g/m ² ).

A composite fibrous structure (filaments + particles) is produced at the desired dry mass feed rate.

The basis weight of a cut sample of the composite fibrous structure is measured as defined by the basis weight method defined herein.

Sample from the transverse center of the composite fiber structure or at the CD centerline of the composite fiber structure.

This is recorded as the composite fiber structure basis weight (g/m ² ).

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

For clarity, an example of an inclusion efficiency calculation is shown below.

A base fibrous structure (filaments only - no particles) is made from the filament-forming composition at a 55% (0.55) solids concentration. The feed rate of the filament-forming composition to the die is 1600 g/min. A sample cut through the centerline of the base fibrous structure exhibits a basis weight of 264 g/m ² . A composition fibrous structure (filaments + solid additives, e.g. particles) is then made as described above for the base fibrous structure, except that the solid additives e.g. Add to the filaments at the particle feed rate. A sample cut from the composite fiber structure exhibits a basis weight of 870 g/m ² . At these values, an exemplary inclusion efficiency calculation is as follows.

Inclusion efficiency is reported to the nearest 1%.

Moisture Content Test Method The moisture content (moisture) content present in the fibrous elements and/or particles and/or fibrous structures is measured using the following Moisture Content Test Method. Fibrous elements and/or particles and/or fibrous structures in the form of pre-cut sheets, or portions thereof (“samples”), were conditioned at 23° C.±1.5° C. for at least 24 hours prior to testing. Place in a regulated room at a temperature of 0° C. and a relative humidity of 50%±2%. Each fibrous structure sample has an area of at least 4 square inches, but a dimension small enough to fit properly on the weighing pan of the balance. Using a balance capable of measuring to at least four decimal places under the temperature and humidity conditions described above, weigh the sample to less than 0.5% change from the previous (measured) weight over a period of 10 minutes. Record every 5 minutes until The final weight is recorded as the "equilibrium weight". Within 10 minutes, the samples are placed on foil in a forced air oven at 70° C.±2° C. and 4%±2% relative humidity for 24 hours to dry. After drying for 24 hours, the sample is removed and weighed within 15 seconds. This weight is called the "dry weight" of the sample.

Calculate the moisture content (moisture) of the sample as follows.

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

Diameter Test Method A Scanning Electron Microscope (SEM) or optical microscope and image analysis software are used to determine the diameter of discrete fiber elements or fiber elements within a fiber structure. A magnification of 200 to 10,000 times is selected to properly magnify the fiber element for measurement. When using SEM, the samples are sputtered with gold or palladium compounds to avoid charging and vibration of the fiber elements in the electron beam. A manual procedure is used to measure the fiber element diameter from images (on a monitor screen) obtained using an SEM or optical microscope. Using the mouse and cursor tools, find the edge of a randomly selected fiber element and then the other edge of the fiber element across its width (i.e. perpendicular to the direction of the fiber element at that point). Measure up to A calibrated image analysis tool provides the scale to get the actual reading in microns. For the fiber elements within the fiber structure, SEM or optical microscopy is used to randomly select a number of fiber elements from the entire sample of the fiber structure. At least two portions of the fibrous structure are cut and tested in this manner. For statistical analysis, a total of at least 100 such measurements are performed and all data are then recorded. The recorded data are used to calculate the mean fiber element diameter (mean), the standard deviation of the fiber element diameter, and the median fiber element diameter.

Another useful statistic is the calculation of the amount of population of fiber elements that is below a certain upper limit. To determine this statistic, the software was programmed to count how many fiber element diameter results were less than the upper limit, and that count (divided by the total number of data and multiplied by 100%) was , as percent less than the upper limit (eg, percent less than 1 micrometer in diameter or submicron percent). We denote the measured diameter (in μm) for an individual circular fiber element as di.

If the fiber element has a non-circular cross-section, the measurement of the diameter of the fiber element is taken as the hydraulic diameter and set equal to the hydraulic diameter. The hydraulic diameter is the cross-sectional area of the fibrous element times four divided by the perimeter of the cross-section of the fibrous element (perimeter in the case of hollow fibrous elements). Number-average diameter, or mean diameter, is calculated as follows:

Weight Average Molecular Weight Test Method The weight average molecular weight (Mw) of a material (eg, polymer) is determined by gel permeation chromatography (GPC) using a mixed bed column. The following components: Millenium®, Model 600E pump, system controller and controller software version 3.2, Model 717 Plus autosampler, and CHM-009246 column heater (all from Waters Corporation, Milford, Mass., USA). A high performance liquid chromatograph (HPLC) with The column is a PL gel 20 μm mixed A column (gel molecular weight: 1,000 g/mol to 40,000,000 g/mol), 600 mm long and 7.5 mm internal diameter, and the guard column is 50 mm long and 7.5 mm ID. of PL gel 20 μm. The column temperature is 55° C. and the injection volume is 200 μL. The detector was a DAWN ( ® Enhanced Optical System (EOS). The gain of the odd numbered detectors is set to 101. The gain of the even numbered detector is set to 20.9. A Wyatt Technology Optilab® differential refractometer is set at 50°C. Set the gain to 10. The mobile phase is HPLC grade dimethylsulfoxide with 0.1% w/v LiBr and the mobile phase flow rate is 1 mL/min isocratic. Run time is 30 minutes.

Samples are prepared by dissolving material in mobile phase, nominally 3 mg of material per mL of mobile phase. The sample is covered and then stirred using a magnetic stirrer for about 5 minutes. The samples are then placed in a convection oven at 85°C for 60 minutes. The samples are then allowed to cool to room temperature. Samples are then filtered through a 5 mL syringe through a 5 μm nylon membrane (type: Spartan-25, manufactured by Schleicher & Schuell, Keene, NH, USA) into 5 milliliter (mL) autosampler vials.

For each series of measured samples (3 or more samples of material), a blank sample of solvent is injected onto the column. A check sample is then prepared in the same manner as for the sample above. A check sample contains 2 mg/mL pullulan (Polymer Laboratories) with a weight average molecular weight of 47,300 g/mole. A check sample is run before each sample set is run. Blank samples, check samples, and material test samples are tested in duplicate. A blank sample is used for the last measurement. The light scattering detector and differential refractometer were obtained from the "Dawn EOS Light Scattering Instrument Hardware Manual" and "Optilab® DSP Interferometric Refractometer Hardware Manual", both produced by Wyatt Technology Corp., Santa Barbara, CA. , both incorporated herein by reference).

Calculate the weight average molecular weight of the sample using the detector software. A dn/dc (differential change in refractive index with concentration) value of 0.066 is used. Baselines of the laser photodetector and refractive index detector are corrected to remove detector dark current and solvent scattering interferences. If the laser photodetector signal is saturated or exhibits excessive noise, the value is not used for molecular mass calculations. Regions for molecular weight characterization are selected such that the 90° detector signals for laser light scattering and refractive index are both greater than three times their respective baseline noise levels. Typically, the high molecular weight side of the chromatogram is limited by the refractive index signal and the low molecular weight side by the laser light signal.

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

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

All documents cited in this application, including any cross-referenced or related patents or patent applications, and any patent application or patent to which this application claims priority or benefit thereof, are to be excluded or limited. Unless stated otherwise, it is incorporated herein by reference in its entirety. Citation of any document is not considered prior art to any invention disclosed or claimed herein, or taken alone or in combination with any other reference(s) It is not considered to teach, suggest or disclose all such inventions at times. Further, if any meaning or definition of a term in this document conflicts with the meaning or definition of the same term in a document incorporated by reference, the meaning or definition given to that term in this document shall control. shall be

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

Claims (14)

A continuous process for making a fibrous structure comprising:
a. providing a water-soluble filament-forming material;
b. forming an aqueous composition comprising a water-soluble filament-forming material;
c. processing the aqueous composition to produce a filament-forming composition;
d. delivering a filament-forming composition to a die;
e. spinning a filament-forming composition to form a plurality of water-soluble filaments;
f. collecting the water-soluble filaments on a collecting device to form a fiber structure;
g. die-cutting the fibrous structure to obtain an article of manufacture ;
h. a step of packaging the article of manufacture;
A continuous process, including Said water-soluble filament-forming material comprises a hydroxyl polymer, preferably said hydroxyl polymer is pullulan, hydroxypropylmethylcellulose, hydroxyethylcellulose, methylcellulose, hydroxypropylcellulose, polyvinylpyrrolidone, carboxymethylcellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum. , Gum Acacia, Gum Arabic, Polyacrylic Acid, Methyl Methacrylate Copolymer, Carboxyvinyl Polymer, Dextrin, Pectin, Chitin, Levan, Ercinan, Collagen, Gelatin, Zein, Gluten, Soy Protein, Casein, Polyvinyl Alcohol, Carboxylated Polyvinyl Alcohol, selected from the group consisting of sulfonated polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, proteins, chitosan, chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethylcellulose, polyethylene oxide and mixtures thereof, more preferably 2. The continuous process of claim 1, wherein said hydroxyl polymer comprises polyvinyl alcohol. 3. The continuous process of claim 1 or 2, wherein the water-soluble filament-forming material is in the form of pellets. Claims 1-, wherein in step b, at least 30% by weight of water is added to said water-soluble filament-forming material, preferably in step b, at least 40% by weight of water is added to said water-soluble filament-forming material. 4. A continuous process according to any one of clauses 3 and 3. Continuous process according to any one of the preceding claims, wherein the step of processing said aqueous composition is carried out in an extruder, preferably said extruder is a twin-screw extruder. Said aqueous composition present in said extruder exhibits a % solids content of 20% to 95%, preferably said aqueous composition present in said extruder exhibits a % solids content of 30% to 85%. , more preferably, the aqueous composition present in the extruder exhibits a % solids content of 40% to 70%. Said filament-forming composition exits said extruder at an exit pressure of 10-80 bar, preferably said filament-forming composition exits said extruder at an exit pressure of 15-75 bar, more preferably said A continuous process according to claim 5, wherein the filament-forming composition exits the extruder at an exit pressure of 20-65 bar. 6. The continuous process of claim 5, wherein said extruder exposes said filament-forming composition to a temperature of at least 49[deg.]C. Said filament-forming composition exits said extruder at an SME of 0.10-0.50 kW-h/kg based on solids throughput, preferably said filament-forming composition exits said extruder at an SME of 0.12 based on solids throughput. More preferably, the filament-forming composition exits the extruder with an SME of -0.45 kW-h/kg, and more preferably, the filament-forming composition exits the extruder with an SME of 0.14-0.35 kW-h/kg on a solids throughput basis. 6. The continuous process of claim 5, exiting from. Said continuous process further comprises mixing a plurality of solid additives with said water-soluble filaments to form a fibrous structure, preferably said solid additives comprise particles, preferably said particles are , water-soluble particles and/or water-insoluble particles. Said particles are aggregates, preferably said aggregates comprise water-soluble and/or water-insoluble materials, more preferably said aggregates are water-soluble particles, water-insoluble particles, or 11. The continuous process of claim 10, comprising a combination of 11. The continuous process of claim 10, wherein said particles comprise active agent-containing particles. Said water-soluble filaments comprise actives present within said filaments, preferably said actives are fabric care actives, dishwashing actives, carpet care actives, surface care actives, air care actives, 13. Any one of claims 1 to 12 selected from the group consisting of oral care actives, hair care actives, shampoos, conditioners, keratinous tissue care agents, toilet bowl cleaners, skin care actives and mixtures thereof. continuous process. 14. The continuous process of claim 13, wherein said active agent is added to said continuous process in one of steps b, c, d or combinations thereof.

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