U.S. patent application number 16/250484 was filed with the patent office on 2019-08-01 for process for making an article of manufacture.
This patent application is currently assigned to The Procter & Gamble Company. The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Gavin John Broad, Frank William Denome, Richard Allen Diemar, Andreas Josef Dreher, Stephen Robert Glassmeyer, Gregory Charles Gordon, Mark William Hamersky, Paul R. Mort, III, Dinah Achole Nyangiro, Michael Sean Pratt, Anthony Edward Reed, Mark Robert Sivik, Jeffrey Moss Vaughn.
Application Number | 20190233970 16/250484 |
Document ID | / |
Family ID | 65516740 |
Filed Date | 2019-08-01 |
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United States Patent
Application |
20190233970 |
Kind Code |
A1 |
Reed; Anthony Edward ; et
al. |
August 1, 2019 |
Process for Making an Article of Manufacture
Abstract
A process, for example a continuous process, for making an
article of manufacture containing a fibrous structure and more
particularly a process for making an article of manufacture
containing a fibrous structure, such as a soluble fibrous
structure, containing soluble filaments is provided.
Inventors: |
Reed; Anthony Edward; (West
Chester, OH) ; Pratt; Michael Sean; (Hamilton,
OH) ; Mort, III; Paul R.; (Cincinnati, OH) ;
Glassmeyer; Stephen Robert; (Cincinnati, OH) ;
Nyangiro; Dinah Achole; (Mason, OH) ; Hamersky; Mark
William; (Hamilton, OH) ; Diemar; Richard Allen;
(West Chester, OH) ; Vaughn; Jeffrey Moss;
(Colerain Township, OH) ; Broad; Gavin John;
(Liberty Township, OH) ; Gordon; Gregory Charles;
(Loveland, OH) ; Denome; Frank William;
(Cincinnati, OH) ; Sivik; Mark Robert; (Mason,
OH) ; Dreher; Andreas Josef; (Cincinnati,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Assignee: |
The Procter & Gamble
Company
|
Family ID: |
65516740 |
Appl. No.: |
16/250484 |
Filed: |
January 17, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62622295 |
Jan 26, 2018 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D01D 5/00 20130101; D01F
2/28 20130101; D10B 2321/06 20130101; D01F 4/00 20130101; D01F 6/14
20130101; D01D 5/04 20130101; D01F 9/00 20130101; D01F 11/00
20130101; D10B 2401/024 20130101; D04H 3/007 20130101; D01F 1/10
20130101; D01D 1/09 20130101; D01D 7/00 20130101; D01D 10/02
20130101 |
International
Class: |
D01D 1/09 20060101
D01D001/09; D01D 5/04 20060101 D01D005/04; D01F 1/10 20060101
D01F001/10; D01F 6/14 20060101 D01F006/14; D01D 7/00 20060101
D01D007/00; D04H 3/007 20060101 D04H003/007 |
Claims
1. A process for making a fibrous structure, the process comprising
the steps of: a. providing one or more soluble filament-forming
materials; b. forming an aqueous composition comprising the one or
more soluble filament-forming materials; c. processing the aqueous
composition to produce a filament-forming composition; d.
delivering the filament-forming composition to one or more dies; e.
spinning the filament-forming composition to form a plurality of
soluble filaments; and f. collecting the soluble filaments on a
collection device to form a fibrous structure.
2. The process according to claim 1 wherein at least one of the one
or more soluble filament-forming materials comprises a hydroxyl
polymer.
3. The process according to claim 2 wherein the hydroxyl polymer
comprises polyvinyl alcohol.
4. The process according to claim 1 wherein at least one of the one
or more filament-forming materials is in the form of pellets.
5. The process according to claim 1 wherein at least about 30% by
weight of water is added to the one or more filament-forming
materials in step b.
6. The process according to claim 1 wherein the step of processing
the aqueous composition occurs within an extruder.
7. The process according to claim 6 wherein the aqueous composition
present in the extruder exhibits a % solids of from about 20% to
about 95%.
8. The process according to claim 6 wherein the filament-forming
composition exits the extruder at an exit pressure of from about 10
to about 80 bar.
9. The process according to claim 6 wherein the extruder subjects
the filament-forming composition to a temperature of at least
49.degree. C.
10. The process according to claim 6 wherein the filament-forming
composition exits the extruder on a solids throughput basis of from
about 0.10 to about 0.50 kW-h/kg.
11. The process according to claim 1 wherein the process further
comprises the step of commingling a plurality of solid additives
with the soluble filaments to form a composite structure.
12. The process according to claim 11 wherein the solid additives
comprise particles.
13. The process according to claim 12 wherein at least one of the
particles is an agglomerate.
14. The process according to claim 12 wherein the particles
comprise active agent-containing particles.
15. The process according to claim 1 wherein at least one of the
soluble filaments comprises one or more active agents present
within the filament.
16. The process according to claim 15 wherein at least one of the
one or more active agents is added in the process in at least one
of steps b, c, and d.
17. The process according to claim 1 wherein the process further
comprises the step of converting the fibrous structure into an
article of manufacture.
18. The process according to claim 1 wherein the process further
comprises one or more converting operations selected from the group
consisting of: slitting, stacking, calendering, treating with
optional ingredients, die cutting, printing, packaging, and
combinations thereof.
19. The process according to claim 18 wherein the one or more
converting operations are performed on a single converting
line.
20. The process according to claim 18 wherein the one or more
converting operations yields a consumer useable saleable unit.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a process, for example a
continuous process, for making an article of manufacture comprising
a fibrous structure and more particularly to a process for making
an article of manufacture comprising a fibrous structure, such as a
soluble fibrous structure, comprising soluble filaments, for
example water-soluble filaments.
BACKGROUND OF THE INVENTION
[0002] Processes for making fibrous structures, for example soluble
fibrous structures, and/or components thereof, such as soluble
filaments, are known in the art. Further, the fibrous structures
and/or components thereof have been ultimately incorporated into an
article of manufacture, such as a consumer product, for example
fabric care products, hair care products, tooth care products, and
the like. However, such known processes to date have been
discontinuous. In other words, such known processes have at least
two or more discrete (discontinuous) steps or unit operations that
interrupt the process of making an article of manufacture, for
example one or more steps of making a fibrous structure uncoupled
and/or discrete from one or more steps of converting the made
fibrous structure into the article of manufacture, for example a
consumer product. Such a non-continuous/discontinuous process may
comprise one or more of the following steps: 1) a filament-forming
composition making step, such as a batch process to make a
filament-forming composition; 2) a spinning step for spinning the
filament-forming composition to make filaments, for example soluble
filaments; 3) optionally, a commingling (coforming) step for
commingling solid additives, for example particles, with filaments;
4) a collection step for collecting the filaments and/or commingled
filaments and solid additives on a collection device to form a
fibrous structure, for example a soluble fibrous structure; 5) a
converting operation (one or more steps for converting (for example
slitting and/or stacking and/or calendering and/or treating with
minors, such as perfumes, enzymes, bleaches, flavoring agents,
effervescent agents, and the like, die-cutting, and printing) the
fibrous structure into one or more articles of manufacture, for
example a consumer product); and 6) optionally a packaging step for
packaging the articles of manufacture.
[0003] One problem faced by formulators is how to make such
articles of manufacture comprising fibrous structures, for example
soluble fibrous structures, continuous or more continuous than the
known discontinuous process. In other words, one problem faced by
formulators is how to combine multiple process steps from above
into a continuous process such that they are not discrete,
discontinuous process steps.
[0004] Accordingly, there is a need for a process for making
articles of manufacture, for example consumer products, comprising
a fibrous structure, for example a soluble fibrous structure, in a
continuous or at least partially continuous process.
SUMMARY OF THE INVENTION
[0005] The present invention fulfills the need described above by
providing a continuous process and/or continuous process steps
within the process to make an article of manufacture, for example a
consumer product, comprising a fibrous structure, for example a
soluble fibrous structure.
[0006] One solution to the problem identified above is to provide a
process for making an article of manufacture, for example a
consumer product, comprising a fibrous structure, for example a
soluble fibrous structure, in a continuous or more continuous
process. Such a continuous process comprises at least the following
steps: 1) a filament-forming composition making step to make a
filament-forming composition; 2) a spinning step for spinning the
filament-forming composition to make filaments, for example soluble
filaments; 3) optionally, a commingling (coforming) step for
commingling solid additives, for example particles, with the
filaments; and 4) a collection step for collecting the filaments
and/or commingled filaments and solid additives on a collection
device to form a fibrous structure, for example a soluble fibrous
structure, wherein the steps (1-4) when present are performed in a
continuous manner, one step after the other without any breaks or
stoppages or interruptions in the process from making a
filament-forming composition to spinning the filament-forming
composition into filaments (optionally commingling solid additives
with the filaments) to collecting the filaments (and/or commingled
filaments and solid additives) on a collection to form a fibrous
structure, which may then be converted into an article of
manufacture and ultimately packaged, for example into a consumer
package. The continuous process may further comprise 5) a
converting operation (one or more steps for converting (for example
slitting and/or stacking and/or calendering and/or treating with
minors, such as perfumes, enzymes, bleaches, flavoring agents,
effervescent agents, and the like, die-cutting, and printing) the
fibrous structure into one or more articles of manufacture, for
example a consumer product); and 6) optionally a packaging step for
packaging the articles of manufacture.
[0007] The present invention provides a continuous process for
making a fibrous structure and ultimately an article of
manufacture.
[0008] In one example of the present invention, a process for
making a fibrous structure, the process comprising the steps of:
[0009] a. providing one or more soluble filament-forming materials;
[0010] b. forming an aqueous composition comprising the one or more
soluble filament-forming materials; [0011] c. processing the
aqueous composition to produce a filament-forming composition;
[0012] d. delivering the filament-forming composition to one or
more dies; [0013] e. spinning the filament-forming composition to
form a plurality of soluble filaments; and [0014] f. collecting the
soluble filaments on a collection device to form a fibrous
structure is provided. In one example, one or more active agents
may be added in the process in at least one of steps b, c, and
d.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic representation of an example of a
process according to the present invention;
[0016] FIG. 2 is a schematic representation of an example of a
portion of the process according to the present invention;
[0017] FIG. 3 is a schematic representation of an example of an
extruder screw suitable for use in the process according to the
present invention;
[0018] FIG. 4 is a schematic representation of an example of a
portion of the process according to the present invention;
[0019] FIG. 5 is a top plan view of a die suitable for use in the
process according to the present invention;
[0020] FIG. 6 is a schematic representation of an example of a
portion of the process according to the present invention; and
[0021] FIG. 7 is a schematic representation of an example of
collection zones on a collection device suitable for use in the
process according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0022] "Fibrous structure" as used herein means a structure that
comprises one or more filaments and optionally, one or more
particles. In one example, a fibrous structure according to the
present invention means an association of filaments and optionally,
particles that together form a structure, such as a unitary
structure, capable of performing a function.
[0023] The fibrous structures of the present invention may be
single layered or multi-layered. If multi-layered, the fibrous
structures may comprise at least two and/or at least three and/or
at least four and/or at least five layers and/or at least six
layers, for example one or more filament layers, one or more
particle layers and/or one or more composite structure layers
having a mixture of filaments and particles. A layer may comprise a
particle layer within the fibrous structure or between filament
layers within a fibrous structure. A layer comprising filaments may
sometimes be referred to as a ply. A ply may be a fibrous structure
which may be single layered or multi-layered as described herein.
In one example, a layer may be formed by a single spinning die
and/or particle delivery source or if it is a composite structure
layer, then is may be formed by a single spinning die and a
particle delivery source.
[0024] In one example, the fibrous structures of the present
invention may comprise single or multiple layers, at least one of
which must comprise fibers. Layers may include additives (for
example, pastes or sprays) applied to said fibers and/or particles
comingled with said fibers in a composite structure.
[0025] In one example, 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 may exhibit a basis weight of less than 5000 g/m.sup.2 as
measured according to the Basis Weight Test Method described
herein. In one example, the single- or multi-ply fibrous structure
according to the present invention may exhibit a basis weight of
greater than 10 g/m.sup.2 to about 5000 g/m.sup.2 and/or greater
than 10 g/m.sup.2 to about 3000 g/m.sup.2 and/or greater than 10
g/m.sup.2 to about 2000 g/m.sup.2 and/or greater than 10 g/m.sup.2
to about 1000 g/m.sup.2 and/or greater than 20 g/m.sup.2 to about
800 g/m.sup.2 and/or greater than 30 g/m.sup.2 to about 600
g/m.sup.2 and/or greater than 50 g/m.sup.2 to about 500 g/m.sup.2
and/or greater than 300 g/m.sup.2 to about 3000 g/m.sup.2 and/or
greater than 500 g/m.sup.2 to about 2000 g/m.sup.2 as measured
according to the Basis Weight Test Method.
[0026] In one example, a single ply comprising a multi-layered
fibrous structure comprises a first layer, such as a scrim layer
comprising 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 and a second layer, for
example a layer comprising a plurality of filaments, alone or as a
composite structure layer comprising filaments and solid additives,
for example particles, present 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.
[0027] In one example, the fibrous structure of the present
invention is a "unitary fibrous structure."
[0028] "Unitary fibrous structure" as used herein is an arrangement
comprising a plurality of two or more and/or three or more
filaments that are inter-entangled or otherwise associated with one
another to form a fibrous structure and/or fibrous structure plies.
A unitary fibrous structure of the present invention may be one or
more plies within a multi-ply fibrous structure. In one example, a
unitary fibrous structure of the present invention may comprise
three or more different filaments. In another example, a unitary
fibrous structure of the present invention may comprise two or more
different filaments.
[0029] "Article" as used herein refers to a consumer use unit, a
consumer unit dose unit, a consumer use saleable unit, a single
dose unit, or other use form comprising a unitary fibrous structure
and/or comprising one or more fibrous structures of the present
invention.
[0030] "Fibrous element" as used herein means an elongate
particulate having a length greatly exceeding its average diameter,
i.e. a length to average diameter ratio of at least about 10. A
fibrous element may be a filament or a fiber. In one example, the
fibrous element is a single filament rather than a yarn comprising
a plurality of filaments.
[0031] The fibrous elements of the present invention may be spun
from fibrous element-forming compositions also referred to as
filament-forming compositions via suitable spinning process
operations, such as meltblowing, spunbonding, electro-spinning,
and/or rotary spinning.
[0032] The fibrous elements of the present invention may be
monocomponent (single, unitary solid piece rather than two
different parts, like a core/sheath bicomponent) and/or
multicomponent. For example, the fibrous elements may comprise
bicomponent fibers and/or filaments. The bicomponent fibers and/or
filaments may be in any form, such as side-by-side, core and
sheath, islands-in-the-sea and the like.
[0033] "Filament" as used herein means an elongate particulate as
described above that exhibits a length of greater than or equal to
5.08 cm (2 in.) and/or greater than or equal to 7.62 cm (3 in.)
and/or greater than or equal to 10.16 cm (4 in.) and/or greater
than or equal to 15.24 cm (6 in.).
[0034] Filaments are typically considered continuous or
substantially continuous in nature. Filaments are relatively longer
than fibers. Non-limiting examples of filaments include meltblown
and/or spunbond filaments. Non-limiting examples of polymers that
can be spun into filaments include natural polymers, such as
starch, starch derivatives, cellulose, such as rayon and/or
lyocell, and cellulose derivatives, hemicellulose, hemicellulose
derivatives, and synthetic polymers including, but not limited to
polyvinyl alcohol and also thermoplastic polymer filaments, such as
polyesters, nylons, polyolefins such as polypropylene filaments,
polyethylene filaments, and biodegradable thermoplastic fibers such
as polylactic acid filaments, polyhydroxyalkanoate filaments,
polyesteramide filaments and polycaprolactone filaments.
[0035] "Fiber" as used herein means an elongate particulate as
described above that exhibits a length of less than 5.08 cm (2 in.)
and/or less than 3.81 cm (1.5 in.) and/or less than 2.54 cm (1
in.).
[0036] Fibers are typically considered discontinuous in nature.
Non-limiting examples of fibers include staple fibers produced by
spinning a filament or filament tow of the present invention and
then cutting the filament or filament tow into segments of less
than 5.08 cm (2 in.) thus producing fibers.
[0037] In one example, one or more fibers may be formed from a
filament of the present invention, such as when the filaments are
cut to shorter lengths (such as less than 5.08 cm in length). Thus,
in one example, the present invention also includes a fiber made
from a filament of the present invention, such as a fiber
comprising one or more filament-forming materials and one or more
fiber adjuncts, such as active agents. Therefore, references to
filament and/or filaments of the present invention herein also
include fibers made from such filament and/or filaments unless
otherwise noted. Fibers are typically considered discontinuous in
nature relative to filaments, which are considered continuous in
nature.
[0038] "Fibrous element-forming composition" and/or
"filament-forming composition" as used herein means a composition
that is suitable for making a filament of the present invention
such as by meltblowing and/or spunbonding. The filament-forming
composition comprises one or more filament-forming materials that
exhibit properties that make them suitable for spinning into a
filament. In one example, the filament-forming material comprises a
polymer. In addition to one or more filament-forming materials, the
filament-forming composition may comprise one or more fiber
adjuncts, for example one or more active agents. In addition, the
filament-forming composition may comprise one or more polar
solvents, such as water, into which one or more, for example all,
of the filament-forming materials and/or one or more, for example
all, of the active agents are dissolved and/or dispersed prior to
spinning a filament, such as a filament from the filament-forming
composition.
[0039] In one example, a filament made from a filament-forming
composition of the present invention is such that one or more fiber
adjuncts, for example one or more active agents, may be present in
the filament rather than on the filament, such as a coating
composition comprising one or more active agents, which may be the
same or different from the active agents in the filaments and/or
particles. The total level of filament-forming materials and total
level of active agents present in the filament-forming composition
may be any suitable amount so long as the filaments of the present
invention are produced therefrom.
[0040] In one example, one or more fiber adjuncts, such as active
agents, may be present in the filament and one or more additional
fiber adjuncts, such as active agents, may be present on a surface
of the filament. In another example, a filament of the present
invention may comprise one or more fiber adjuncts, such as active
agents, that are present in the filament when originally made, but
then bloom to a surface of the filament prior to and/or when
exposed to conditions of intended use of the filament.
[0041] "Fibrous element-forming material" and/or "filament-forming
material" as used herein means a material, such as a polymer or
monomers capable of producing a polymer that exhibits properties
suitable for making a filament. In one example, the
filament-forming material comprises one or more substituted
polymers such as an anionic, cationic, zwitterionic, and/or
nonionic polymer. In another example, the polymer may comprise a
hydroxyl polymer, such as a polyvinyl alcohol ("PVOH"), a partially
hydrolyzed polyvinyl acetate and/or a polysaccharide, such as
starch and/or a starch derivative, such as an ethoxylated starch
and/or acid-thinned starch, carboxymethylcellulose, hydroxypropyl
cellulose, hydroxyethyl cellulose, and methyl cellulose. In another
example, the polymer may comprise polyethylenes and/or
terephthalates. In yet another example, the filament-forming
material is a polar solvent-soluble material.
[0042] "Particle" as used herein means a solid additive, such as a
powder, granule, agglomerate, encapsulate, microcapsule, and/or
prill. The shape of the particle can be in the form of spheres,
rods, plates, tubes, squares, rectangles, discs, stars, fibers or
have regular or irregular random forms. The particles of the
present invention, at least those of at least 44 .mu.m, can be
measured by the Particle Size Distribution Test Method described
herein. For particles that are less than 44 .mu.m, a different test
method may be used, for example light scattering, to determine the
particle sizes less than 44 .mu.m, for example perfume
microcapsules that typically range from about 15 .mu.m to about 44
.mu.m and/or about 25 .mu.m in size.
[0043] In one aspect, particles may comprise re-cycled
fibrous-structure materials, specifically where said fibrous
materials are re-cycled by grinding fibers into a finely-divided
solid and re-incorporating said finely-divided solids into
agglomerates, granules or other particle forms. In another aspect,
particles may comprise re-cycled fibrous-structure materials,
specifically where said fibrous materials are incorporated into a
fluid paste, suspension or solution, and then processed to form
agglomerates, granules or other particle forms. In another aspect,
said fluid pastes, suspensions or solutions comprising recycled
fibrous materials may be directly applied to fibrous layers in the
process of making new fibrous articles.
[0044] "Active agent-containing particle" as used herein means a
solid additive, for example a particle, comprising one or more
active agents. In one example, the active agent-containing particle
is an active agent in the form of a particle (in other words, the
particle comprises 100% active agent(s)). The active
agent-containing particle may exhibit a particle size of 5000 .mu.m
or less as measured according to the Particle Size Distribution
Test Method described herein.
[0045] In one example of the present invention, the fibrous
structure comprises a plurality of particles, for example active
agent-containing particles, for example at least one active
agent-containing particle, and a plurality of filaments in a weight
ratio of particles, for example active agent-containing particles
to filaments of 1:100 or greater and/or 1:50 or greater and/or 1:10
or greater and/or 1:3 or greater and/or 1:2 or greater and/or 1:1
or greater and/or 2:1 or greater and/or 3:1 or greater 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 from about 10:1 to about
1:100 and/or from about 8:1 to about 1:50 and/or from about 7:1 to
about 1:10 and/or from about 7:1 to about 1:3 and/or from about 6:1
to 1:2 and/or from about 5:1 to about 1:1 and/or from about 4:1 to
about 1:1 and/or from about 3:1 to about 1.5:1.
[0046] In another example of the present invention, the fibrous
structure comprises a plurality of particles, for example active
agent-containing particles, and a plurality of filaments in a
weight ratio of particles, for example active agent-containing
particles, to filaments of from about 20:1 to about 1:1 and/or from
about 10:1 to about 1:1 and/or from about 10:1 to about 1.5:1
and/or from about 8:1 to about 1.5:1 and/or from about 8:1 to about
2:1 and/or from about 7:1 to about 2:1 and/or from about 7:1 to
about 3:1 and/or from about 6:1 to about 2.5:1.
[0047] In yet another example of the present invention, the fibrous
structure comprises a plurality of particles, for example active
agent-containing particles, and a plurality of filaments in a
weight ratio of particles, for example active agent-containing
particles, to filaments of from about 1:1 to about 1:100 and/or
from about 1:15 to about 1:80, and/or from about 1:2 to about 1:60
and/or from about 1:3 to about 1:50 and/or from about 1:3 to about
1:40.
[0048] In another example, the fibrous structure of the present
invention comprises a plurality of particles, for example active
agent-containing particles, at a basis weight of greater than 1
g/m.sup.2 and/or greater than 10 g/m.sup.2 and/or greater than 20
g/m.sup.2 and/or greater than 30 g/m.sup.2 and/or greater than 40
g/m.sup.2 and/or from about 1 g/m.sup.2 to about 5000 g/m.sup.2
and/or to about 3500 g/m.sup.2 and/or to about 2000 g/m.sup.2
and/or from about 1 g/m.sup.2 to about 2000 g/m.sup.2 and/or from
about 10 g/m.sup.2 to about 1000 g/m.sup.2 and/or from about 10
g/m.sup.2 to about 500 g/m.sup.2 and/or from about 20 g/m.sup.2 to
about 400 g/m.sup.2 and/or from about 30 g/m.sup.2 to about 300
g/m.sup.2 and/or from about 40 g/m.sup.2 to about 200 g/m.sup.2 as
measured by the Basis Weight Test Method described herein.
[0049] In another example, the fibrous structure of the present
invention comprises a plurality of filaments at a basis weight of
greater than 1 g/m.sup.2 and/or greater than 10 g/m.sup.2 and/or
greater than 20 g/m.sup.2 and/or greater than 30 g/m.sup.2 and/or
greater than 40 g/m.sup.2 and/or from about 1 g/m.sup.2 to about
3000 g/m.sup.2 and/or from about 10 g/m.sup.2 to about 5000
g/m.sup.2 and/or to about 3000 g/m.sup.2 and/or to about 2000
g/m.sup.2 and/or from about 20 g/m.sup.2 to about 2000 g/m.sup.2
and/or from about 30 g/m.sup.2 to about 1000 g/m.sup.2 and/or from
about 30 g/m.sup.2 to about 500 g/m.sup.2 and/or from about 30
g/m.sup.2 to about 300 g/m.sup.2 and/or from about 40 g/m.sup.2 to
about 100 g/m.sup.2 and/or from about 40 g/m.sup.2 to about 80
g/m.sup.2 as measured by the Basis Weight Test Method described
herein. In one example, the fibrous structure comprises two or more
layers wherein filaments are present in at least one of the layers
at a basis weight of from about 1 g/m.sup.2 to about 500
g/m.sup.2.
[0050] "Commingled" and/or "commingling" as used herein means the
state or form where particles are mixed with fibrous elements, for
example filaments. The mixture of filaments and particles can be
throughout a composite structure or within a plane or a region of
the composite structure. In one example, the commingled filaments
and particles may form at least a surface of a composite structure.
In one example, the particles may be homogeneously dispersed
throughout the composite structure and/or plane and/or region of
the composite structure. In one example, the particles may be
homogeneously distributed throughout the composite structure, which
avoids and/or prevents sag and/or free movement and/or migration of
the particles within the composite structure to other areas within
the composite structure thus resulting in higher concentrated zones
of particles and lower concentrated zones or zero concentration
zones of particles within the composite structure. In one example,
.mu.CT cross-sections of a composite structure can show whether the
particles are homogeneously distributed throughout a composite
structure.
[0051] "Fiber adjunct" as used herein means any material present in
the filament of the present invention that is not a
filament-forming material. In one example, a fiber adjunct
comprises an active agent. In another example, a fiber adjunct
comprises a processing aid. In still another example, a fiber
adjunct comprises a filler. In one example, a fiber adjunct
comprises any material present in the filament that its absence
from the filament would not result in the filament losing its
filament structure, in other words, its absence does not result in
the filament losing its solid form. In another example, a fiber
adjunct, for example an active agent, comprises a non-polymer
material.
[0052] In another example, a fiber adjunct may comprise a
plasticizer for the filament. Non-limiting examples of suitable
plasticizers for the present invention include polyols, copolyols,
polycarboxylic acids, polyesters and dimethicone copolyols.
Examples of useful polyols include, but are not limited to,
glycerin, diglycerin, propylene glycol, ethylene glycol, butylene
glycol, pentylene glycol, cyclohexane dimethanol, hexanediol,
2,2,4-trimethylpentane-1,3-diol, polyethylene glycol (200-600),
pentaerythritol, sugar alcohols such as sorbitol, manitol, lactitol
and other mono- and polyhydric low molecular weight alcohols (e.g.,
C2-C8 alcohols); mono di- and oligo-saccharides such as fructose,
glucose, sucrose, maltose, lactose, high fructose corn syrup
solids, and dextrins, and ascorbic acid.
[0053] In one example, the plasticizer includes glycerin and/or
propylene glycol and/or glycerol derivatives such as propoxylated
glycerol. In still another example, 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
[0054] In another example, a fiber adjunct may comprise a rheology
modifier, such as a shear modifier and/or an extensional modifier.
Non-limiting examples of rheology modifiers include but not limited
to polyacrylamide, polyurethanes and polyacrylates that may be used
in the filaments of the present invention. Non-limiting examples of
rheology modifiers are commercially available from The Dow Chemical
Company (Midland, Mich.).
[0055] In yet another example, a fiber adjunct may comprise one or
more colors and/or dyes that are incorporated into the filaments of
the present invention to provide a visual signal when the filaments
are exposed to conditions of intended use and/or when an active
agent is released from the filaments and/or when the filament's
morphology changes.
[0056] In still yet another example, a fiber adjunct may comprise
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 amide, silicones,
aminosilicones, fluoropolymers, and mixtures thereof. In one
example, the release agents and/or lubricants may be applied to the
filament, in other words, after the filament is formed. In one
example, one or more release agents/lubricants may be applied to
the filament prior to collecting the filaments on a collection
device to form a fibrous structure. In another example, one or more
release agents/lubricants may be applied to a fibrous structure
formed from the filaments of the present invention prior to
contacting one or more fibrous structures, such as in a stack of
fibrous structures. In yet another example, one or more release
agents/lubricants may be applied to the filament of the present
invention and/or fibrous structure comprising the filament prior to
the filament and/or fibrous structure contacting a surface, such as
a surface of equipment used in a processing system so as to
facilitate removal of the filament and/or fibrous structure and/or
to avoid layers of filaments and/or plies of fibrous structures of
the present invention sticking to one another, even inadvertently.
In one example, the release agents/lubricants comprise
particulates.
[0057] In even still yet another example, a fiber adjunct may
comprise one or more anti-blocking and/or detackifying agents.
Non-limiting examples of suitable anti-blocking and/or detackifying
agents include starches, starch derivatives, crosslinked
polyvinylpyrrolidone, crosslinked cellulose, microcrystalline
cellulose, silica, metallic oxides, calcium carbonate, talc, mica,
and mixtures thereof.
[0058] "Conditions of intended use" as used herein means the
temperature, physical, chemical, and/or mechanical conditions that
a filament and/or particle and/or fibrous structure of the present
invention is exposed to when the filament and/or particle and/or
fibrous structure is used for one or more of its designed purposes.
For example, if a filament and/or a particle and/or a fibrous
structure comprising a filament is designed to be used in a washing
machine for laundry care purposes, the conditions of intended use
will include those temperature, chemical, physical and/or
mechanical conditions present in a washing machine, including any
wash water, during a laundry washing operation. In another example,
if a filament and/or a particle and/or a fibrous structure
comprising a filament is designed to be used by a human as a
shampoo for hair care purposes, the conditions of intended use will
include those temperature, chemical, physical and/or mechanical
conditions present during the shampooing of the human's hair.
Likewise, if a filament and/or a particle and/or a fibrous
structure comprising a filament is designed to be used in a
dishwashing operation, by hand or by a dishwashing machine, the
conditions of intended use will include the temperature, chemical,
physical and/or mechanical conditions present in a dishwashing
water and/or dishwashing machine, during the dishwashing
operation.
[0059] "Active agent" as used herein means a fiber adjunct that
produces an intended effect in an environment external to a
filament and/or a particle and/or a fibrous structure comprising a
filament of the present invention, such as when the filament and/or
a particle and/or fibrous structure is exposed to conditions of
intended use of the filament and/or a particle and/or a fibrous
structure comprising a filament. In one example, an active agent
comprises a fiber adjunct that treats a surface, such as a hard
surface (i.e., kitchen countertops, bath tubs, toilets, toilet
bowls, sinks, floors, walls, teeth, cars, windows, mirrors, dishes)
and/or a soft surface (i.e., fabric, hair, skin, carpet, crops,
plants,). In another example, an active agent comprises additive
fiber adjunct that creates a chemical reaction (i.e., foaming,
fizzing, effervescing, coloring, warming, cooling, lathering,
disinfecting and/or clarifying and/or chlorinating, such as in
clarifying water and/or disinfecting water and/or chlorinating
water). In yet another example, an active agent comprises a fiber
adjunct that treats an environment (i.e., deodorizes, purifies,
perfumes air). In one example, the active agent is formed in situ,
such as during the formation of the filament and/or particle
containing the active agent, for example the filament and/or
particle may comprise a water-soluble polymer (e.g., starch) and a
surfactant (e.g., anionic surfactant), which may create a polymer
complex or coacervate that functions as the active agent used to
treat fabric surfaces.
[0060] "Treats" as used herein with respect to treating a surface
means that the active agent provides a benefit to a surface or
environment. Treats includes regulating and/or immediately
improving a surface's or environment's appearance, cleanliness,
smell, purity and/or feel. In one example treating in reference to
treating a keratinous tissue (for example skin and/or hair) surface
means regulating and/or immediately improving the keratinous
tissue's cosmetic appearance and/or feel. For instance, "regulating
skin, hair, or nail (keratinous tissue) condition" includes:
thickening of skin, hair, or nails (e.g, building the epidermis
and/or dermis and/or sub-dermal [e.g., subcutaneous fat or muscle]
layers of the skin, and where applicable the keratinous layers of
the nail and hair shaft) to reduce skin, hair, or nail atrophy,
increasing the convolution of the dermal-epidermal border (also
known as the rete ridges), preventing loss of skin or hair
elasticity (loss, damage and/or inactivation of functional skin
elastin) such as elastosis, sagging, loss of skin or hair recoil
from deformation; melanin or non-melanin change in coloration to
the skin, hair, or nails such as under eye circles, blotching
(e.g., uneven red coloration due to, e.g., rosacea) (hereinafter
referred to as "red blotchiness"), sallowness (pale color),
discoloration caused by telangiectasia or spider vessels, and
graying hair. Treats may include providing a benefit to fabrics
like during a cleaning or softening in a laundry machine, providing
a benefit to hair like during shampooing, conditioning, or coloring
of hair, or providing a benefit to environments like a toilet bowl
by cleaning or disinfecting it.
[0061] In another example, treating means removing stains and/or
odors from fabric articles, such as clothes, towels, linens, and/or
hard surfaces, such as countertops and/or dishware including pots
and pans.
[0062] "Fabric care active agent" as used herein means an active
agent that when applied to a fabric provides a benefit and/or
improvement to the fabric. Non-limiting examples of benefits and/or
improvements to a fabric include cleaning (for example by
surfactants), stain removal, stain reduction, wrinkle removal,
color restoration, static control, wrinkle resistance, permanent
press, wear reduction, wear resistance, pill removal, pill
resistance, soil removal, soil resistance (including soil release),
shape retention, shrinkage reduction, softness, fragrance,
anti-bacterial, anti-viral, odor resistance, and odor removal.
[0063] "Dishwashing active agent" as used herein means an active
agent that when applied to dishware, glassware, pots, pans,
utensils, and/or cooking sheets provides a benefit and/or
improvement to the dishware, glassware, plastic items, pots, pans
and/or cooking sheets. Non-limiting examples of benefits and/or
improvements to the dishware, glassware, plastic items, pots, pans,
utensils, and/or cooking sheets include food and/or soil removal,
cleaning (for example by surfactants) stain removal, stain
reduction, grease removal, water spot removal and/or water spot
prevention, glass and metal care, sanitization, shining, and
polishing.
[0064] "Hard surface active agent" as used herein means an active
agent when applied to floors, countertops, sinks, windows, mirrors,
showers, baths, and/or toilets provides a benefit and/or
improvement to the floors, countertops, sinks, windows, mirrors,
showers, baths, and/or toilets. Non-limiting examples of benefits
and/or improvements to the floors, countertops, sinks, windows,
mirrors, showers, baths, and/or toilets include food and/or soil
removal, cleaning (for example by surfactants), stain removal,
stain reduction, grease removal, water spot removal and/or water
spot prevention, limescale removal, disinfection, shining,
polishing, and freshening.
[0065] "Keratinous tissue active agent" as used herein means an
active agent that may be useful for treating keratinous tissue
(e.g., hair, skin, or nails) condition. For a hair care active
agent, "treating" or "treatment" or "treat" includes regulating
and/or immediately improving keratinous tissue cosmetic appearance
and/or feel. For instance, "regulating skin, hair, or nail
condition" includes: thickening of skin, hair, or nails (e.g.,
building the epidermis and/or dermis and/or sub-dermal [e.g.,
subcutaneous fat or muscle] layers of the skin, and where
applicable the keratinous layers of the nail and hair shaft) to
reduce skin, hair, or nail atrophy, increasing the convolution of
the dermal-epidermal border (also known as the rete ridges),
preventing loss of skin or hair elasticity (loss, damage and/or
inactivation of functional skin elastin) such as elastosis,
sagging, loss of skin or hair recoil from deformation; melanin or
non-melanin change in coloration to the skin, hair, or nails such
as under eye circles, blotching (e.g., uneven red coloration due
to, e.g., rosacea) (hereinafter referred to as "red blotchiness"),
sallowness (pale color), discoloration caused by telangiectasia or
spider vessels, and graying hair. Another example of keratinous
tissue active agent may be an active agent used in the shampooing,
conditioning, or dyeing of hair.
[0066] "Weight ratio" as used herein means the ratio between two
materials on their dry basis. For example, the weight ratio of
filament-forming materials to active agents within a filament is
the ratio of the weight of filament-forming material on a dry
weight basis (g or %) in the filament to the weight of fiber
adjunct, such as active agent(s) on a dry weight basis (g or
%--same units as the filament-forming material weight) in the
filament. In another example, the weight ratio of particles to
filaments within a fibrous structure is the ratio of the weight of
particles on a dry weight basis (g or %) in the fibrous structure
to the weight of filaments on a dry weight basis (g or %--same
units as the particle weight) in the fibrous structure.
[0067] "Water-soluble material" as used herein means a material
that is miscible in water. In other words, a material that is
capable of forming a stable (does not separate for greater than 5
minutes after forming the homogeneous solution) homogeneous
solution with water at ambient conditions.
[0068] "Ambient conditions" as used herein means 23.degree.
C..+-.1.0.degree. C. and a relative humidity of 50%.+-.2%.
[0069] "Weight average molecular weight" as used herein means the
weight average molecular weight as determined using gel permeation
chromatography according to the protocol found in Colloids and
Surfaces A. Physico Chemical & Engineering Aspects, Vol. 162,
2000, pg. 107-121 as measured according to the Weight Average
Molecular Weight Test Method described herein.
[0070] "Length" as used herein, with respect to a filament, means
the length along the longest axis of the filament from one terminus
to the other terminus. If a filament has a kink, curl or curves in
it, then the length is the length along the entire path of the
filament from one terminus to the other terminus.
[0071] "Diameter" as used herein, with respect to a filament, is
measured according to the Diameter Test Method described herein. In
one example, a filament of the present invention exhibits a
diameter of less than 100 .mu.m and/or less than 75 .mu.m and/or
less than 50 .mu.m and/or less than 25 .mu.m and/or less than 20
.mu.m and/or less than 15 .mu.m and/or less than 10 .mu.m and/or
less than 6 .mu.m and/or greater than 1 .mu.m and/or greater than 3
.mu.m.
[0072] "Triggering condition" as used herein in one example means
anything, as an act or event, that serves as a stimulus and
initiates or precipitates a change in the filament and/or particle
and/or fibrous structure of the present invention, such as a loss
or altering of the filament's and/or fibrous structure's physical
structure and/or a release of a fiber adjunct, such as an active
agent therefrom. In another example, the triggering condition may
be present in an environment, such as water, when a filament and/or
particle and/or fibrous structure of the present invention is added
to the water. In other words, nothing changes in the water except
for the fact that the filament and/or fibrous structure of the
present invention is added to the water.
[0073] "Morphology changes" as used herein with respect to a
filament's and/or particle's morphology changing means that the
filament experiences a change in its physical structure.
Non-limiting examples of morphology changes for a filament and/or
particle of the present invention include dissolution, melting,
swelling, shrinking, breaking into pieces, exploding, lengthening,
shortening, and combinations thereof. The filaments and/or
particles of the present invention may completely or substantially
lose their filament or particle physical structure or they may have
their morphology changed or they may retain or substantially retain
their filament or particle physical structure as they are exposed
to conditions of intended use.
[0074] "By weight on a dry filament basis" and/or "by weight on a
dry particle basis" and/or "by weight on a dry fibrous structure
basis" means the weight of the filament and/or particle and/or
fibrous structure, respectively, measured immediately after the
filament and/or particle and/or fibrous structure, respectively,
has been conditioned in a conditioned room at a temperature of
23.degree. C..+-.1.0.degree. C. and a relative humidity of
50%.+-.10% for 2 hours. In one example, by weight on a dry filament
basis and/or dry particle basis and/or dry fibrous structure basis
means that the filament and/or particle and/or fibrous structure
comprises less than 20% and/or less than 15% and/or less than 10%
and/or less than 7% and/or less than 5% and/or less than 3% and/or
to 0% and/or to greater than 0% based on the dry weight of the
filament and/or particle and/or fibrous structure of moisture, such
as water, for example free water, as measured according to the
Water Content Test Method described herein.
[0075] "Total level" as used herein, for example with respect to
the total level of one or more active agents present in the
filament and/or particle and/or fibrous structure, means the sum of
the weights or weight percent of all of the subject materials, for
example active agents. In other words, a filament and/or particle
and/or fibrous structure may comprise 25% by weight on a dry
filament basis and/or dry particle basis and/or dry fibrous
structure basis of an anionic surfactant, 15% by weight on a dry
filament basis and/or dry particle basis and/or dry fibrous
structure basis of a nonionic surfactant, 10% by weight of a
chelant on a dry filament basis and/or dry particle basis and/or
dry fibrous structure basis, and 5% by weight of a perfume a dry
filament basis and/or dry particle basis and/or dry fibrous
structure basis so that the total level of active agents present in
the filament and/or particle and/or fibrous structure is greater
than 50%; namely 55% by weight on a dry filament basis and/or dry
particle basis and/or dry fibrous structure basis.
[0076] "Fibrous structure product" as used herein means a solid
form, for example a rectangular solid, sometimes referred to as a
sheet, that comprises one or more active agents, for example a
fabric care active agent, a dishwashing active agent, a hard
surface active agent, and mixtures thereof. In one example, a
fibrous structure product of the present invention comprises one or
more surfactants, one or more enzymes (such as in the form of an
enzyme prill and/or an enzyme liquid), one or more perfumes and/or
one or more suds suppressors.
[0077] In one example, one or more active agents, in particle or
liquid form, may be deposited onto one or more surfaces of the
fibrous structures of the present invention. For example, enzyme
suspensions, perfumes, microcapsule slurries, oils, silicones,
surfactant pastes, sometimes referred to herein as minors, may be
deposited onto one or more surfaces of the fibrous structures
during making of the fibrous structures and/or converting of the
fibrous structures. Such application may reside on the surface of
the fibrous layer or may substantially imbibe into the fibrous
structure.
[0078] In another example, a fibrous structure product of the
present invention comprises a builder and/or a chelating agent. In
another example, a fibrous structure product of the present
invention comprises a bleaching agent (such as an encapsulated
bleaching agent).
[0079] "Different from" or "different" as used herein means, with
respect to a material, such as a filament as a whole and/or a
filament-forming material within a filament and/or an active agent
within a filament, that one material, such as a filament and/or a
filament-forming material and/or an active agent, is chemically,
physically and/or structurally different from another material,
such as a filament and/or a filament-forming material and/or an
active agent. For example, a filament-forming material in the form
of a filament is different from the same filament-forming material
in the form of a fiber. Likewise, a starch polymer is different
from a cellulose polymer. However, different molecular weights of
the same material, such as different molecular weights of a starch,
are not different materials from one another for purposes of the
present invention.
[0080] "Random mixture of polymers" as used herein means that two
or more different filament-forming materials are randomly combined
to form a filament. Accordingly, two or more different
filament-forming materials that are orderly combined to form a
filament, such as a core and sheath bicomponent filament, is not a
random mixture of different filament-forming materials for purposes
of the present invention.
[0081] "Associate," "Associated," "Association," and/or
"Associating" as used herein with respect to filaments and/or
particle means combining, either in direct contact or in indirect
contact, filaments and/or particles such that a fibrous structure
is formed. In one example, the associated filaments and/or
particles may be bonded together for example by adhesives and/or
thermal bonds. In another example, the filaments and/or particles
may be associated with one another by being deposited onto the same
fibrous structure making belt and/or patterned belt.
[0082] "Machine Direction" or "MD" as used herein means the
direction parallel to the flow of the fibrous structure through the
fibrous structure making machine and/or fibrous structure product
manufacturing equipment.
[0083] "Cross Machine Direction" or "CD" as used herein means the
direction perpendicular to the machine direction in the same plane
of the fibrous structure and/or fibrous structure product
comprising the fibrous structure.
[0084] "Ply" or "Plies" as used herein means an individual fibrous
structure optionally to be disposed in a substantially contiguous,
face-to-face relationship with other plies, forming a multiple ply
fibrous structure. It is also contemplated that a single fibrous
structure can effectively form two "plies" or multiple "plies", for
example, by being folded on itself. A ply may comprise layers of
filaments, filament/particle blends, and/or particles. In another
embodiment, there may be a layer of filaments or particles between
plies.
[0085] As used herein, the articles "a" and "an" when used herein,
for example, "an anionic surfactant" or "a fiber" is understood to
mean one or more of the material that is claimed or described.
[0086] 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.
[0087] Unless otherwise noted, all component or composition levels
are in reference to the active level of that component or
composition, and are exclusive of impurities, for example, residual
solvents or by-products, which may be present in commercially
available sources.
Process for Making an Article of Manufacture
[0088] In one example of the present invention, as shown in FIG. 1,
a process 10 for making, for example continuously making, an
article of manufacture 12 comprising a fibrous structure 14, for
example a soluble fibrous structure, comprises at least the
following steps: 1) a filament-forming composition making operation
16 comprising one or more steps to make a filament-forming
composition 18, which is then delivered, for example via piping, to
the next operation; namely, a spinning operation 20; 2) a spinning
operation 20 comprising one or more steps for spinning a
filament-forming composition, for example the filament-forming
composition 18 made in the filament-forming composition making
operation 16, to make filaments 22, for example soluble filaments;
3) optionally, a commingling operation 24 comprising one or more
steps of commingling, for example coforming, a plurality of solid
additives, for example particles 26, with the filaments 22; and 4)
a collecting operation 28 comprising one or more collection steps
for collecting the filaments 22 and/or commingled filaments 22 and
solid additives, for example particles 26, on a collection device,
such as a belt and/or rotary drum, to form a fibrous structure 14
comprising filaments 22 and optionally, solid additives, for
example particles 26, for example a soluble fibrous structure,
wherein the operations (1-4) when present are performed in a
continuous manner, one step after the other without any breaks or
stoppages or interruptions in the process from making a
filament-forming composition 18 to spinning the filament-forming
composition 18 into filaments 22 (optionally commingling solid
additives, for example particles 26, with the filaments 22) to
collecting the filaments 22 (and/or commingled filaments 22 and
solid additives, for example particles 26) on a collection device
to form a fibrous structure 14 comprising filaments 22 and
optionally, solid additives, for example particles 26.
[0089] Once the fibrous structure 14 is formed, then the fibrous
structure 14 may then be converted into an article of manufacture
12, which may be a consumable, saleable unit, via a converting
operation 30, which comprises one or more steps for converting the
fibrous structure 14 into an article of manufacture 12, wherein one
or more of the converting steps may be continuous with the earlier
operations (1-4) of the process 10. Once the fibrous structure 14
has been converted into an article of manufacture 12 comprising the
fibrous structure 14, for example one or more, two or more, three
or more, four or more, five or more plies of the fibrous structure
14, then the article of manufacture 12 can be packaged into a
package 32 comprising an external packaging material 34, such as a
packaging film, a cardboard box, and the like, via a packaging
operation 36.
[0090] In one example, the process for making an article of
manufacture and/or process steps such as the spinning operation,
the commingling (coforming) operation, the collecting operation,
the converting operation, and the packaging operation, according to
the present invention may independently be performed at a relative
humidity of from about 20% to about 75% and/or from about 30% to
about 65% and/or from about 35% to about 60%.
[0091] The converting operation 30 may comprise one or more steps
for converting (for example slitting and/or stacking and/or
calendering and/or treating with optional ingredients (such as
adding optional ingredients to the fibrous structure 14, for
example to a surface of the fibrous structure 14), such as
perfumes, enzymes, bleaches, flavoring agents, effervescent agents,
and the like, die-cutting, and printing) the fibrous structure 14
into one or more articles of manufacture 12, for example a consumer
product); and 6) optionally, a packaging operation 36 comprising
one or more steps for packaging one or more articles of manufacture
12, for example a consumer product, such as a soluble consumer
product, into a package 32.
[0092] In one example, the converting operation may include die
cutting into a desired shape, for example to maximize the number of
articles of manufacture produced from a fibrous structure or
multiple desired shapes, printing, optional ingredient (minors)
additions, rolling up a fibrous structure on a roll as converting
line step, including where all this is done in a single process or
on a single converting line. For example, the process of the
present invention may comprise one or more converting operations
and/or steps selected from the group consisting of: slitting,
stacking, calendering, treating with optional ingredients, die
cutting, printing, packaging, mechanical plybonding, chemical
plybonding, and/or combinations thereof. In one example, one or
more or all of these converting operations and/or steps are
performed on a single converting line, which may be directly
coupled to the fibrous structure making line (for example
spinning/commingling/collecting operations) and the
filament-forming composition making operation. In one example, as
discussed herein, the total process from filament-forming
composition operation through the converting operation, and
optionally the packaging operation to make an article of
manufacture according to the present invention may occur on a
single manufacturing line, for example a single, continuous
manufacturing line. The converting operation may ultimately yield a
consumer useable saleable unit.
[0093] In one example, process is such that a fibrous structure,
for example a composite structure, formed in the collecting
operation is further transformed with converting operations and/or
steps selected from the group consisting of: slitting, stacking,
calendering, treating with optional ingredients, die cutting,
printing, packaging, mechanical plybonding, chemical plybonding,
and/or combinations thereof on a unitary manufacturing line, for
example on a single ply, multi-ply, or any surface of a single or
multi-ply article into a consumer useable saleable unit.
[0094] a. Filament-Forming Composition Making Operation (16)
[0095] As shown in FIG. 2, in one example, a filament-forming
composition 18 is made by providing one or more filament-forming
materials 38, for example one or more soluble filament-forming
materials, for example one or more hydroxyl polymers, such as
polyvinyl alcohol, to which water or another polar solvent are
added resulting in an aqueous or polar solvent composition
comprising the soluble filament-forming materials and water or
polar solvent. The aqueous or polar solvent composition is then
processed, for example polymer processed, in an extruder to form a
filament-forming composition 18, which is then suitable for
delivering to one or more dies for spinning into a plurality of
filaments 22 in a spinning operation 20. In one example, the
aqueous or polar solvent composition may be processed in a batch
tank (not shown).
[0096] In one example, the filament-forming material 38 is
sufficiently cooked to form a homogeneous aqueous or polar solvent
composition of the filament-forming material 38.
[0097] In one example, at least about 30% and/or at least about 40%
and/or to about 70% and/or to about 60% by weight of water is added
to the one or more filament-forming materials 38 during the
filament-forming composition making operation 16.
[0098] In one example, the filament-forming material 38 may be
added at a solids concentration of greater than 40% and/or greater
than 50% and/or greater than 60% and/or from about 60% to about 80%
and/or from about 60% to about 70%.
[0099] In one example, the filament-forming material 38 may be
present in the filament-forming composition at a level of greater
than 5% and/or greater than 10% and/or greater than 13% and/or less
than 50% and/or less than 40% and/or less than 30% and/or less than
25%
[0100] In one example, the filament-forming material 38 may be
present in the extruder at a level of greater than 10% and/or
greater than 20% and/or greater than 30% and/or less than 90%
and/or less than 80% and/or less than 70% and/or less than 65%.
[0101] In one example, the filament-forming material 38 may be in
solid form, for example in a dry solid form 40, such as pellets
and/or powder. In one example, the filament-forming material 38 and
water and/or another polar solvent utilized to solubilize the
filament-forming material 38 are added to an extruder 42 via a
hopper 44, for example a twin screw extruder, and heated,
processed, and mixed to solubilize the filament-forming material
38. In one example, entrained air within the aqueous solution
and/or polar solvent solution comprising the filament-forming
material 18 within the extruder 40 is minimized and/or eliminated.
The water and/or polar solvent may be added to the extruder 42 via
a pump 46.
[0102] When the filament-forming material 38 is in solid form, the
solid filament-forming material, for example one or more hydroxyl
polymers, such as polyvinyl alcohol, is added from a hopper 44, for
example in a continuous process, to an extruder 42, for example a
single screw extruder or twin screw extruder, for example a twin
screw extruder, such as a Coperion ZSK 26 twin screw extruder (Max.
Speed 1200 rpm, Max. Torque per Screw Shaft 106 Nm, Diameter of
Screws 25.5 mm, Length of Screws 900 mm, # of Barrel Sections 9,
Heating and Cooling for each Zone, Flight Depth 4.55 mm, Est.
Throughput 20-60 kg/hr). In this example, as shown in FIG. 3 the
addition of the solid filament-forming material to the extruder 42
occurs in Zone 1 of the extruder 42. The purpose of adding the
filament-forming material 38 to an extruder 42 is to achieve
hydration of the filament-forming material 38 and to solubilize the
filament-forming material 38, especially if it is originally in a
solid form.
[0103] Non-limiting examples of suitable filament-forming materials
38 include polymers, for example polymers selected from the group
consisting of: pullulan, hydroxypropylmethyl cellulose,
hydroxyethyl cellulose, hydroxypropyl cellulose, methyl cellulose,
polyvinyl pyrrolidone, carboxymethyl cellulose, sodium alginate,
xanthan gum, tragacanth gum, guar gum, acacia gum, Arabic gum,
polyacrylic acid, methylmethacrylate copolymer, carboxyvinyl
polymer, dextrin, pectin, chitin, levan, elsinan, collagen,
gelatin, zein, gluten, soy protein, casein, polyvinyl alcohol,
carboxylated polyvinyl alcohol, sulfonated polyvinyl alcohol,
starch, starch derivatives, hemicellulose, hemicellulose
derivatives, proteins, chitosan, chitosan derivatives, polyethylene
glycol, tetramethylene ether glycol, hydroxymethyl cellulose,
polyethylene oxide, and mixtures thereof.
[0104] In one example, the filament-forming material 38 is a
water-soluble material that produces a soluble filament, for
example a water-soluble filament.
[0105] In one example, the filament-forming material 38 comprises
polyvinyl alcohol.
[0106] Water and/or another polar solvent is added via a pump 46,
for example in a continuous process, to the extruder 42 containing
the filament-forming material 18, to mix with and solubilize the
filament-forming material 18 within the extruder 42. The water
and/or other polar solvent are added to the extruder 42 in Zone 3
as shown in FIG. 3.
[0107] The extruder 42 may be run such that it exhibits a wet
throughput of at least about 5 and/or at least about 10 and/or at
least about 15 and/or at least about 20 and/or at least about 40 at
least about 80 and/or from about 5 to about 200 and/or from about
80 to about 135 kg/hr, in one example to produce a full
filament-forming material flow rate of from about 100 to about 700
kg/hr and/or from about 345 to about 575 kg/hr, a dry throughput of
at least about 2 and/or at least about 4 and/or at least about 6
and/or at least about 10 and/or at least about 15 and/or at least
about 20 and/or from about 2 to about 120 and/or from about 10 to
about 85 and/or from about 20 to about 85 kg/hr and/or from about
50 to about 85 kg/hr, a maximum screw speed of less than about 1600
rpm and/or less than about 1400 rpm and/or less than about 1200 rpm
and/or from about 200 to about 1600 rpm and/or from about 400 to
1400 rpm and/or from about 600 to about 1200 rpm, a % solids
(filament-forming material 38) of from about 20 to about 95% and/or
from about 30 to about 85% and/or from about 40 to about 70%, an
exit pressure of from about 10 to about 80 and/or from about 15 to
about 75 and/or from about 20 to about 65 bar setpoint, the
filament-forming composition may exit the extruder at a SME (solids
throughput basis) of from about 0.10 to about 0.50 and/or from
about 0.12 to about 0.45 and/or from about 0.14 to about 0.35
kW-h/kg, and wherein the extruder subjects the filament-forming
composition to a temperature of at least 49.degree. C., with
example barrel temperatures of the extruder run as shown in Table 1
below:
TABLE-US-00001 TABLE 1 Zone 2 3 4 5 6 7 8 9 8-0 Pump Die Temp
Setpoint (.degree. C.) 25 49 66 121 121 135 135 135 135 135 135 "A"
Temp Setpoint (.degree. C.) 40 100 150 150 150 150 150 150 150 150
150 "B" Temp Setpoint (.degree. C.) 40 100 150 150 160 160 160 160
160 160 160 "C" Temp Setpoint (.degree. C.) 40 100 150 150 160 170
170 170 170 170 170 "D" Temp Setpoint (.degree. C.) 40 80 80 130
140 140 170 170 170 170 170 "E"
[0108] In addition to solubilizing the filament-forming material 38
in an extruder 42 to produce a filament-forming composition 18, one
or more active agents 48, for example one or more surfactants, such
as a surfactant blend, for example a blend of anionic surfactants,
for example two or more different anionic surfactants, may be mixed
with the filament-forming composition 18 via one or more static
mixers 50, such as SMX mixers.
[0109] In one example, 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. The surfactants may be blended and or
co-neutralized with sodium hydroxide to form a low water containing
paste. In addition, other surfactants, such as alyklethoxylate
sulfates (AES), cosurfactants, such as amine oxide, linear alcohol
ethoxylates, glucamide-based surfactants, and branched versions of
the alkyl chain, such as MLAS and HSAS.
[0110] In one example, in addition to the one or more surfactants,
structurant, such as polyethylene oxide, such as a PEO 100K and/or
PEO N60K, and/or polyvinylpyrrolidone, may be mixed with the
surfactants to provide phase stability. Optionally, other
ingredients may also be mixed with the surfactants, such as salts,
for example sodium sulfate.
[0111] In one example, the filament-forming composition 18 and thus
at least one filament 22 produced from spinning the
filament-forming composition 18 comprises one or more active agents
48, in the case of the filament 22 the one or more active agents 48
are present within the filament 22.
[0112] In one example, the active agent 48 comprises a surfactant
selected from the group consisting of: anionic surfactants,
cationic surfactants, nonionic surfactants, zwitterionic
surfactants, amphoteric surfactants, and mixtures thereof.
[0113] In one example, the one or more active agents 48 is selected
from the group consisting of: fabric care active agents,
dishwashing active agents, carpet care active agents, surface care
active agents, air care active agents, oral care active agents (for
example teeth cleaning agents, teeth whitening agents, tooth care
agents, periodontal gum care agents, mouthwash agents, denture
cleaning agents, tongue cleaning agents, breath freshening agents,
fluoride agents, mouth rinse agents, anti-cavity agents, flavoring
agents), hair care active agents (shampoos and/or conditioners),
keratinaceous tissue care agents, toilet bowl cleaning agents, skin
care active agents, and mixtures thereof.
[0114] In one example, at least one of the active agents 48
comprises one or more effervescent agents.
[0115] 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
[0116] The filament-forming material is any suitable material, such
as a polymer or monomers capable of producing a polymer that
exhibits properties suitable for making a fibrous element, such as
by a spinning process.
[0117] In one example, the filament-forming material may comprise a
polar solvent-soluble material, such as an alcohol-soluble material
and/or a water-soluble material.
[0118] In another example, the filament-forming material may
comprise a non-polar solvent-soluble material.
[0119] In still another example, the filament forming material may
comprise a polar solvent-soluble material and be free (less than 5%
and/or less than 3% and/or less than 1% and/or 0% by weight on a
dry fibrous element basis and/or dry soluble fibrous structure
basis) of non-polar solvent-soluble materials.
[0120] In yet another example, the filament-forming material may be
a film-forming material. In still yet another example, the
filament-forming material may be synthetic or of natural origin and
it may be chemically, enzymatically, and/or physically
modified.
[0121] In even another example of the present invention, the
filament-forming material may comprise a polymer selected from the
group consisting of: polymers derived from acrylic monomers such as
the ethylenically unsaturated carboxylic monomers and ethylenically
unsaturated monomers, polyvinyl alcohol, polyacrylates,
polymethacrylates, copolymers of acrylic acid and methyl acrylate,
polyvinylpyrrolidones, polyalkylene oxides, starch and starch
derivatives, pullulan, gelatin, hydroxypropylmethylcelluloses,
methyl celluloses, and carboxymethycelluloses.
[0122] In still another example, the filament-forming material may
comprises a polymer selected from the group consisting of:
polyvinyl alcohol, polyvinyl alcohol derivatives, starch, starch
derivatives, cellulose derivatives, hemicellulose, hemicellulose
derivatives, proteins, sodium alginate, hydroxypropyl
methylcellulose, chitosan, chitosan derivatives, polyethylene
glycol, tetramethylene ether glycol, polyvinyl pyrrolidone,
hydroxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose,
and mixtures thereof.
[0123] In another example, the filament-forming material comprises
a polymer selected from the group consisting of: pullulan,
hydroxypropylmethyl cellulose, hydroxyethyl cellulose,
hydroxypropyl cellulose, methyl cellulose, polyvinyl pyrrolidone,
carboxymethyl cellulose, sodium alginate, xanthan gum, tragacanth
gum, guar gum, acacia gum, Arabic gum, polyacrylic acid,
methylmethacrylate copolymer, carboxyvinyl polymer, dextrin,
pectin, chitin, levan, elsinan, collagen, gelatin, zein, gluten,
soy protein, casein, polyvinyl alcohol, starch, starch derivatives,
hemicellulose, hemicellulose derivatives, proteins, chitosan,
chitosan derivatives, polyethylene glycol, tetramethylene ether
glycol, hydroxymethyl cellulose, and mixtures thereof.
Polar Solvent-Soluble Materials
[0124] Non-limiting examples of polar solvent-soluble materials
include polar solvent-soluble polymers. The polar solvent-soluble
polymers may be synthetic or natural original and may be chemically
and/or physically modified. In one example, the polar
solvent-soluble polymers exhibit a weight average molecular weight
of at least 10,000 g/mol and/or at least 20,000 g/mol and/or at
least 40,000 g/mol and/or at least 80,000 g/mol and/or at least
100,000 g/mol and/or at least 1,000,000 g/mol and/or at least
3,000,000 g/mol and/or at least 10,000,000 g/mol and/or at least
20,000,000 g/mol and/or to about 40,000,000 g/mol and/or to about
30,000,000 g/mol as measured according to the Weight Average
Molecular Weight Test Method described herein.
[0125] In one example, the polar solvent-soluble polymers are
selected from the group consisting of: alcohol-soluble polymers,
water-soluble polymers and mixtures thereof. Non-limiting examples
of water-soluble polymers include water-soluble hydroxyl polymers,
water-soluble thermoplastic polymers, water-soluble biodegradable
polymers, water-soluble non-biodegradable polymers and mixtures
thereof. In one example, the water-soluble polymer comprises
polyvinyl alcohol. In another example, the water-soluble polymer
comprises starch. In yet another example, the water-soluble polymer
comprises polyvinyl alcohol and starch.
[0126] a. Water-soluble Hydroxyl Polymers--Non-limiting examples of
water-soluble hydroxyl polymers in accordance with the present
invention include polyols, such as polyvinyl alcohol, polyvinyl
alcohol derivatives, polyvinyl alcohol copolymers, starch, starch
derivatives, starch copolymers, chitosan, chitosan derivatives,
chitosan copolymers, cellulose derivatives such as cellulose ether
and ester derivatives, cellulose copolymers, hemicellulose,
hemicellulose derivatives, hemicellulose copolymers, gums,
arabinans, galactans, proteins and various other polysaccharides
and mixtures thereof.
[0127] In one example, a water-soluble hydroxyl polymer of the
present invention comprises a polysaccharide.
[0128] "Polysaccharides" as used herein means natural
polysaccharides and polysaccharide derivatives and/or modified
polysaccharides. Suitable water-soluble polysaccharides include,
but are not limited to, starches, starch derivatives, chitosan,
chitosan derivatives, cellulose derivatives, hemicellulose,
hemicellulose derivatives, gums, arabinans, galactans and mixtures
thereof. The water-soluble polysaccharide may exhibit a weight
average molecular weight of from about 10,000 to about 40,000,000
g/mol and/or greater than 100,000 g/mol and/or greater than
1,000,000 g/mol and/or greater than 3,000,000 g/mol and/or greater
than 3,000,000 to about 40,000,000 g/mol as measured according to
the Weight Average Molecular Weight Test Method described
herein.
[0129] The water-soluble polysaccharides may comprise non-cellulose
and/or non-cellulose derivative 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, chitosan, chitosan derivatives,
hemicellulose, hemicellulose derivatives, gums, arabinans,
galactans and mixtures thereof.
[0130] In another example, a water-soluble hydroxyl polymer of the
present invention comprises a non-thermoplastic polymer.
[0131] The water-soluble hydroxyl polymer may have a weight average
molecular weight of from about 10,000 g/mol to about 40,000,000
g/mol and/or greater than 100,000 g/mol and/or greater than
1,000,000 g/mol and/or greater than 3,000,000 g/mol and/or greater
than 3,000,000 g/mol to about 40,000,000 g/mol as measured
according to the Weight Average Molecular Weight Test Method
described herein. Higher and lower molecular weight water-soluble
hydroxyl polymers may be used in combination with hydroxyl polymers
having a certain desired weight average molecular weight.
[0132] Well known modifications of water-soluble hydroxyl polymers,
such as natural starches, include chemical modifications and/or
enzymatic modifications. For example, natural starch can be
acid-thinned, hydroxy-ethylated, hydroxy-propylated, and/or
oxidized. In addition, the water-soluble hydroxyl polymer may
comprise dent corn starch.
[0133] Naturally occurring starch is generally a mixture of linear
amylose and branched amylopectin polymer of D-glucose units. The
amylose is a substantially linear polymer of D-glucose units joined
by (1,4)-.alpha.-D links. The amylopectin is a highly branched
polymer of D-glucose units joined by (1,4)-.alpha.-D links and
(1,6)-.alpha.-D links at the branch points. Naturally occurring
starch typically contains relatively high levels of amylopectin,
for example, corn starch (64-80% amylopectin), waxy maize (93-100%
amylopectin), rice (83-84% amylopectin), potato (about 78%
amylopectin), and wheat (73-83% amylopectin). Though all starches
are potentially useful herein, the present invention is most
commonly practiced with high amylopectin natural starches derived
from agricultural sources, which offer the advantages of being
abundant in supply, easily replenishable and inexpensive.
[0134] As used herein, "starch" includes any naturally occurring
unmodified starches, modified starches, synthetic starches and
mixtures thereof, as well as mixtures of the amylose or amylopectin
fractions; the starch may be modified by physical, chemical, or
biological processes, or combinations thereof. The choice of
unmodified or modified starch for the present invention may depend
on the end product desired. In one embodiment of the present
invention, the starch or starch mixture useful in the present
invention has an amylopectin content from about 20% to about 100%,
more typically from about 40% to about 90%, even more typically
from about 60% to about 85% by weight of the starch or mixtures
thereof.
[0135] Suitable naturally occurring starches can include, but are
not limited to, corn starch, potato starch, sweet potato starch,
wheat starch, sago palm starch, tapioca starch, rice starch,
soybean starch, arrow root starch, amioca starch, bracken starch,
lotus starch, waxy maize starch, and high amylose corn starch.
Naturally occurring starches particularly, corn starch and wheat
starch, are the preferred starch polymers due to their economy and
availability.
[0136] Polyvinyl alcohols herein can be grafted with other monomers
to modify its properties. A wide range of monomers has been
successfully grafted to polyvinyl alcohol. Non-limiting examples of
such monomers include vinyl acetate, styrene, acrylamide, acrylic
acid, 2-hydroxyethyl methacrylate, acrylonitrile, 1,3-butadiene,
methyl methacrylate, methacrylic acid, maleic acid, itaconic acid,
sodium vinylsulfonate, sodium allylsulfonate, sodium methylallyl
sulfonate, sodium phenylallylether sulfonate, sodium
phenylmethallylether sulfonate, 2-acrylamide-methyl propane
sulfonic acid (AMPs), vinylidene chloride, vinyl chloride, vinyl
amine and a variety of acrylate esters.
[0137] In one example, the water-soluble hydroxyl polymer is
selected from the group consisting of: polyvinyl alcohols,
hydroxymethylcelluloses, hydroxyethylcelluloses,
hydroxypropylmethylcelluloses methyl cellulose, and mixtures
thereof. A non-limiting example of a suitable polyvinyl alcohol
includes those commercially available from Sekisui Specialty
Chemicals America, LLC (Dallas, Tex.) under the CELVOL.RTM. trade
name. A non-limiting example of a suitable
hydroxypropylmethylcellulose includes those commercially available
from the Dow Chemical Company (Midland, Mich.) under the
METHOCEL.RTM. trade name including combinations with above
mentioned hydroxypropylmethylcelluloses.
[0138] b. Water-soluble Thermoplastic Polymers--Non-limiting
examples of suitable water-soluble thermoplastic polymers include
thermoplastic starch and/or starch derivatives, polylactic acid,
polyhydroxyalkanoate, polycaprolactone, polyesteramides and certain
polyesters, and mixtures thereof.
[0139] The water-soluble thermoplastic polymers of the present
invention may be hydrophilic or hydrophobic. The water-soluble
thermoplastic polymers may be surface treated and/or internally
treated to change the inherent hydrophilic or hydrophobic
properties of the thermoplastic polymer.
[0140] The water-soluble thermoplastic polymers may comprise
biodegradable polymers.
[0141] Any suitable weight average molecular weight for the
thermoplastic polymers may be used. For example, the weight average
molecular weight for a thermoplastic polymer in accordance with the
present invention is greater than about 10,000 g/mol and/or greater
than about 40,000 g/mol and/or greater than about 50,000 g/mol
and/or less than about 500,000 g/mol and/or less than about 400,000
g/mol and/or less than about 200,000 g/mol as measured according to
the Weight Average Molecular Weight Test Method described
herein.
Non-Polar Solvent-Soluble Materials
[0142] 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. A
non-limiting example of a polyester includes polyethylene
terephthalate.
[0143] The non-polar solvent-soluble materials may comprise a
non-biodegradable polymer such as polypropylene, polyethylene and
certain polyesters.
[0144] Any suitable weight average molecular weight for the
thermoplastic polymers may be used. For example, the weight average
molecular weight for a thermoplastic polymer in accordance with the
present invention is greater than about 10,000 g/mol and/or greater
than about 40,000 g/mol and/or greater than about 50,000 g/mol
and/or less than about 500,000 g/mol and/or less than about 400,000
g/mol and/or less than about 200,000 g/mol as measured according to
the Weight Average Molecular Weight Test Method described
herein.
Active Agents
[0145] Active agents are a class of fiber adjunct that are designed
and intended to provide a benefit to something other than the
fibrous element and/or particle and/or soluble fibrous structure
itself, such as providing a benefit to an environment external to
the fibrous element and/or particle and/or soluble fibrous
structure. Active agents may be any suitable fiber adjunct that
produces an intended effect under intended use conditions of the
fibrous 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 such as shampoo agents and/or hair
colorant agents, hair conditioning agents, skin care agents,
sunscreen agents, and skin conditioning agents; laundry care and/or
conditioning agents such as fabric care agents, fabric conditioning
agents, fabric softening agents, fabric anti-wrinkling agents,
fabric care anti-static agents, fabric care stain removal agents,
soil release agents, dispersing agents, suds suppressing agents,
suds boosting agents, anti-foam agents, and fabric refreshing
agents; liquid and/or powder dishwashing agents (for hand
dishwashing and/or automatic dishwashing machine applications),
hard surface care agents, and/or conditioning agents and/or
polishing agents; other cleaning and/or conditioning agents such as
antimicrobial agents, antibacterial agents, antifungal agents,
fabric hueing agents, perfume, bleaching agents (such as oxygen
bleaching agents, hydrogen peroxide, percarbonate bleaching agents,
perborate bleaching agents, chlorine bleaching agents), bleach
activating agents, chelating agents, builders, lotions, brightening
agents, air care agents, carpet care agents, dye
transfer-inhibiting agents, clay soil removing agents,
anti-redeposition agents, polymeric soil release agents, polymeric
dispersing agents, alkoxylated polyamine polymers, alkoxylated
polycarboxylate polymers, amphilic graft copolymers, dissolution
aids, buffering systems, water-softening agents, water-hardening
agents, pH adjusting agents, enzymes, flocculating agents,
effervescent agents, preservatives, cosmetic agents, make-up
removal agents, lathering agents, deposition aid agents,
coacervate-forming agents, clays, thickening agents, latexes,
silicas, drying agents, odor control agents, antiperspirant agents,
cooling agents, warming agents, absorbent gel agents,
anti-inflammatory agents, dyes, pigments, acids, and bases; liquid
treatment active agents; agricultural active agents; industrial
active agents; ingestible active agents such as medicinal agents,
teeth whitening agents, tooth care agents, mouthwash agents,
periodontal gum care agents, edible agents, dietary agents,
vitamins, minerals; water-treatment agents such as water clarifying
and/or water disinfecting agents, and mixtures thereof.
[0146] Non-limiting examples of suitable cosmetic agents, skin care
agents, skin conditioning agents, hair care agents, and hair
conditioning agents are described in CTFA Cosmetic Ingredient
Handbook, Second Edition, The Cosmetic, Toiletries, and Fragrance
Association, Inc. 1988, 1992.
[0147] 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 active agents described above.
Likewise, bleaching agents may be used for fabric care, hard
surface cleaning, dishwashing and even teeth whitening. Therefore,
one of ordinary skill in the art will appreciate that the active
agents will be selected based upon the desired intended use of the
fibrous element and/or particle and/or soluble fibrous structure
made therefrom.
[0148] For example, if the fibrous element and/or particle and/or
soluble fibrous structure made therefrom is to be used for hair
care and/or conditioning then one or more suitable surfactants,
such as a lathering surfactant could be selected to provide the
desired benefit to a consumer when exposed to conditions of
intended use of the fibrous element and/or particle and/or soluble
fibrous structure incorporating the fibrous element and/or
particle.
[0149] In one example, if the fibrous element and/or particle
and/or soluble fibrous structure made therefrom is designed or
intended to be used for laundering clothes in a laundry operation,
then one or more suitable surfactants and/or enzymes and/or
builders and/or perfumes and/or suds suppressors and/or bleaching
agents could be selected to provide the desired benefit to a
consumer when exposed to conditions of intended use of the fibrous
element and/or particle and/or soluble fibrous structure
incorporating the fibrous element and/or particle. In another
example, if the fibrous element and/or particle and/or soluble
fibrous structure made therefrom is designed to be used for
laundering clothes in a laundry operation and/or cleaning dishes in
a dishwashing operation, then the fibrous element and/or particle
and/or soluble fibrous structure may comprise a laundry detergent
composition or dishwashing detergent composition or active agents
used in such compositions. In still another example, if the fibrous
element and/or particle and/or soluble fibrous structure made
therefrom is designed to be used for cleaning and/or sanitizing a
toilet bowl, then the fibrous element and/or particle and/or
soluble fibrous structure made therefrom may comprise a toilet bowl
cleaning composition and/or effervescent composition and/or active
agents used in such compositions.
[0150] In one example, the active agent is selected from the group
consisting of: surfactants, bleaching agents, enzymes, suds
suppressors, suds boosting agents, fabric softening agents, denture
cleaning agents, hair cleaning agents, hair care agents, personal
health care agents, hueing agents, and mixtures thereof.
[0151] In one example, at least one of the active agents is
selected from the group consisting of: skin benefit agents,
medicinal agents, lotions, fabric care agents, dishwashing agents,
carpet care agents, surface care agents, hair care agents, air care
agents, and mixtures thereof.
[0152] The filament-forming composition 18 may then be mixed via
static mixers 50, such as SMX mixers, jacketed or unjacketed,
and/or pumped via piping and/or pumps 46, such as a booster pump,
to a spinning operation 20. The filament-forming composition 18
produced from the filament-forming composition making operation 16
may be delivered to one or more dies and/or one or more beams of
dies via one or more pumps 46. Before being delivered to the
spinning operation 20, the rheology of the filament-forming
composition 18 may be measured, offline or online, for example with
an online rheometer 52, to ensure that the filament-forming
composition's 18 rheology is suitable for spinning into filaments
22 via the spinning operation 20.
[0153] In one example, two or more different filament-forming
compositions may be produced and spun during the spinning
operation, such as from a split die, such as a 50/50 CD width split
die wherein each half of the die is spins two or more different
filament-forming compositions to form two or more different
filaments during the spinning operation and ultimately resulting in
a fibrous structure comprising two or more different filaments
produced from two or more different filament-forming
compositions.
[0154] In another example, two or more different filament-forming
compositions may be produced and spun during the spinning
operation, such as from two or more parallel dies, for example two
or more parallel full CD width dies wherein each die is spins a
different filament-forming composition to form two or more
different filaments during the spinning operation and ultimately
resulting in a fibrous structure comprising two or more different
filaments produced from two or more different filament-forming
compositions.
[0155] The formation and/or attenuation of a filament requires a
delicate balance of forces to be successful. First, the
filament-forming composition 18 must form a stable filament 20 as
it exits the die. When the viscosity of the filament-forming
composition 18 is too high, full attenuation cannot be achieved.
When the viscosity of the filament-forming composition 18 is too
low, the filament 20 will break under the attenuation forces.
Additionally, after the filament 20 has been attenuated down to
about 20 um diameter, stabilization ensues. The stabilization
process can be achieved in a number of ways, most notably drying
and/or crystallization. The rheological properties of the filament
20 as it transitions from a liquid (filament-forming composition
18) to a solid (filament 20) are of paramount importance in
successful filament spinning. In one example, the filament-forming
composition 18 of the present invention exhibits a Capillary Number
of greater than 1 and/or greater than 2 and/or greater than 3
and/or greater than 4 and/or greater than 5. In a fibrous element
spinning process, the fibrous elements need to have initial
stability as they leave the spinning die. In one example, the
filament-forming composition 18 exhibits a Capillary Number of from
at least about 1 to about 50 and/or at least about 3 to about 50
and/or at least about 5 to about 30 such that the filament-forming
composition 18 can be effectively polymer processed (spun) into a
filament 22.
[0156] The Capillary Number is a dimensionless number used to
characterize the likelihood of this droplet breakup. A larger
Capillary Number indicates greater fluid stability upon exiting the
die. The Capillary Number is defined as follows:
Ca = v * .eta. .sigma. ##EQU00001##
V is the fluid velocity at the die exit (units of Length per Time),
.eta. is the fluid viscosity at the conditions of the die (units of
Mass per Length*Time), .sigma. is the surface tension of the fluid
(units of mass per Time.sup.2). When velocity, viscosity, and
surface tension are expressed in a set of consistent units, the
resulting Capillary Number will have no units of its own; the
individual units will cancel out.
[0157] The Capillary Number is defined for the conditions at the
exit of the die. The fluid velocity is the average velocity of the
fluid passing through the die opening. The average velocity is
defined as follows:
V = Vol ' Area ##EQU00002##
Vol'=volumetric flowrate (units of Length.sup.3 per Time),
Area=cross-sectional area of the die exit (units of
Length.sup.2).
[0158] When the die opening is a circular hole, then the fluid
velocity can be defined as
V = Vol ' .pi. * R 2 ##EQU00003##
R is the radius of the circular hole (units of length).
[0159] The shear viscosity of the filament-forming composition 18
may be in the range of from about 0.1 Pa-s to about 50 Pa-s and/or
from about 0.3 Pa-s to about 40 Pa-s and/or from about 0.5 Pa-s to
about 35 Pa-s at 3000 s.sup.-1 at the operating temperature range
of the spinning operation 20. The extensional viscosity of the
filament-forming composition 18 may be in the range of from about
50 Pa-s to about 200 Pa-s and/or grom 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 at a strain rate of 700 s.sup.-1 as measured by an e-VROC
instrument or equivalent from RheoSense of San Ramon, Calif. The
Pressure P23/P14 ratio on SSEVR should be greater than 0.8 and/or
greater than 0.9 and/or greater than 1.
[0160] In one example, the filament-forming composition may
comprise at least 20% and/or at least 30% and/or at least 40%
and/or at least 45% and/or at least 50% to about 90% and/or to
about 85% and/or to about 80% and/or to about 75% by weight of one
or more filament-forming materials, one or more active agents, and
mixtures thereof. The filament-forming composition may comprise
from about 10% to about 80% by weight of a polar solvent, such as
water.
[0161] In one example, non-volatile components of the
filament-forming composition may comprise from about 20% and/or 30%
and/or 40% and/or 45% and/or 50% to about 75% and/or 80% and/or 85%
and/or 90% by weight based on the total weight of the
filament-forming composition. The non-volatile components may be
composed of filament-forming materials, such as backbone polymers,
active agents and combinations thereof. Volatile components of the
filament-forming composition will comprise the remaining percentage
and range from 10% to 80% by weight based on the total weight of
the filament-forming composition.
[0162] For successful fiber spinning of complex mixtures, such as
molten fatty alcohols or aqueous surfactant solutions it is
generally necessary to add a polymeric ingredient called a
structurant. The structurant's purpose is to increase the shear and
extensional viscosity of the fluid to enable fiber formation. The
structurant is generally a high molecular weight species, usually
in the 100,000-6,000,000 g/mol range. However, a balance is often
struck between concentration and molecular weight, such that when a
lower molecular weight species is used, it requires a higher level
to function properly. Likewise, when a higher molecular species is
used, lower levels can be used to enable fiber spinning. An
important aspect of the structurant is its solubility in the
spinning fluid to enable viscosity build for fiber formation. The
structurants polyvinylpyrrolidone and polyethylene oxide have been
found to be two such polymers that meet the criteria of solubility
in the spinning fluid and capable of being produced at high
molecular weights.
[0163] b. Spinning Operation (20)
[0164] The filaments 22 of the present invention comprising one or
more filament-forming materials 18 and optionally, one or more
active agents 48, present within the filament 22 may be made as
shown in FIGS. 4 and 5. As shown in FIGS. 4 and 5, a spinning
operation 20 for making a filaments 22 from a filament-forming
composition 18, in a continuous process, according to the present
invention comprises the steps of:
[0165] a. providing a filament-forming composition 18 delivered to
the spinning operation 20 from a filament-forming composition
making operation 16, wherein the filament-forming composition 18
comprises one or more filament-forming materials 38 and optionally,
one or more active agents 48 and/or one or more polar solvents
(such as water), and optionally one or more deterrent agents;
and
[0166] b. spinning the filament-forming composition 18, such as via
one or more dies, for example one or more spinning dies 54, for
example a multi-row capillary spinning die, such as a
Biax-fiberfilm multi-row capillary die, into one or more filaments
22 comprising the one or more filament-forming materials 38 and
optionally, the one or more active agents 48 and the one or more
deterrent agents.
[0167] In one example, the step of spinning further comprises the
step of providing a filament-forming composition comprising one or
more filament-forming materials to the one or more dies, for
example one or more spinning dies 54.
[0168] The filament-forming composition 18 may be processed (spun)
from the spinning die 54 at a temperature of from about 20.degree.
C. to about 100.degree. C. and/or from about 30.degree. C. to about
90.degree. C. and/or from about 35.degree. C. to about 70.degree.
C. and/or from about 40.degree. C. to about 60.degree. C. when
making filaments 22 from the filament-forming composition 18.
[0169] The filament-forming composition 18 may be transported via
suitable piping 56, with or without a pump 46, from the
filament-forming composition making operation 16 to the spinning
die 54. A pump 46, such as a Zenith.RTM., H-9000, having a capacity
of 30 and/or 45 cubic centimeters per revolution (cc/rev),
manufactured by Colfax Corporation, Zenith Pumps Division, of
Monroe, N.C., USA may be used to facilitate transport of the
filament-forming composition 18 to a spinning die 54. The flow of
the filament-forming composition 18 from the filament-forming
composition making operation 16 to the spinning die 54 may be
controlled by adjusting the number of revolutions per minute (rpm)
of the pump 46.
[0170] The filaments 22 spun from the spinning die 54 may be
collected, for example continuously onto a collection device 58,
such as a belt and/or fabric, for example a patterned belt, and/or
a rotary drum, that is continuously operating to move the collected
filaments 22, which form a fibrous structure 14, such as a
plurality of inter-entangled filaments, on the collection device 58
further down the process to other operations in the making of the
article of manufacture 12 of the present invention.
[0171] In one example, the process may further comprise the step of
spinning a plurality of filaments from a first die, for example a
first spinning die, and then collecting those first filaments on a
collection device prior to collecting commingled filaments and
solid additives, for example particles, onto the first filaments
already present on the collection device.
[0172] The total level of the one or more filament-forming
materials present in the fibrous element 10, when active agents are
present therein, may be less than 80% and/or less than 70% and/or
less than 65% and/or 50% or less by weight on a dry fibrous element
basis and/or dry soluble fibrous structure basis and the total
level of the one or more active agents, when present in the fibrous
element may be greater than 20% and/or greater than 35% and/or 50%
or greater 65% or greater and/or 80% or greater by weight on a dry
fibrous element basis and/or dry soluble fibrous structure
basis.
[0173] As shown in FIGS. 4 and 5, the spinning die 54 may comprise
a plurality of filament-forming holes that include a melt capillary
34 encircled by a concentric attenuation fluid hole 36 through
which a fluid, such as air, passes to facilitate attenuation of the
filament-forming composition 22 into a fibrous element 10 as it
exits the filament-forming hole 32.
[0174] In one example, the spinning die 54 shown in FIG. 5 has two
or more rows of circular extrusion nozzles (filament-forming holes
60) spaced from one another at a pitch P of about 1.524 millimeters
(about 0.060 inches). The nozzles have individual inner diameters
of about 0.305 millimeters (about 0.012 inches) and individual
outside diameters of about 0.813 millimeters (about 0.032 inches).
Each individual nozzle comprises a melt capillary 62 encircled by
an annular and divergently flared orifice (concentric attenuation
fluid hole 64) to supply attenuation air to each individual melt
capillary 62. The filament-forming composition 18 extruded through
the extrusion nozzles (filament-forming holes 60) is surrounded and
attenuated by generally cylindrical, humidified air streams
supplied through the orifices to produce filaments 22.
[0175] Attenuation air can be provided by heating compressed air
from a source by an electrical-resistance heater, for example, a
heater manufactured by Chromalox, Division of Emerson Electric, of
Pittsburgh, Pa., USA.
[0176] The embryonic filaments 22 are dried by a drying air stream
having a temperature from about 149.degree. C. (about 300.degree.
F.) to about 315.degree. C. (about 600.degree. F.) by an electrical
resistance heater and/or a gas burner (direct or indirect) (not
shown) supplied through drying nozzles and discharged at an angle
of about 90.degree. relative to the general orientation of the
embryonic filaments 22 being spun. The dried filaments 22 may be
collected on a collection device 58, such as a belt or fabric, in
one example a belt or fabric capable of imparting a pattern, for
example a non-random repeating pattern to a fibrous structure 14,
such as a soluble fibrous structure, formed as a result of
collecting the filaments 22 on the belt or fabric. The addition of
a vacuum source 66 directly under a formation zone 68, the area on
the collection device 58 where the filaments 22 contact the
collection device 58, may be used to aid collection of the
filaments 22 on the collection device 58. The spinning and
collection of the filaments 22 produce a fibrous structure 14, for
example a soluble fibrous structure, comprising inter-entangled
filaments.
[0177] In one example, a spinning enclosure 70, which is a housing
that at least partially encloses, in one example fully encloses to
the extent that the collection device 58 and fibrous structure 14
carried on the collection device 58 are able to move freely under
the spinning enclosure 70, the filaments 22 being spun from the
spinning die 54 to the collection device 58. The spinning enclosure
70 at least partially controls the environment that the filaments
22 are exposed to down the spinline from the spinning die 54 to the
collection device 58.
[0178] In one example, during the spinning step, any volatile
solvent, such as water, present in the filament-forming composition
18 is removed, such as by drying, as the filament 22 is formed. In
one example, greater than 30% and/or greater than 40% and/or
greater than 50% of the weight of the filament-forming
composition's 18 volatile solvent, such as water, is removed during
the spinning step, such as by drying the filament 22 being
produced.
[0179] In one example, the filaments 22 are spun from one die, for
example one spinning die 54, for example a multi-row capillary
die.
[0180] In one example, two or more different filaments 22 are spun
from at least one die, for example one spinning die 54 (the same
spinning die 54).
[0181] In one example, the filaments 22 are spun from two or more
dies, for example two or more spinning dies 54.
[0182] In one example, the process of the present invention may
comprise two or more spinning operations 20. In one example, a
first spinning operation 20 comprises spinning filaments 22 from a
filament-forming composition 18 comprising one or more
filament-forming materials 38 with or without active agents 48 and
without the inclusion of solid additives, for example particles 26
via a commingling operation 24, to produce a fibrous structure 14
on a collection device 58, which may be the same collection device
58 upon which the filaments 22 from a second spinning operation 20
are collected. A second spinning operation 20 downstream of the
first spinning operation 20 comprises spinning filaments 22 from a
filament-forming composition 18 comprising one or more
filament-forming materials 38 with or without active agents 48 and
with the inclusion of solid additives, for example particles 26 via
a commingling operation 24, onto the fibrous structure 14 formed by
the first spinning operation 20.
[0183] The filament-forming composition 18 may comprise any
suitable total level of filament-forming materials 38 and any
suitable level of active agents 48 so long as the filament 22
produced from the filament-forming composition 18 comprises a total
level of filament-forming materials 38 in the filament 22 of from
about 5% to 100% or less by weight on a dry filament basis and/or
dry soluble fibrous structure basis and a total level of active
agents 48 in the filament 22 of from 0% to about 95% by weight on a
dry filament basis and/or dry soluble fibrous structure basis.
[0184] c. Commingling Operation (24)
[0185] In one example, as shown in FIG. 6, particles 26 may be
added to the filaments 22 being spun from one die, for example the
spinning die 54 within the spinning enclosure 70. The addition of
particles 26 may be accomplished during the formation of the
filaments 22 and/or after collection of the filaments 22 on the
collection device 58. The particles 26 may be added into the
fibrous structure 14 and/or filaments 22 from a particle source 72.
The particles 26 may be added such that the particles 26 are
collected on a surface of the collection device 58 inside the
spinning enclosure 70. The collection device 58 may be operable
within the formation zone 68, which may be inside the spinning
enclosure 70. The spinning enclosure 70 may be positioned above the
collection device 58 and encompass the formation zone 68 on the
collection device 58.
[0186] The addition of particles 26 may result in said particles 26
being entrapped and/or entrained within the filaments 22 and/or
fibrous structure 14 collected on the collection device 58.
[0187] A particle source 72, for example a feeder, suitable to
supply a flow of particles is placed directly above the drying
region for the fibrous elements as shown in FIG. 6. In this case
for example a vibratory feeder made by Retsch.RTM. of Haan,
Germany, is used. In order to aid in a consistent distribution of
particles in the cross direction the particles are fed onto a tray
(not shown) that started off the width of the particle source 72
and ended at the same width as the spinning die 54 face to ensure
particles 26 are delivered into all areas of filament 22 formation.
The tray is completely enclosed with the exception of the exit to
minimize disruption of the particle feed.
[0188] In one example, a split particle source or two or more
separate particle sources capable of delivering two or more
different (for example different in type, composition, size,
properties, etc.) particles may be used as the particle source in
the commingling operation such that the resulting fibrous structure
may comprise different zones and/or regions comprising different
particles, which may ultimately result in a layered fibrous
structure having different particles in each layer after the
initially formed fibrous structure is slit and stacked.
[0189] While filaments 22 are being formed, the particle source 72
is turned on and particles 26 are introduced into the filament 22
stream. The particles 26 are commingled with the filaments 22
within the spinning enclosure 70. The commingled filaments 22 and
particles 26 are collected on the collection device 58 as a
composite structure (filaments 22 and particles 26 commingled
together). In one example, the step of collecting the commingled
filaments 22 and particles 26, for example on the collection device
58, occurs within the spinning enclosure 70. The composite
structure is referred to as a fibrous structure 14.
[0190] The particles 26 may be introduced into the spinning
enclosure 70 between the spinning die 54 and the collection device
58, as shown in FIGS. 4 and 6, at any angle so long as at least a
portion of the particles 26 contact the filaments 22 at the
formation zone 68. As shown in FIG. 6, if the introduction of the
particles 26 into the filament 22 stream is not tailored to result
in the particles 26 contacting the filaments 22 in the formation
zone 68 then the particles may end up downstream (points in the
process that are closer to the finished article of manufacture
and/or packaged article of manufacture relative to the referenced
point, for example if the reference point is the spinning operation
or collecting operation, then downstream means converting operation
and/or packaging operation) of the formation zone 68 as shown by
the particle trajectory line A in FIG. 6 and/or upstream (points in
the process that are farther away from the finished article of
manufacture 12 and/or packaged article of manufacture 32 relative
to the referenced point, for example if the reference point is the
spinning operation or collecting operation, then upstream means,
for example the filament-forming composition making operation 16)
of the formation zone 68 as shown by the particle trajectory line B
in FIG. 6.
[0191] In one example, the solid additives, for example particles
26, contact the filaments 22 on the upstream side of the spinning
enclosure 70 ("the filaments' upstream side").
[0192] In another example, the solid additives, for example
particles 26, contact the filaments 22 on the downstream side of
the spinning enclosure 70 ("the filaments' downstream side").
[0193] In another example, the solid additives, for example
particles 26, contact the filaments 22 on both the upstream and
downstream sides of the spinning enclosure 70 ("the filaments'
upstream side and downstream side").
[0194] FIG. 7 illustrates schematically another example of the
commingling operation 24 wherein the particles 26 land on the
collection device 58 in a particle landing zone 74 and contact the
filaments 22 within the formation zone 68.
[0195] The solid additives, for example particles 26, may contact
the filaments 22 at a contact angle (the contact angle is relative
to the filament stream direction emanating and exiting from the
spinning die 54) of greater than or equal to about 0.degree. but
less than or equal to about 90.degree. and/or greater than or equal
to about 10.degree. but less than or equal to about 90.degree.
and/or greater than or equal to about 20.degree. but less than or
equal to about 90.degree. and/or greater than or equal to about
30.degree. but less than or equal to about 90.degree. and/or at
least about 40.degree. but less than about 90.degree. and/or at a
contact angle of at least about 45.degree. but less than about
90.degree..
[0196] The solid additives, for example particles 26, may be
dispersed throughout the fibrous structure 14 at an overall MD
basis weight variation % RSD of less than 40.0% and/or less than
30.0% and/or less than 25.0% and/or less than 20.0% and/or less
than 15.0% and/or less than 10.0% and/or less than 5.0% and/or
about 0% as measured according to the CD and MD Basis Weight
Variation Test Method described herein.
[0197] The solid additives, for example particles 26, may be
dispersed throughout the fibrous structure 14 at an overall CD
basis weight variation % RSD of less than 40.0% and/or less than
30.0% and/or less than 25.0% and/or less than 20.0% and/or less
than 15.0% and/or less than 10.0% and/or less than 5.0% and/or
about 0% as measured according to the CD and MD Basis Weight
Variation Test Method described herein.
[0198] The solid additives, for example particles 26, may contact
the filaments at a velocity of 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 6 m/s or less and/or from about 1 m/s to about 20
m/s.
[0199] The solid additives, for example particles 26, may be
commingled with the filaments 22 such that a solid additive
inclusion efficiency (for example particle inclusion efficiency) of
greater than 40% and/or at least 42% and/or at least 45% and/or at
least 50% and/or at least 54% and/or at least 65% and/or at least
75% and/or at least 85% and/or at least 90% and/or at least 95%
and/or at least 98% as measured according to the Inclusion
Efficiency Test Method described herein.
[0200] In one example, the step of commingling comprises
introducing the solid additives, for example particles 26, into the
plurality of filaments 22, for example soluble filaments, between
at least one of the dies, for example spinning dies 54 and the
collection device 58. In one example, the solid additives, for
example particles 26, are introduced more proximal to the at least
one die, for example spinning die 54 than to the collection device
58. In another example, the solid additives, for example particles
26, are introduced more proximal to the collection device 58 than
to at least one die, for example spinning die 54.
[0201] In one example, the commingling operation (step) comprises
introducing the solid additives, for example particles 26, into the
filaments 22, for example soluble filaments, spun from two
different spinning dies 54.
[0202] The solid additives, for example particles 26, may comprise
one or more types or different types of particles 26. In one
example, the solid additives, for example particles 26, comprise a
mixture of particles 26 of differing compositions. In another
example, the solid additives, for example particles 26, comprise a
blend of particle of differing composition. In another example, the
solid additives, for example particles 26, comprise water-soluble
particles and/or water-insoluble particles, which may comprise
water-swellable particles. Further, in one example, the particles
26 may be in the form of an agglomerate, for example an agglomerate
comprising a water-soluble material and/or a water-insoluble
material.
[0203] In one example, the solid additives, for example particles
26, may exhibit a D50 particle size of from about 100 .mu.m to
about 5000 .mu.m and/or from about 100 .mu.m to about 2000 .mu.m
and/or from about 250 .mu.m to about 1200 .mu.m and/or from about
250 .mu.m to about 850 .mu.m as measured according to the Particle
Size Distribution Test Method described herein.
[0204] In one example, the solid additives, for example particles
26, may exhibit a D10 of 250 .mu.m as measured according to the
Particle Size Distribution Test Method described herein.
[0205] In another example, the solid additives, for example
particles 26, may exhibit a D90 of 1200 .mu.m and/or 850 .mu.m as
measured according to the Particle Size Distribution Test Method
described herein.
[0206] In one example, the solid additives, for example particles
26, may exhibit a D10 of greater than 44 .mu.m and/or greater than
90 .mu.m and/or greater than 150 .mu.m and/or greater than 212
.mu.m and/or greater than 300 .mu.m as measured according to the
Particle Size Distribution Test Method described herein.
[0207] In one example, the solid additives, for example particles
26, may exhibit a D90 of less than 1400 .mu.m and/or less than 1180
.mu.m and/or less than 850 .mu.m and/or less than 600 .mu.m and/or
less than 425 .mu.m as measured according to the Particle Size
Distribution Test Method described herein.
[0208] In one example, the solid additives, for example particles
26, may exhibit any combination of the above-identified D10, D50,
and/or D90 so long as D50, when present, is greater than D10, when
present, and D90, when present, is greater than D10 and D50, when
present.
[0209] In one example, the solid additives, for example particles
26, may exhibit any combination of the above-identified D10 and D90
so long as D90 is greater than D10.
[0210] In one example, the solid additives, for example particles
26, may exhibit a D10 of greater than 212 .mu.m and a D90 of less
than 1180 .mu.m as measured according to the Particle Size
Distribution Test Method described herein.
[0211] In one example, the solid additives, for example particles
26, may exhibit a D10 of greater than 90 .mu.m and a D90 of less
than 425 .mu.m as measured according to the Particle Size
Distribution Test Method described herein.
[0212] In one example, the spinning operation 20 may comprise two
or more spinning dies 54 arranged adjacent to each other in the
machine direction and/or in the cross-machine direction. In one
example, when the spinning operation 20 comprises two or more dies
arranged adjacent to each other in the machine direction, a
commingling operation 24 may be positioned between two adjacent (in
the machine direction) dies, for example two adjacent spinning dies
54.
[0213] The particles 26 used in the present invention for
commingling with the filaments 22 may be active agent-containing
particles.
[0214] d. Collecting Operation (28)
[0215] As shown in FIGS. 1, 4, and 6, the filaments 22 from the
spinning operation 20, and optionally the solid additives, for
example particles 26, from the commingling operation 24, are
collected on a collection device 58 during the collecting operation
28 to form a fibrous structure 14, which may be a composite
structure (commingled filaments 22 and particles 26).
[0216] In one example, the collection device 58 may be a belt, such
as a patterned belt that imparts a texture, such as a
three-dimensional texture to at least one surface of the fibrous
structure 14 and/or a rotary drum. The collection device 58 may
impart a pattern, for example a non-random, repeating pattern which
may be continuous, discontinuous, and/or semi-continuous in nature.
The collection device 58 may create different regions within the
fibrous structure 14, for example different average densities.
Test Methods
[0217] Unless otherwise specified, all tests described herein
including those described under the Definitions section and the
following test methods are conducted on samples that have been
conditioned in a conditioned room at a temperature of 23.degree.
C..+-.1.0.degree. C. and a relative humidity of 50%.+-.2% for a
minimum of 2 hours prior to the test. The samples tested are
"usable units." "Usable units" as used herein means sheets, flats
from roll stock, pre-converted flats, and/or single or multi-ply
products. All tests are conducted under the same environmental
conditions and in such conditioned room. Do not test samples that
have defects such as wrinkles, tears, holes, and like. Samples
conditioned as described herein are considered dry samples (such as
"dry filaments") for testing purposes. All instruments are
calibrated according to manufacturer's specifications.
Basis Weight Test Method
[0218] Basis weight is defined as the weight in g/m.sup.2 of a
sample being tested. It is determined by accurately weighing a
known area of a conditioned sample using an appropriate balance,
recording the weight and area of sample tested, applying the
appropriate conversion factors, and finally calculating the basis
weight in g/m.sup.2 of the sample.
[0219] Basis weight is measured by cutting a sample from a single
web, a stack of webs, or other appropriate plied up, or consumer
salable unit and weighing the sample using a top loading analytical
balance with a resolution of .+-.0.001 g. The sample must be
equilibrated at a temperature of 73.degree..+-.2.degree. F.
(23.degree..+-.1.degree. C.) and a relative humidity of 50%
(.+-.2%) for a minimum of two hours prior to cutting samples.
During weighing, the balance is protected from air drafts and other
disturbances using a draft shield. A precision cutting die,
measuring 1.625.times.1.625 in (41.275.times.41.275 mm) is used to
prepare all samples. Select usable sample areas which are clean,
free of holes, tears, wrinkles and other defects.
[0220] For each sample use the die cutter described above to cut a
sample, weigh the mass of the sample, and record the mass result to
the nearest 0.001 g.
[0221] The Basis Weight is calculated in g/m2 as follows:
Basis Weight=(Mass of sample)/(Area of sample).
[0222] Or specifically,
Basis Weight (g/m2)=(Mass of sample (g))/(0.001704 m2).
[0223] Report result to the nearest 0.1 g/m2. Sample dimensions can
be changed or varied using a similar precision cutter as mentioned
above. If the sample dimension is decreased, then several samples
should be measured and the mean value reported as its basis
weight.
[0224] Particle Size Distribution Test Method
[0225] The particle size distribution test is conducted to
determine characteristic sizes of solid additives, for example
particles. It is conducted using ASTM D 502-89, "Standard Test
Method for Particle Size of Soaps and Other Detergents", approved
May 26, 1989, with a further specification for sieve sizes and
sieve time used in the analysis. Following section 7, "Procedure
using machine-sieving method," a nest of clean dry sieves
containing U.S. Standard (ASTM E 11) sieves #4 (4.75 mm), #6 (3.35
mm), #8 (2.36 mm), #12 (1.7 mm), #16 (1.18 mm), #20 (850
micrometer), #30 (600 micrometer), #40 (425 micrometer), #50 (300
micrometer), #70 (212 micrometer), #100 (150 micrometer), #170 (90
micrometer), #325 (44 micrometer) and pan is required to cover the
range of particle sizes referenced herein. The prescribed
Machine-Sieving Method is used with the above sieve nest. A
suitable sieve-shaking machine can be obtained from W.S. Tyler
Company, Ohio, U.S.A. The sieve-shaking test sample is
approximately 100 grams and is shaken for 5 minutes.
[0226] The data are plotted on a semi-log plot with the micrometer
size opening of each sieve plotted on the logarithmic abscissa and
the cumulative mass percent finer (CMPF) is plotted on the linear
ordinate. An example of the above data representation is given in
ISO 9276-1:1998, "Representation of results of particle size
analysis--Part 1: Graphical Representation", Figure A.4. A
characteristic particle size (Dx, x=10, 50, 90), for the purpose of
this invention, is defined as the abscissa value at the point where
the cumulative mass percent is equal to x percent, and is
calculated by a straight line interpolation between the data points
directly above (a) and below (b) the x value using the following
equation:
Dx=10{circumflex over ( )}[Log(Da)-(Log(Da)-Log(Db))*(Qa-x
%)/(Qa-Qb)]
where Log is the base 10 logarithm, Qa and Qb are the cumulative
mass percentile values of the measured data immediately above and
below the x.sup.th percentile, respectively; and Da and Db are the
micrometer sieve size values corresponding to these data. Example
data and calculations:
TABLE-US-00002 sieve size weight on cumulative mass % (micrometer)
sieve (g) finer (CMPF) 1700 0 100% 1180 0.68 99.3% 850 10.40 89.0%
600 28.73 60.3% 425 27.97 32.4% 300 17.20 15.2% 212 8.42 6.8% 150
4.00 2.8% Pan 2.84 0.0%
[0227] For D10 (x=10), the micrometer screen size where CMPF is
immediately above 10% (Da) is 300 micrometer, the screen below (Db)
is 212 micrometer. The cumulative mass immediately above 10% (Qa)
is 15.2%, below (Qb) is 6.8%. D10=10{circumflex over (
)}[Log(300)-(Log(300)-Log(212))*(15.2%-10%)/(15.2%-6.8%)]=242
micrometer.
[0228] For D90 (x=90), the micrometer screen size where CMPF is
immediately above 90% (Da) is 1180 micrometer, the screen below
(Db) is 850 micrometer. The cumulative mass immediately above 90%
(Qa) is 99.3%, below (Qb) is 89.0%. D90=10{circumflex over (
)}[Log(1180)-(Log(1180)-Log(850))*(99.3%-90%)/(99.3%-89.0%)]=878
micrometer.
[0229] For D50 (x=50), the micrometer screen size where CMPF is
immediately above 50% (Da) is 600 micrometer, the screen below (Db)
is 425 micrometer. The cumulative mass immediately above 50% (Qa)
is 60.3%, below (Qb) is 32.4%. D50=10{circumflex over (
)}[Log(600)-(Log(600)-Log(425))*(60.3%-50%)/(60.3%-32.4%)]=528
micrometer.
CD and MD Basis Weight Variation Test Method
[0230] The cross direction (CD) basis weight variation is measured
with this method by sampling the web in the cross direction at a
given fixed machine direction (MD) position, measuring the basis
weight for samples taken at this MD position, and then calculating
the % Relative Standard Deviation (RSD) for the sample set. This
analysis is performed for as many samples as needed to sample the
entire cross direction of a given web. As one sampling example, if
the web is about 53 cm wide and the sample die cutter for basis
eight is 4.1275 cm wide as it is in the Basis Weight Method
described herein, then about 12 samples may be taken across the
web. Samples at the web edges may not completely fill the sampling
die when cutting across a full MD position, for example, the die
cutter extends past the edge of the web, should be discarded.
Sampling at a given MD position may vary slightly, as long as the
entire CD width is reasonably sampled at the respective MD
position. The sampling is completed for a total of 10 fixed MD
positions spaced about 1 m apart. The CD basis weight variation is
recorded for each MD position and the values at each position are
used to get a CD basis weight variation % RSD per MD sampled
position. The average for the 10 rows or MD positions sampled is
reported as the overall CD basis weight variation % RSD.
[0231] The machine direction (MD) basis weight variation is
measured with this method by sampling the web in the Machine
Direction at a given fixed cross direction (CD) position, measuring
the basis weight for samples taken at the given CD position,
replicating the measurement at other CD positions, and then
calculating the overall MD basis weight variation % RSD for the
entire sample set.
[0232] The overall CD basis weight variation % RSD and overall MD
basis weight variation % RSD can be averaged to get an overall web
basis weight variation % RSD.
[0233] Procedure for Measuring Cross Direction Variability at Fixed
Machine Direction Position
[0234] Choose a Machine Direction position of the web from which to
sample.
[0235] Follow the Basis Weight Test Method described herein to
measure the basis weigh of all samples.
[0236] Cut as many samples as necessary to sample the entire web
width at a given MD position.
[0237] As one example, if a web is about 53 cm wide and the sample
die cutter is 4.1275 cm wide, then about 12 samples may be taken
across the web. Sampling at a given MD position may vary slightly,
as long as the entire CD width is reasonably sampled at the
respective MD position.
[0238] Discard samples at the edges of the full web that do not
completely fill the sampling die when cutting.
[0239] Calculate the basis weight for each sample taken along the
given MD position.
[0240] Calculate the mean sample basis weight for this fixed MD
position.
[0241] Calculate the standard deviation for the samples at the
fixed MD position.
[0242] Calculate the % RSD (Relative Standard Deviation) for the
samples at this MD position by dividing the standard deviation by
the mean sample basis weight and multiply by 100 to yield a %
value.
[0243] Repeat the above for a total of 10 rows or 10 MD positions,
sampling at about 1 meter intervals of the web from the
process.
[0244] Average the % RSD for all ten rows and report it as the
overall CD basis weight variation % RSD. This value is reported to
the nearest 0.1%.
[0245] Procedure for Measuring Machine Direction Variability at
Fixed Cross Direction Position
[0246] Sample from the web at its cross direction centerline
position.
[0247] Follow the Basis Weight Test Method described herein to
measure the basis weight of all samples.
[0248] Cut ten samples along the web's cross direction centerline
position at about 1 m intervals in the MD direction of the web from
the process.
[0249] Calculate the basis weight for each sample.
[0250] Calculate the mean sample basis weight for CD centerline
position.
[0251] Calculate the standard deviation for the same sample
set.
[0252] Calculate the MD basis weight variation % RSD at the CD
centerline position by dividing the standard deviation by the mean
sample basis weight and multiplying by 100 to get a % value. Report
this value to the nearest 0.1%.
[0253] Repeat the above cross direction centerline position
measurement by doing the same sampling and measurement along a
mid-line on the left half of the CD centerline and then along a
mid-line on the right half of the CD centerline.
[0254] From the above analysis, there will be three values
generated:
[0255] % RSD for the CD centerline position
[0256] % RSD for the mid-line on the left half of the CD
centerline
[0257] % RSD for the mid-line on the right half of the CD
centerline
[0258] Average the % RSD for these three CD positions and report it
as the overall MD basis weight variation % RSD. This value is
reported to the nearest 0.1%.
Inclusion Efficiency Test Method
[0259] Inclusion efficiency is a measure of the percentage of solid
additives, for example particles, captured and retained in the
fibrous structure during the commingling (coforming) operation to
the number of solid additives, for example particles, introduced
(fed) into the commingling (coforming) operation. A higher
percentage of inclusion efficiency indicates better solid additive,
for example particle, entrainment is being realized by the
commingling (coforming) operation and/or coforming apparatus and/or
process conditions operable during the commingling (coforming)
operation.
[0260] In general, the inclusion efficiency is:
Inclusion Efficiency = Ratio of mass of particles to mass of
filaments in fibrous structure Ratio of mass of particles to mass
of dry filament feed rate .times. 100 ##EQU00004##
[0261] which is better calculated as follows:
Inclusion Efficiency = 100 .times. ( ( Composite fibrous structure
basis weight ( g / m 2 ) - Filament fibrous structure ( void of
solid additives ) basis weight ( g / m 2 ) ) ( Total Particle feed
rate ( g / min ) ) / Total Filament - forming composition feed rate
( g / min ) .times. Filament - forming composition Solids
concentration ) ##EQU00005##
[0262] Procedure
[0263] Run the commingling (coforming) operation at steady state
conditions to make a base fibrous structure (filament only) with no
particles.
[0264] Measure the basis weight of cut sample of base fibrous
structure as defined in the Basis Weight method defined herein.
[0265] Sample from the center of the base fibrous structure cross
direction or at the base fibrous structure's CD centerline.
[0266] Record this as the base fibrous structure basis weight
(g/m.sup.2).
[0267] Make composite fibrous structure (filaments+particles) at a
desired dry mass feed rate.
[0268] Measure the basis weight of cut sample of the composite
fibrous structure as defined in the Basis Weight method defined
herein.
[0269] Sample from the center of the composite fibrous structure
cross direction or at the composite fibrous structure's CD
centerline.
[0270] Record this as the composite fibrous structure basis weight
(g/m.sup.2).
[0271] Total Particle feed rate and Total Filament-forming
Composition feed rate are process parameters. Total Particle feed
rate is measured by collecting the entire particle feed stream over
a one minute interval and reported in g/min to the nearest 1 g/min
Total Filament-forming Composition feed rate is measured using
inline process flow meters and is reported in g/min to the nearest
1 g/min. Filament-forming Composition Solids concentration is the
ratio of the mass of filament-forming composition material left
after drying to the mass of starting filament-forming composition.
This can be measured using a Mettler Toledo HC103 or equivalent
Moisture Analyzer. Filament-forming Composition Solids
concentration is reported as a fractional value to the nearest 0.01
units or as a percentage to the nearest 1%.
[0272] For clarity, an example of an Inclusion Efficiency
calculation is shown below.
[0273] A base fibrous structure (filament only--no particles) is
made from a filament-forming composition at 55% (0.55) solids
concentration. The filament-forming composition feed rate to the
die is 1600 g/min. A sample cut the base fibrous structure's
centerline exhibits a basis weight of 264 g/m.sup.2. A composition
fibrous structure (filaments+solid additives, for example
particles) is then made as described above with respect to the base
fibrous structure, but the solid additives, for example particles,
are added to the filaments at a Total Particle feed rate of 2350
g/min. A sample cut from the composite fibrous structure exhibits a
basis weight 870 g/m.sup.2. With these values, the example
Inclusion Efficiency calculation is as follows:
Inclusion Efficiency = ( 870 g / m 2 - 264 g / m 2 ) / ( 264 g / m
2 ) ( 2350 g / min ) / ( 1600 g / min * 0.55 ) .times. 100 = 86 %
##EQU00006##
[0274] Inclusion Efficiency is reported to the nearest 1%.
Water Content Test Method
[0275] The water (moisture) content present in a fibrous element
and/or particle and/or fibrous structure is measured using the
following Water Content Test Method. A fibrous element and/or
particle and/or fibrous structure or portion thereof ("sample") in
the form of a pre-cut sheet is placed in a conditioned room at a
temperature of 23.degree. C..+-.1.0.degree. C. and a relative
humidity of 50%.+-.2% for at least 24 hours prior to testing. Each
fibrous structure sample has an area of at least 4 square inches,
but small enough in size to fit appropriately on the balance
weighing plate. Under the temperature and humidity conditions
mentioned above, using a balance with at least four decimal places,
the weight of the sample is recorded every five minutes until a
change of less than 0.5% of previous weight is detected during a 10
minute period. The final weight is recorded as the "equilibrium
weight". Within 10 minutes, the samples are placed into the forced
air oven on top of foil for 24 hours at 70.degree. C..+-.2.degree.
C. at a relative humidity of 4%.+-.2% for drying. After the 24
hours of drying, the sample is removed and weighed within 15
seconds. This weight is designated as the "dry weight" of the
sample.
[0276] The water (moisture) content of the sample is calculated as
follows:
% Water in sample = 100 % .times. ( Equilibrium weight of sample -
Dry weight of sample ) Dry weight of sample ##EQU00007##
The % Water (moisture) in sample for 3 replicates is averaged to
give the reported % Water (moisture) in sample. Report results to
the nearest 0.1%.
Diameter Test Method
[0277] The diameter of a discrete fibrous element or a fibrous
element within a fibrous structure is determined by using a
Scanning Electron Microscope (SEM) or an Optical Microscope and an
image analysis software. A magnification of 200 to 10,000 times is
chosen such that the fibrous elements are suitably enlarged for
measurement. When using the SEM, the samples are sputtered with
gold or a palladium compound to avoid electric charging and
vibrations of the fibrous element in the electron beam. A manual
procedure for determining the fibrous element diameters is used
from the image (on monitor screen) taken with the SEM or the
optical microscope. Using a mouse and a cursor tool, the edge of a
randomly selected fibrous element is sought and then measured
across its width (i.e., perpendicular to fibrous element direction
at that point) to the other edge of the fibrous element. A scaled
and calibrated image analysis tool provides the scaling to get
actual reading in .mu.m. For fibrous elements within a fibrous
structure, several fibrous element are randomly selected across the
sample of the fibrous structure using the SEM or the optical
microscope. At least two portions of the fibrous structure are cut
and tested in this manner. Altogether at least 100 such
measurements are made and then all data are recorded for
statistical analysis. The recorded data are used to calculate
average (mean) of the fibrous element diameters, standard deviation
of the fibrous element diameters, and median of the fibrous element
diameters.
[0278] Another useful statistic is the calculation of the amount of
the population of fibrous elements that is below a certain upper
limit. To determine this statistic, the software is programmed to
count how many results of the fibrous element diameters are below
an upper limit and that count (divided by total number of data and
multiplied by 100%) is reported in percent as percent below the
upper limit, such as percent below 1 micrometer diameter or
%-submicron, for example. We denote the measured diameter (in
.mu.m) of an individual circular fibrous element as di.
[0279] In the case that the fibrous elements have non-circular
cross-sections, the measurement of the fibrous element diameter is
determined as and set equal to the hydraulic diameter which is four
times the cross-sectional area of the fibrous element divided by
the perimeter of the cross-section of the fibrous element (outer
perimeter in case of hollow fibrous elements). The number-average
diameter, alternatively average diameter is calculated as:
d num = i = 1 n d i n ##EQU00008##
Weight Average Molecular Weight Test Method
[0280] The weight average molecular weight (Mw) of a material, such
as a polymer, is determined by Gel Permeation Chromatography (GPC)
using a mixed bed column. A high performance liquid chromatograph
(HPLC) having the following components: Millenium.RTM., Model 600E
pump, system controller and controller software Version 3.2, Model
717 Plus autosampler and CHM-009246 column heater, all manufactured
by Waters Corporation of Milford, Mass., USA, is utilized. The
column is a PL gel 20 .mu.m Mixed A column (gel molecular weight
ranges from 1,000 g/mol to 40,000,000 g/mol) having a length of 600
mm and an internal diameter of 7.5 mm and the guard column is a PL
gel 20 .mu.m, 50 mm length, 7.5 mm ID. The column temperature is
55.degree. C. and the injection volume is 200 .mu.L. The detector
is a DAWN.RTM. Enhanced Optical System (EOS) including Astra.RTM.
software, Version 4.73.04 detector software, manufactured by Wyatt
Technology of Santa Barbara, Calif., USA, laser-light scattering
detector with K5 cell and 690 nm laser. Gain on odd numbered
detectors set at 101. Gain on even numbered detectors set to 20.9.
Wyatt Technology's Optilab.RTM. differential refractometer set at
50.degree. C. Gain set at 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. The run time is 30 minutes.
[0281] A sample is prepared by dissolving the material in the
mobile phase at nominally 3 mg of material/1 mL of mobile phase.
The sample is capped and then stirred for about 5 minutes using a
magnetic stirrer. The sample is then placed in an 85.degree. C.
convection oven for 60 minutes. The sample is then allowed to cool
undisturbed to room temperature. The sample is then filtered
through a 5 .mu.m Nylon membrane, type Spartan-25, manufactured by
Schleicher & Schuell, of Keene, N.H., USA, into a 5 milliliter
(mL) autosampler vial using a 5 mL syringe.
[0282] For each series of samples measured (3 or more samples of a
material), a blank sample of solvent is injected onto the column.
Then a check sample is prepared in a manner similar to that related
to the samples described above. The check sample comprises 2 mg/mL
of pullulan (Polymer Laboratories) having a weight average
molecular weight of 47,300 g/mol. The check sample is analyzed
prior to analyzing each set of samples. Tests on the blank sample,
check sample, and material test samples are run in duplicate. The
final run is a run of the blank sample. The light scattering
detector and differential refractometer is run in accordance with
the "Dawn EOS Light Scattering Instrument Hardware Manual" and
"Optilab.RTM. DSP Interferometric Refractometer Hardware Manual,"
both manufactured by Wyatt Technology Corp., of Santa Barbara,
Calif., USA, and both incorporated herein by reference.
[0283] The weight average molecular weight of the sample is
calculated using the detector software. A dn/dc (differential
change of refractive index with concentration) value of 0.066 is
used. The baselines for laser light detectors and the refractive
index detector are corrected to remove the contributions from the
detector dark current and solvent scattering. If a laser light
detector signal is saturated or shows excessive noise, it is not
used in the calculation of the molecular mass. The regions for the
molecular weight characterization are selected such that both the
signals for the 90.degree. detector for the laser-light scattering
and refractive index are greater than 3 times their respective
baseline noise levels. Typically, the high molecular weight side of
the chromatogram is limited by the refractive index signal and the
low molecular weight side is limited by the laser light signal.
[0284] The weight average molecular weight can be calculated using
a "first order Zimm plot" as 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 result with the least error from a regression
fit is used to calculate the molecular mass. The reported weight
average molecular weight is the average of the two runs of the
material test sample.
[0285] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0286] Every document cited herein, including any cross referenced
or related patent or application and any patent application or
patent to which this application claims priority or benefit
thereof, is hereby incorporated herein by reference in its entirety
unless expressly excluded or otherwise limited. The citation of any
document is not an admission that it is prior art with respect to
any invention disclosed or claimed herein or that it alone, or in
any combination with any other reference or references, teaches,
suggests or discloses any such invention. Further, to the extent
that any meaning or definition of a term in this document conflicts
with any meaning or definition of the same term in a document
incorporated by reference, the meaning or definition assigned to
that term in this document shall govern.
[0287] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *