U.S. patent application number 16/869807 was filed with the patent office on 2020-08-20 for web material and method for making same.
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 Brian Patrick Croll, Frank William Denome, Andreas Josef Dreher, Gregory Charles Gordon, Alyssandrea Hope Hamad-Ebrahimpour, Stephen Joseph Hodson, John Gerhard Michael, Mark Robert Sivik, Paul Dennis Trokhan.
Application Number | 20200261326 16/869807 |
Document ID | 20200261326 / US20200261326 |
Family ID | 1000004812906 |
Filed Date | 2020-08-20 |
Patent Application | download [pdf] |
![](/patent/app/20200261326/US20200261326A1-20200820-C00001.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00002.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00003.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00004.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00005.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00006.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00007.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00008.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00009.png)
![](/patent/app/20200261326/US20200261326A1-20200820-C00010.png)
![](/patent/app/20200261326/US20200261326A1-20200820-D00000.png)
View All Diagrams
United States Patent
Application |
20200261326 |
Kind Code |
A1 |
Sivik; Mark Robert ; et
al. |
August 20, 2020 |
Web Material and Method for Making Same
Abstract
A web material containing one or more active agents and methods
for making same are provided.
Inventors: |
Sivik; Mark Robert; (Mason,
OH) ; Gordon; Gregory Charles; (Loveland, OH)
; Denome; Frank William; (Cincinnati, OH) ;
Hamad-Ebrahimpour; Alyssandrea Hope; (Cincinnati, OH)
; Hodson; Stephen Joseph; (Franklin, OH) ; Croll;
Brian Patrick; (Hamilton, OH) ; Michael; John
Gerhard; (Cincinnati, OH) ; Dreher; Andreas
Josef; (Cincinnati, OH) ; Trokhan; Paul Dennis;
(Hamilton, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Assignee: |
The Procter & Gamble
Company
|
Family ID: |
1000004812906 |
Appl. No.: |
16/869807 |
Filed: |
May 8, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15259095 |
Sep 8, 2016 |
10646413 |
|
|
16869807 |
|
|
|
|
14860830 |
Sep 22, 2015 |
9480628 |
|
|
15259095 |
|
|
|
|
13229845 |
Sep 12, 2011 |
9175250 |
|
|
14860830 |
|
|
|
|
PCT/US2011/042644 |
Jun 30, 2011 |
|
|
|
13229845 |
|
|
|
|
61361126 |
Jul 2, 2010 |
|
|
|
61361129 |
Jul 2, 2010 |
|
|
|
61361146 |
Jul 2, 2010 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C11D 1/22 20130101; A61Q
5/12 20130101; A61K 8/027 20130101; B32B 5/26 20130101; A61Q 19/00
20130101; C11D 17/049 20130101; C11D 1/75 20130101; A61Q 5/06
20130101; A61K 2800/596 20130101; C11D 17/06 20130101; A61K 8/0216
20130101; D01F 1/10 20130101; A61K 8/8129 20130101; A61Q 5/02
20130101; C11D 1/29 20130101; C11D 17/0039 20130101; A61Q 5/00
20130101; C11D 17/041 20130101 |
International
Class: |
A61K 8/02 20060101
A61K008/02; D01F 1/10 20060101 D01F001/10; A61K 8/81 20060101
A61K008/81; A61Q 5/00 20060101 A61Q005/00; B32B 5/26 20060101
B32B005/26; C11D 17/04 20060101 C11D017/04; C11D 17/00 20060101
C11D017/00; A61Q 19/00 20060101 A61Q019/00; C11D 17/06 20060101
C11D017/06; A61Q 5/02 20060101 A61Q005/02; A61Q 5/06 20060101
A61Q005/06; A61Q 5/12 20060101 A61Q005/12; C11D 1/22 20060101
C11D001/22; C11D 1/29 20060101 C11D001/29; C11D 1/75 20060101
C11D001/75 |
Claims
1. A web material comprising a plurality of inter-entangled
filaments associated with one another such that the web material is
formed, wherein the plurality of inter-entangled filaments comprise
one or more hair care active agents present in the plurality of
inter-entangled filaments at a total level of greater than 20% by
weight on a dry filament basis, wherein at least one of the hair
care active agents comprises a surfactant, and one or more polar
solvent-soluble filament-forming materials, and wherein the
plurality of inter-entangled filaments exhibit a diameter of
greater than 1 .mu.m and less than 100 .mu.m as measured according
to the Diameter Test Method and wherein the web material exhibits
an average dissolution time less than 950 s/g as measured according
to the Dissolution Test Method.
2. The web material according to claim 1 wherein at least one of
the one or more hair care active agents is releasable from the
plurality of inter-entangled filaments when exposed to conditions
of intended use.
3. The web material according to claim 1 wherein at least one of
the one or more hair care active agents is selected from the group
consisting of: shampoo agents and/or hair colorant agents, hair
conditioning agents, and mixtures thereof.
4. The web material according to claim 1 wherein the plurality of
inter-entangled filaments comprise two or more different hair care
active agents.
5. The web material according to claim 1 wherein the web material
further comprises a dissolution aid.
6. The web material according to claim 1 wherein the web material
exhibits a water content of from 0% to about 20% by weight as
measured according to the Water Content Test Method.
7. The web material according to claim 1 wherein the plurality of
inter-entangled filaments comprise a plurality of fibers.
8. The web material according to claim 1 wherein the plurality of
inter-entangled filaments comprise at least one fiber.
9. The web material according to claim 1 wherein the plurality of
inter-entangled filaments comprise a plurality of filaments,
fibers, or combinations thereof.
10. A web material comprising a plurality of inter-entangled
filaments associated with one another such that the web material is
formed, wherein the plurality of inter-entangled filaments comprise
one or more hair care active agents present in the plurality of
inter-entangled filaments at a total level of greater than 20% by
weight on a dry filament basis, wherein at least one of the hair
care active agents comprises a surfactant, and one or more
filament-forming materials, and wherein the plurality of
inter-entangled filaments exhibit a diameter of greater than 1
.mu.m and less than 100 .mu.m as measured according to the Diameter
Test Method, wherein the web material exhibits a MD Peak Elongation
of greater than 10% as measured according to the Elongation Test
Method and wherein the web material exhibits an average dissolution
time less than 950 s/g as measured according to the Dissolution
Test Method.
11. The web material according to claim 10 wherein at least one of
the one or more hair care active agents is releasable from the
plurality of inter-entangled filaments when exposed to conditions
of intended use.
12. The web material according to claim 10 wherein at least one of
the one or more hair care active agents is selected from the group
consisting of: shampoo agents and/or hair colorant agents, hair
conditioning agents, and mixtures thereof.
13. The web material according to claim 10 wherein the plurality of
inter-entangled filaments comprise a plurality of fibers.
14. The web material according to claim 10 wherein the plurality of
inter-entangled filaments comprise at least one fiber.
15. The web material according to claim 10 wherein the plurality of
inter-entangled filaments comprise a plurality of filaments,
fibers, or combinations thereof.
16. A web material comprising a plurality of inter-entangled
filaments associated with one another such that the web material is
formed, wherein the plurality of inter-entangled filaments comprise
one or more hair care active agents present in the plurality of
inter-entangled filaments at a total level of greater than 20% by
weight on a dry filament basis, wherein at least one of the one or
more hair care active agents comprises a surfactant, and one or
more filament-forming materials, and wherein the plurality of
inter-entangled filaments exhibit a diameter of greater than 1
.mu.m and less than 100 .mu.m as measured according to the Diameter
Test Method, wherein the web material exhibits a GM Modulus of less
than 15,000 g/cm.sup.2 as measured according to the Modulus Test
Method and wherein the web material exhibits an average dissolution
time less than 950 s/g as measured according to the Dissolution
Test Method.
17. The web material according to claim 16 wherein at least one of
the one or more active agents is releasable from the plurality of
inter-entangled filaments when exposed to conditions of intended
use.
18. The web material according to claim 16 wherein the plurality of
inter-entangled filaments comprise a plurality of fibers.
19. The web material according to claim 16 wherein the plurality of
inter-entangled filaments comprise at least one fiber.
20. The web material according to claim 16 wherein the plurality of
inter-entangled filaments comprise a plurality of filaments,
fibers, or combinations thereof.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to web materials, more
particularly to web materials comprising one or more active agents,
and methods for making same.
BACKGROUND OF THE INVENTION
[0002] Web materials are known in the art. For example, a polyester
nonwoven that is impregnated and/or coated with a detergent
composition is known in the art as shown in prior art FIGS. 1 and
2. As shown in prior art FIGS. 1 and 2, a known nonwoven substrate
10 is made of dissolvable fibers 12 wherein the nonwoven substrate
10 is coated and/or impregnated with an additive 14, such as an
active agent, rather than the additive 14, such as an active agent,
being present in the dissolvable fibers 12. An example of such a
web material is commercially available as Purex.RTM. Complete
3-in-1 Laundry Sheets from The Dial Corporation.
[0003] Further, an article of manufacture formed from a cast
solution of a detergent composition is also known in the art and is
commercially available as Dizolve.RTM. Laundry Sheets commercially
available from Dizolve Group Corporation.
[0004] However, such known web materials and/or articles of
manufacture exhibit negatives that make them problematic for
consumers. For example, the known web materials and/or articles of
manufacture are relatively stiff and/or inflexible as measured by
the Plate Stiffness Test Method described herein. Further, the web
materials and/or articles of manufacture typically deliver such a
low level of detergent composition and/or detergent actives that
the cleaning performance is less than desired by consumers. Another
negative with is that the web materials and/or articles of
manufacture may leave remnants of the web material and/or articles
of manufacture after the washing operation, for example the
polyester nonwoven substrate does not dissolve during the washing
operation.
[0005] In light of the foregoing, it is clear that there is a need
for a web material that overcomes the negatives associated with
known web materials and/or articles of manufacture described
above.
SUMMARY OF THE INVENTION
[0006] The present invention fulfills the need described above by
providing novel web materials. In one example of the present
invention, a web material comprising one or more active agents,
wherein the web material exhibits a basis weight of less than 500
g/m.sup.2 and/or less than 450 g/m.sup.2 and/or less than 400
g/m.sup.2 and/or less than 350 g/m.sup.2 and/or less than 300
g/m.sup.2 and/or less than 250 g/m.sup.2 and/or less than 200
g/m.sup.2 as measured by the Basis Weight Test Method described
herein is provided.
[0007] In another example of the present invention, a web material
comprising one or more active agents, wherein the web material
exhibits a thickness of less than 50 mils and/or less than 40 mils
and/or less than 30 mils and/or less than 25 mils and/or less than
20 mils and/or greater than 0.01 mils and/or greater than 0.1 mils
and/or greater than 1 mil and/or greater than 2 mils and/or greater
than 5 mils as measured by the Thickness Test Method described
herein is provided.
[0008] In another example of the present invention, a web material
comprising one or more active agents, wherein the web material
exhibits a thickness of greater than 0.01 mm and/or greater than
0.05 mm and/or greater than 0.1 mm and/or to about 20 mm and/or to
about 10 mm and/or to about 5 mm and/or to about 2 mm and/or to
about 0.5 mm and/or to about 0.3 mm as measured by the Thickness
Test Method described herein is provided herein.
[0009] In still another example of the present invention, a web
material comprising one or more active agents, wherein the web
material exhibits a Geometric Mean (GM) Modulus of less than 20,000
g/cm.sup.2 and/or less than 15,000 g/cm.sup.2 and/or less than
12,000 g/cm.sup.2 and/or less than 10,000 g/cm.sup.2 and/or less
than 8,000 g/cm.sup.2 and/or greater than 10 g/cm.sup.2 and/or
greater than 50 g/cm.sup.2 and/or greater than 100 g/cm.sup.2
and/or greater than 500 g/cm.sup.2 and/or greater than 1,000
g/cm.sup.2 as measured by the Modulus Test Method described herein
is provided.
[0010] In still yet another example of the present invention, a web
material comprising one or more active agents, wherein the web
material exhibits a Machine Direction (MD) Peak Elongation of
greater than 10% and/or greater than 20% and/or greater than 30%
and/or greater than 50% and/or to about 200% and/or to about 100%
and/or to about 75% as measured according to the Elongation Test
Method described herein is provided.
[0011] In still yet another example of the present invention, a web
material comprising one or more active agents, wherein the web
material exhibits a Cross Machine Direction (CD) Peak Elongation of
greater than 10% and/or greater than 20% and/or greater than 30%
and/or greater than 50% and/or to about 200% and/or to about 100%
and/or to about 75% as measured according to the Elongation Test
Method described herein is provided.
[0012] In yet another example of the present invention, a web
material comprising one or more active agents, wherein the web
material exhibits a Dry Burst of less than 5000 g and/or less than
4000 g and/or less than 3000 g and/or less than 2500 g and/or less
than 2000 g and/or less than 1500 g and/or to about 100 g and/or to
about 300 g and/or to about 500 g as measured according to the Dry
Burst Test Method described herein is provided.
[0013] In even yet another example of the present invention, a web
material comprising one or more active agents, wherein the web
material exhibits a Density of less than 0.38 g/cm.sup.3 and/or
less than 0.35 g/cm.sup.3 and/or less than 0.33 g/cm.sup.3 and/or
less than 0.31 g/cm.sup.3 and/or less than 28 g/cm.sup.3 and/or
less than 25 g/cm.sup.3 as measured according to the Density Test
Method described herein is provided.
[0014] In yet another example of the present invention, a web
material comprising one or more active agents, wherein the web
material exhibits a Plate Stiffness of less than 50 N*mm and/or
less than 40 N*mm and/or less than 30 N*mm and/or less than 20 N*mm
and/or less than 15 N*mm and/or less than 10 N*mm and/or less than
7 N*mm and/or less than 5 N*mm and/or less than 3 N*mm as measured
according to the Plate Stiffness Test Method described herein is
provided.
[0015] In another example of the present invention, a nonwoven web
comprising a plurality of filaments, wherein at least one of the
filaments comprises one or more filament-forming materials and one
or more active agents that are releasable from the filament when
the filament is exposed to conditions of intended use, wherein the
total level of the one or more filament-forming materials present
in the filament is 50% or less by weight on a dry filament basis
and/or dry web material basis and the total level of the one or
more active agents present in the filament is 50% or greater by
weight on a dry filament basis and/or dry web material basis, is
provided.
[0016] In another example of the present invention, a nonwoven web
comprising a plurality of filaments, wherein at least one of the
filaments comprises one or more filament-forming materials and one
or more active agents that are releasable from the filament as the
filament's morphology changes, wherein the total level of the one
or more filament-forming materials present in the filament is less
than 65% by weight on a dry filament basis and/or dry web material
basis and the total level of the one or more active agents present
in the filament is greater than 35% by weight on a dry filament
basis and/or dry web material basis, is provided.
[0017] In another example of the present invention, a nonwoven web
comprising a plurality of filaments, wherein at least one of the
filaments comprises one or more filament-forming materials and one
or more ingestible active agents that are releasable from the
filament upon ingesting by an animal, wherein the total level of
the one or more filament-forming materials present in the filament
is less than 80% by weight on a dry filament basis and/or dry web
material basis and the total level of the one or more active agents
present in the filament is greater than 20% by weight on a dry
filament basis and/or dry web material basis, is provided.
[0018] In still another example of the present invention, a
nonwoven web comprising a plurality of filaments, wherein at least
one of the filaments comprises one or more filament-forming
materials and one or more non-perfume active agents, wherein the
total level of the non-perfume active agents present in the
filament is greater than 35% by weight on a dry filament basis
and/or dry web material basis and wherein the filament releases one
or more of the non-perfume active agents when the filament is
exposed to conditions of intended use, is provided.
[0019] Accordingly, the present invention provides web materials
and methods for making such web materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic representation of a prior art nonwoven
substrate made of dissolvable fibers that is coated with an
additive;
[0021] FIG. 2 is a cross-sectional view of FIG. 1 taken along line
2-2 of FIG. 1;
[0022] FIG. 3 is a schematic representation of a filament according
to the present invention;
[0023] FIG. 4 is a schematic representation of an example of a
nonwoven web according to the present invention;
[0024] FIG. 5 is a schematic representation of an apparatus
suitable for making a filament according to the present invention;
and
[0025] FIG. 6 is a schematic representation of a die suitable for
spinning a filament according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0026] "Filament" as used herein means an elongate particulate
having a length greatly exceeding its diameter, i.e. a length to
diameter ratio of at least about 10.
[0027] The filaments of the present invention may be spun from
filament-forming compositions via suitable spinning processes
operations, such as meltblowing and/or spunbonding.
[0028] The filaments of the present invention may be monocomponent
and/or multicomponent. For example, the filaments may comprise
bicomponent filaments. The bicomponent filaments may be in any
form, such as side-by-side, core and sheath, islands-in-the-sea and
the like.
[0029] The filaments of the present invention exhibit 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.).
[0030] Filaments are typically considered continuous or
substantially continuous in nature. Filaments are relatively longer
than fibers (which are less than 5.08 cm in length). Non-limiting
examples of filaments include meltblown and/or spunbond
filaments.
[0031] 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
additives, 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.
[0032] "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 additives, 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.
[0033] In one example as shown in FIG. 3 a filament 16 of the
present invention made from a filament-forming composition of the
present invention is such that one or more additives 18, for
example one or more active agents, may be present in the filament
rather than on the filament, such as a coating as shown in prior
art FIGS. 1 and 2. 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.
[0034] In one example, one or more additives, such as active
agents, may be present in the filament and one or more additional
additives, 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 additives, 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.
[0035] "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") and/or a
polysaccharide, such as starch and/or a starch derivative, such as
an ethoxylated starch and/or acid-thinned starch. 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.
[0036] "Additive" as used herein means any material present in the
filament of the present invention that is not a filament-forming
material. In one example, an additive comprises an active agent. In
another example, an additive comprises a processing aid. In still
another example, an additive comprises a filler. In one example, an
additive 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, an
additive, for example an active agent, comprises a non-polymer
material.
[0037] In another example, an additive comprises 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.
[0038] 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
[0039] In another example, an additive comprises a crosslinking
agent suitable for crosslinking one or more of the filament-forming
materials present in the filaments of the present invention. In one
example, the crosslinking agent comprises a crosslinking agent
capable of crosslinking hydroxyl polymers together, for example via
the hydroxyl polymers hydroxyl moieties. Non-limiting examples of
suitable crosslinking agents include imidazolidinones,
polycarboxylic acids and mixtures thereof. In one example, the
crosslinking agent comprises a urea glyoxal adduct crosslinking
agent, for example a dihydroxyimidazolidinone, such as
dihydroxyethylene urea ("DHEU"). A crosslinking agent can be
present in the filament-forming composition and/or filament of the
present invention to control the filament's solubility and/or
dissolution in a solvent, such as a polar solvent.
[0040] In another example, an additive comprises 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.).
[0041] In yet another example, an additive comprises 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.
[0042] In still yet another example, an additive comprises 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 are applied to the
filament, in other words, after the filament is formed. In one
example, one or more release agents/lubricants are applied to the
filament prior to collecting the filaments on a collection device
to form a nonwoven. In another example, one or more release
agents/lubricants are applied to a nonwoven web formed from the
filaments of the present invention prior to contacting one or more
nonwoven webs, such as in a stack of nonwoven webs. In yet another
example, one or more release agents/lubricants are applied to the
filament of the present invention and/or nonwoven comprising the
filament prior to the filament and/or nonwoven contacting a
surface, such as a surface of equipment used in a processing system
so as to facilitate removal of the filment and/or nonwoven web
and/or to avoid layers of filaments and/or nonwoven webs of the
present invention sticking to one another, even inadvertently. In
one example, the release agents/lubricants comprise
particulates.
[0043] In even still yet another example, an additive comprises 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.
[0044] "Conditions of intended use" as used herein means the
temperature, physical, chemical, and/or mechanical conditions that
a filament of the present invention is exposed to when the filament
is used for one or more of its designed purposes. For example, if a
filament and/or a nonwoven web 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 nonwoven web
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 nonwoven web 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.
[0045] "Active agent" as used herein means an additive that
produces an intended effect in an environment external to a
filament and/or nonwoven web comprising the filament of the
present, such as when the filament is exposed to conditions of
intended use of the filament and/or nonwoven web comprising the
filament. In one example, an active agent comprises an additive
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 an additive that creates a
chemical reaction (i.e., foaming, fizzing, 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 an additive 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 containing
the active agent, for example the filament 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.
[0046] "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.
[0047] 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.
[0048] "Personal care active agent," as used herein, means an
active agent that may be applied to mammalian keratinous tissue
without undue undesirable effects.
[0049] "Keratinous tissue," as used herein, means
keratin-containing layers disposed as the outermost protective
covering of mammals and includes, but is not limited to, skin,
hair, scalp and nails.
[0050] "Beauty benefit," as used herein in reference to mammalian
keratinous tissue includes, but is not limited to cleansing, sebum
inhibition, reducing the oily and/or shiny appearance of skin
and/or hair, reducing dryness, itchiness and/or flakiness, reducing
skin pore size, exfoliation, desquamation, improving the appearance
of the keratinous tissue, conditioning, smoothening, deodorizing
skin and/or providing antiperspirant benefits, etc.
[0051] "Beauty benefit active agent," as used herein, refers to an
active agent that can deliver one or more beauty benefits.
[0052] "Skin care active agent" as used herein, means an active
agent that when applied to the skin provides a benefit or
improvement to the skin. It is to be understood that skin care
active agents are useful not only for application to skin, but also
to hair, scalp, nails and other mammalian keratinous tissue.
[0053] "Hair care active agent" as used herein, means an active
agent that when applied to mammalian hair provides a benefit and/or
improvement to the hair. Non-limiting examples of benefits and/or
improvements to hair include softness, static control, hair repair,
dandruff removal, dandruff resistance, hair coloring, shape
retention, hair retention, and hair growth.
[0054] "Fabric care active agent" as used herein means an active
agent that when applied to fabric provides a benefit and/or
improvement to the fabric. Non-limiting examples of benefits and/or
improvements to 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.
[0055] "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 example 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.
[0056] "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.
[0057] Non-limiting example 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.
[0058] "Agricultural active agent" as used herein means an active
agent that when applied to crops and/or plants provides a benefit
and/or improvement to the crops and/or plants. For example,
insecticides, herbicides, fertilizers, drought resistant agents,
are non-limiting examples of suitable agricultural active agents
that may be present in the filaments of the present invention.
[0059] "Ingestible active agent" as used herein means an active
agent that is suitable for ingestion and/or consuming by an animal,
for example a mammal, such as a human, by way of mouth, nose, eyes,
ears, skin pores, rectum, vagina, or other orifice or wound (such
as delivering an active agent by wound dressing) in the animal.
Non-limiting examples of ingestible active agents include feminine
hygiene active agents, baby care active agents, oral care active
agents, medicinal active agents, vitamins, dietary active agents
(for example delivered in a new food form), pet care active agents,
and mixtures thereof.
[0060] "Liquid treatment active agent" as used herein means an
active agent that when applied to a liquid such as water and/or
alcohol, provides a benefit and/or improvement to the liquid. For
example, chlorine and/or other swimming pool chemicals are
non-limiting examples of suitable liquid treatment active agents.
In another example, water clarifying and/or water disinfecting
active agents, such as are used in commercial water filtering
and/or water treatment technologies such as PUR.RTM. are
non-limiting examples of suitable liquid treatment active agents
that may be present in the filaments of the present invention.
Further, oil dispersants and/or oil scavenging agents are
non-limiting examples of other suitable liquid treatment active
agents.
[0061] "Industrial active agent" as used herein means an active
agent that provides a benefit within an article of manufacture. For
example, glue and/or adhesive to provide bonding between two
object, insecticides incorporated into insulation, such as housing
insulation, oxygen scavenging active agents incorporated into
packaging for food and/or perishable goods, insect repellants
incorporated into articles used by humans to repel insects, and
moisture scavengers incorporated into desiccants are non-limiting
examples of industrial active agents that may be present in the
filaments of the present invention.
[0062] "Weight ratio" as used herein means the weight of
filament-forming material (g or %) on a dry weight basis in the
filament to the weight of additive, such as active agent(s) (g or
%) on a dry weight basis in the filament.
[0063] "Hydroxyl polymer" as used herein includes any
hydroxyl-containing polymer that can be incorporated into a
filament of the present invention, for example as a
filament-forming material. In one example, the hydroxyl polymer of
the present invention includes greater than 10% and/or greater than
20% and/or greater than 25% by weight hydroxyl moieties.
[0064] "Biodegradable" as used herein means, with respect to a
material, such as a filament as a whole and/or a polymer within a
filament, such as a filament-forming material, that the filament
and/or polymer is capable of undergoing and/or does undergo
physical, chemical, thermal and/or biological degradation in a
municipal solid waste composting facility such that at least 5%
and/or at least 7% and/or at least 10% of the original filament
and/or polymer is converted into carbon dioxide after 30 days as
measured according to the OECD (1992) Guideline for the Testing of
Chemicals 301B; Ready Biodegradability--CO.sub.2 Evolution
(Modified Sturm Test) Test incorporated herein by reference.
[0065] "Non-biodegradable" as used herein means, with respect to a
material, such as a filament as a whole and/or a polymer within a
filament, such as a filament-forming material, that the filament
and/or polymer is not capable of undergoing physical, chemical,
thermal and/or biological degradation in a municipal solid waste
composting facility such that at least 5% of the original filament
and/or polymer is converted into carbon dioxide after 30 days as
measured according to the OECD (1992) Guideline for the Testing of
Chemicals 301B; Ready Biodegradability--CO.sub.2 Evolution
(Modified Sturm Test) Test incorporated herein by reference.
[0066] "Non-thermoplastic" as used herein means, with respect to a
material, such as a filament as a whole and/or a polymer within a
filament, such as a filament-forming material, that the filament
and/or polymer exhibits no melting point and/or softening point,
which allows it to flow under pressure, in the absence of a
plasticizer, such as water, glycerin, sorbitol, urea and the
like.
[0067] "Non-thermoplastic, biodegradable filament" as used herein
means a filament that exhibits the properties of being
biodegradable and non-thermoplastic as defined above.
[0068] "Non-thermoplastic, non-biodegradable filament" as used
herein means a filament that exhibits the properties of being
non-biodegradable and non-thermoplastic as defined above.
[0069] "Thermoplastic" as used herein means, with respect to a
material, such as a filament as a whole and/or a polymer within a
filament, such as a filament-forming material, that the filament
and/or polymer exhibits a melting point and/or softening point at a
certain temperature, which allows it to flow under pressure, in the
absence of a plasticizer
[0070] "Thermoplastic, biodegradable filament" as used herein means
a filament that exhibits the properties of being biodegradable and
thermoplastic as defined above.
[0071] "Thermoplastic, non-biodegradable filament" as used herein
means a filament that exhibits the properties of being
non-biodegradable and thermoplastic as defined above.
[0072] "Non-cellulose-containing" as used herein means that less
than 5% and/or less than 3% and/or less than 1% and/or less than
0.1% and/or 0% by weight of cellulose polymer, cellulose derivative
polymer and/or cellulose copolymer is present in filament. In one
example, "non-cellulose-containing" means that less than 5% and/or
less than 3% and/or less than 1% and/or less than 0.1% and/or 0% by
weight of cellulose polymer is present in filament.
[0073] "Polar solvent-soluble material" as used herein means a
material that is miscible in a polar solvent. In one example, a
polar solvent-soluble material is miscible in alcohol and/or water.
In other words, a polar solvent-soluble material is a material that
is capable of forming a stable (does not phase separate for greater
than 5 minutes after forming the homogeneous solution) homogeneous
solution with a polar solvent, such as alcohol and/or water at
ambient conditions.
[0074] "Alcohol-soluble material" as used herein means a material
that is miscible in alcohol. In other words, a material that is
capable of forming a stable (does not phase separate for greater
than 5 minutes after forming the homogeneous solution) homogeneous
solution with an alcohol at ambient conditions.
[0075] "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.
[0076] "Non-polar solvent-soluble material" as used herein means a
material that is miscible in a non-polar solvent. In other words, a
non-polar solvent-soluble material is a material that is capable of
forming a stable (does not phase separate for greater than 5
minutes after forming the homogeneous solution) homogeneous
solution with a non-polar solvent.
[0077] "Ambient conditions" as used herein means 73.degree.
F..+-.4.degree. F. (about 23.degree. C..+-.2.2.degree. C.) and a
relative humidity of 50%.+-.10%.
[0078] "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.
[0079] "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.
[0080] "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.
[0081] "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, such as a loss
or altering of the filament's physical structure and/or a release
of an additive, such as an active agent. In another example, the
triggering condition may be present in an environment, such as
water, when a filament and/or nonwoven web and/or film 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
nonwoven and/or film of the present invention is added to the
water.
[0082] "Morphology changes" as used herein with respect to a
filament's morphology changing means that the filament experiences
a change in its physical structure. Non-limiting examples of
morphology changes for a filament of the present invention include
dissolution, melting, swelling, shrinking, breaking into pieces,
exploding, lengthening, shortening, and combinations thereof. The
filaments of the present invention may completely or substantially
lose their filament physical structure or they may have their
morphology changed or they may retain or substantially retain their
filament physical structure as they are exposed to conditions of
intended use.
[0083] "By weight on a dry filament basis and/or dry web material
basis" means that the weight of the filament and/or web material
measured immediately after the filament and/or web material has
been conditioned in a conditioned room at a temperature of
73.degree. F..+-.4.degree. F. (about 23.degree. C..+-.2.2.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 web material
basis" means that the filament and/or web material 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 weight of the filament and/or web
material of moisture, such as water, for example free water, as
measured according to the Water Content Test Method described
herein.
[0084] "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 web material, 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 web material may comprise
25% by weight on a dry filament basis and/or dry web material basis
of an anionic surfactant, 15% by weight on a dry filament basis
and/or dry web material basis of a nonionic surfactant, 10% by
weight of a chelant, and 5% of a perfume so that the total level of
active agents present in the filament is greater than 50%; namely
55% by weight on a dry filament basis and/or dry web material
basis.
[0085] "Web material" as used herein means a solid form, for
example a rectangular solid, sometimes referred to as a sheet.
[0086] "Web" as used herein means a collection of formed fibers
and/or filaments, such as a fibrous structure, and/or a web
material formed of fibers and/or filaments, such as continuous
filaments, of any nature or origin associated with one another. In
one example, the web is a rectangular solid comprising fibers
and/or filaments that is formed via a spinning process, not a
casting process.
[0087] "Nonwoven web" for purposes of the present invention as used
herein and as defined generally by European Disposables and
Nonwovens Association (EDANA) means a sheet of fibers and/or
filaments, such as continuous filaments, of any nature or origin,
that have been formed into a web by any means, and may be bonded
together by any means, with the exception of weaving or knitting.
Felts obtained by wet milling are not nonwoven webs. In one
example, a nonwoven web according to the present invention means an
orderly arrangement of filaments within a structure in order to
perform a function. In one example, a nonwoven web of the present
invention 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 nonwoven web. In
one example, the nonwoven web of the present invention may
comprise, in addition to the filaments of the present invention,
one or more solid additives, such as particulates and/or
fibers.
[0088] "Particulates" as used herein means granular substances
and/or powders. In one example, the filaments and/or fibers can be
converted into powders.
[0089] 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.
[0090] 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.
[0091] 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.
Filament
[0092] The filament of the present invention comprises one or more
filament-forming materials. In addition to the filament-forming
materials, the filament may further comprise one or more active
agents that are releasable from the filament, such as when the
filament is exposed to conditions of intended use, wherein the
total level of the one or more filament-forming materials present
in the filament is less than 80% by weight on a dry filament basis
and/or dry web material basis and the total level of the one or
more active agents present in the filament is greater than 20% by
weight on a dry filament basis and/or dry web material basis, is
provided.
[0093] In one example, the filament of the present invention
comprises about 100% and/or greater than 95% and/or greater than
90% and/or greater than 85% and/or greater than 75% and/or greater
than 50% by weight on a dry filament basis and/or dry web material
basis of one or more filament-forming materials. For example, the
filament-forming material may comprise polyvinyl alcohol and/or
starch.
[0094] In another example, the filament of the present invention
comprises one or more filament-forming materials and one or more
active agents wherein the total level of filament-forming materials
present in the filament is from about 5% to less than 80% by weight
on a dry filament basis and/or dry web material basis and the total
level of active agents present in the filament is greater than 20%
to about 95% by weight on a dry filament basis and/or dry web
material basis.
[0095] In one example, the filament of the present invention
comprises at least 10% and/or at least 15% and/or at least 20%
and/or less than less than 80% and/or less than 75% and/or less
than 65% and/or less than 60% and/or less than 55% and/or less than
50% and/or less than 45% and/or less than 40% by weight on a dry
filament basis and/or dry web material basis of the
filament-forming materials and greater than 20% and/or at least 35%
and/or at least 40% and/or at least 45% and/or at least 50% and/or
at least 60% and/or less than 95% and/or less than 90% and/or less
than 85% and/or less than 80% and/or less than 75% by weight on a
dry filament basis and/or dry web material basis of active
agents.
[0096] In one example, the filament of the present invention
comprises at least 5% and/or at least 10% and/or at least 15%
and/or at least 20% and/or less than 50% and/or less than 45%
and/or less than 40% and/or less than 35% and/or less than 30%
and/or less than 25% by weight on a dry filament basis and/or dry
web material basis of the filament-forming materials and greater
than 50% and/or at least 55% and/or at least 60% and/or at least
65% and/or at least 70% and/or less than 95% and/or less than 90%
and/or less than 85% and/or less than 80% and/or less than 75% by
weight on a dry filament basis and/or dry web material basis of
active agents. In one example, the filament of the present
invention comprises greater than 80% by weight on a dry filament
basis and/or dry web material basis of active agents.
[0097] In another example, the one or more filament-forming
materials and active agents are present in the filament at a weight
ratio of total level of filament-forming materials to active agents
of 4.0 or less and/or 3.5 or less and/or 3.0 or less and/or 2.5 or
less and/or 2.0 or less and/or 1.85 or less and/or less than 1.7
and/or less than 1.6 and/or less than 1.5 and/or less than 1.3
and/or less than 1.2 and/or less than 1 and/or less than 0.7 and/or
less than 0.5 and/or less than 0.4 and/or less than 0.3 and/or
greater than 0.1 and/or greater than 0.15 and/or greater than
0.2.
[0098] In still another example, the filament of the present
invention comprises from about 10% and/or from about 15% to less
than 80% by weight on a dry filament basis and/or dry web material
basis of a filament-forming material, such as polyvinyl alcohol
polymer and/or a starch polymer, and greater than 20% to about 90%
and/or to about 85% by weight on a dry filament basis and/or dry
web material basis of an active agent. The filament may further
comprise a plasticizer, such as glycerin and/or pH adjusting
agents, such as citric acid.
[0099] In yet another example, the filament of the present
invention comprises from about 10% and/or from about 15% to less
than 80% by weight on a dry filament basis and/or dry web material
basis of a filament-forming material, such as polyvinyl alcohol
polymer and/or a starch polymer, and greater than 20% to about 90%
and/or to about 85% by weight on a dry filament basis and/or dry
web material basis of an active agent, wherein the weight ratio of
filament-forming material to active agent is 4.0 or less. The
filament may further comprise a plasticizer, such as glycerin
and/or pH adjusting agents, such as citric acid.
[0100] In even another example of the present invention, a filament
comprises one or more filament-forming materials and one or more
active agents selected from the group consisting of: enzymes,
bleaching agents, builder, chelants, sensates, dispersants, and
mixtures thereof that are releasable and/or released when the
filament is exposed to conditions of intended use. In one example,
the filament comprises a total level of filament forming materials
of less than 95% and/or less than 90% and/or less than 80% and/or
less than 50% and/or less than 35% and/or to about 5% and/or to
about 10% and/or to about 20% by weight on a dry filament basis
and/or dry web material basis and a total level of active agents
selected from the group consisting of: enzymes, bleaching agents,
builder, chelants, and mixtures thereof of greater than 5% and/or
greater than 10% and/or greater than 20% and/or greater than 35%
and/or greater than 50% and/or greater than 65% and/or to about 95%
and/or to about 90% and/or to about 80% by weight on a dry filament
basis and/or dry web material basis. In one example, the active
agent comprises one or more enzymes. In another example, the active
agent comprises one or more bleaching agents. In yet another
example, the active agent comprises one or more builders. In still
another example, the active agent comprises one or more
chelants.
[0101] In yet another example of the present invention, the
filaments of the present invention may comprise active agents that
may create health and/or safety concerns if they become airborne.
For example, the filament may be used to inhibit enzymes within the
filament from becoming airborne.
[0102] In one example, the filaments of the present invention may
be meltblown filaments. In another example, the filaments of the
present invention may be spunbond filaments. In another example,
the filaments may be hollow filaments prior to and/or after release
of one or more of its active agents.
[0103] The filaments of the present invention may be hydrophilic or
hydrophobic. The filaments may be surface treated and/or internally
treated to change the inherent hydrophilic or hydrophobic
properties of the filament.
[0104] In one example, the filament 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 10 .mu.m and/or less
than 5 .mu.m and/or less than 1 .mu.m as measured according to the
Diameter Test Method described herein. In another example, the
filament of the present invention exhibits a diameter of greater
than 1 .mu.m as measured according to the Diameter Test Method
described herein. The diameter of a filament of the present
invention may be used to control the rate of release of one or more
active agents present in the filament and/or the rate of loss
and/or altering of the filament's physical structure.
[0105] The filament may comprise two or more different active
agents. In one example, the filament comprises two or more
different active agents, wherein the two or more different active
agents are compatible with one another. In another example, the
filament comprises two or more different active agents, wherein the
two or more different active agents are incompatible with one
another.
[0106] In one example, the filament may comprise an active agent
within the filament and an active agent on an external surface of
the filament, such as coating on the filament. The active agent on
the external surface of the filament may be the same or different
from the active agent present in the filament. If different, the
active agents may be compatible or incompatible with one
another.
[0107] In one example, one or more active agents may be uniformly
distributed or substantially uniformly distributed throughout the
filament. In another example, one or more active agents may be
distributed as discrete regions within the filament. In still
another example, at least one active agent is distributed uniformly
or substantially uniformly throughout the filament and at least
another active agent is distributed as one or more discrete regions
within the filament. In still yet another example, at least one
active agent is distributed as one or more discrete regions within
the filament and at least another active agent is distributed as
one or more discrete regions different from the first discrete
regions within the filament.
[0108] The filaments may be used as discrete articles. In one
example, the filaments may be applied to and/or deposited on a
carrier substrate, for example a wipe, paper towel, bath tissue,
facial tissue, sanitary napkin, tampon, diaper, adult incontinence
article, washcloth, dryer sheet, laundry sheet, laundry bar, dry
cleaning sheet, netting, filter paper, fabrics, clothes,
undergarments, and the like.
[0109] In addition, a plurality of the filaments of the present
invention may be collected and pressed into a film thus resulting
in the film comprising the one or more filament-forming materials
and the one or more active agents that are releasable from the
film, such as when the film is exposed to conditions of intended
use.
[0110] In one example, a film of the present invention exhibits an
average disintegration time per g of sample of less than 120 and/or
less than 100 and/or less than 80 and/or less than 55 and/or less
than 50 and/or less than 40 and/or less than 30 and/or less than 20
seconds/gram (s/g) as measured according to the Dissolution Test
Method described herein.
[0111] In another example, a film of the present invention exhibits
an average dissolution time per g of sample of less than 950 and/or
less than 900 and/or less than 800 and/or less than 700 and/or less
than 600 and/or less than 550 seconds/gram (s/g) as measured
according to the Dissolution Test Method described herein.
[0112] In one example, a film of the present invention exhibits a
thickness of greater than 0.01 mm and/or greater than 0.05 mm
and/or greater than 0.1 mm and/or to about 20 mm and/or to about 10
mm and/or to about 5 mm and/or to about 2 mm and/or to about 0.5 mm
and/or to about 0.3 mm as measured by the Thickness Test Method
described herein.
Filament-Forming Material
[0113] 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 filament, such as by a
spinning process.
[0114] 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.
[0115] In another example, the filament-forming material may
comprise a non-polar solvent-soluble material.
[0116] 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 filament basis and/or dry web material basis) of non-polar
solvent-soluble materials.
[0117] 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.
[0118] 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,
methycelluloses, and carboxymethycelluloses.
[0119] 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, and mixtures
thereof.
[0120] In another example, the filament-forming material comprises
a polymer is selected from the group consisting of: pullulan,
hydroxypropylmethyl cellulose, hydroxyethyl cellulose,
hydroxypropyl 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
[0121] 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.
[0122] 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.
[0123] a. Water-Soluble Hydroxyl Polymers --
[0124] 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.
[0125] In one example, a water-soluble hydroxyl polymer of the
present invention comprises a polysaccharide.
[0126] "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.
[0127] 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.
[0128] In another example, a water-soluble hydroxyl polymer of the
present invention comprises a non-thermoplastic polymer.
[0129] 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. 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.
[0130] 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.
[0131] 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.
[0132] 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.
[0133] 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.
[0134] 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-acrylamido-methyl propane
sulfonic acid (AMPs), vinylidene chloride, vinyl chloride, vinyl
amine and a variety of acrylate esters.
[0135] In one example, the water-soluble hydroxyl polymer is
selected from the group consisting of: polyvinyl alcohols,
hydroxymethylcelluloses, hydroxyethylcelluloses,
hydroxypropylmethylcelluloses 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.
[0136] b. Water-Soluble Thermoplastic Polymers--
[0137] 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.
[0138] 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.
[0139] The water-soluble thermoplastic polymers may comprise
biodegradable polymers.
[0140] 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.
Non-Polar Solvent-Soluble Materials
[0141] 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.
[0142] The non-polar solvent-soluble materials may comprise a
non-biodegradable polymer such as polypropylene, polyethylene and
certain polyesters.
[0143] 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.
Active Agents
[0144] Active agents are a class of additives that are designed and
intended to provide a benefit to something other than the filament
itself, such as providing a benefit to an environment external to
the filament. Active agents may be any suitable additive that
produces an intended effect under intended use conditions of the
filament. 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, 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, 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.
[0145] 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.
[0146] 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
filament and/or nonwoven made therefrom.
[0147] For example, if the filament of the present invention and/or
nonwoven 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 filament and/or nonwoven incorporating the filament.
[0148] In one example, if the filament of the present invention
and/or nonwoven 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 filament and/or nonwoven
incorporating the filament. In another example, if the filament of
the present invention and/or nonwoven made therefrom is designed to
be used for laundering clothes in a laundry operation and/or
cleaning dishes in a dishwashing operation, then the filament may
comprise a laundry detergent composition or dishwashing detergent
composition.
[0149] In one example, the active agent comprises a non-perfume
active agent. In another example, the active agent comprises a
non-surfactant active agent. In still another example, the active
agent comprises a non-ingestible active agent, in other words an
active agent other than an ingestible active agent.
Surfactants
[0150] Non-limiting examples of suitable surfactants include
anionic surfactants, cationic surfactants, nonionic surfactants,
zwitterionic surfactants, amphoteric surfactants, and mixtures
thereof. Co-surfactants may also be included in the filaments. For
filaments designed for use as laundry detergents and/or dishwashing
detergents, the total level of surfactants should be sufficient to
provide cleaning including stain and/or odor removal, and generally
ranges from about 0.5% to about 95%. Further, surfactant systems
comprising two or more surfactants that are designed for use in
filaments for laundry detergents and/or dishwashing detergents may
include all-anionic surfactant systems, mixed-type surfactant
systems comprising anionic-nonionic surfactant mixtures, or
nonionic-cationic surfactant mixtures or low-foaming nonionic
surfactants.
[0151] The surfactants herein can be linear or branched. In one
example, suitable linear surfactants include those derived from
agrochemical oils such as coconut oil, palm kernel oil, soybean
oil, or other vegetable-based oils.
[0152] a. Anionic Surfactants
[0153] Non-limiting examples of suitable anionic surfactants
include alkyl sulfates, alkyl ether sulfates, branched alkyl
sulfates, branched alkyl alkoxylates, branched alkyl alkoxylate
sulfates, mid-chain branched alkyl aryl sulfonates, sulfated
monoglycerides, sulfonated olefins, alkyl aryl sulfonates, primary
or secondary alkane sulfonates, alkyl sulfosuccinates, acyl
taurates, acyl isethionates, alkyl glycerylether sulfonate,
sulfonated methyl esters, sulfonated fatty acids, alkyl phosphates,
acyl glutamates, acyl sarcosinates, alkyl sulfoacetates, acylated
peptides, alkyl ether carboxylates, acyl lactylates, anionic
fluorosurfactants, sodium lauroyl glutamate, and combinations
thereof.
[0154] Alkyl sulfates and alkyl ether sulfates suitable for use
herein include materials with the respective formula ROSO.sub.3M
and RO(C.sub.2H.sub.4O).sub.xSO.sub.3M, wherein R is alkyl or
alkenyl of from about 8 to about 24 carbon atoms, x is 1 to 10, and
M is a water-soluble cation such as ammonium, sodium, potassium and
triethanolamine Other suitable anionic surfactants are described in
McCutcheon's Detergents and Emulsifiers, North American Edition
(1986), Allured Publishing Corp. and McCutcheon's, Functional
Materials, North American Edition (1992), Allured Publishing
Corp.
[0155] In one example, anionic surfactants useful in the filaments
of the present invention include C.sub.9-C.sub.15 alkyl benzene
sulfonates (LAS), C.sub.8-C.sub.20 alkyl ether sulfates, for
example alkyl poly(ethoxy) sulfates, C8-C20 alkyl sulfates, and
mixtures thereof. Other anionic surfactants include methyl ester
sulfonates (MES), secondary alkane sulfonates, methyl ester
ethoxylates (MEE), sulfonated estolides, and mixtures thereof.
In another example, the anionic surfactant is selected from the
group consisting of: C.sub.11-C.sub.18 alkyl benzene sulfonates
("LAS") and primary, branched-chain and random C.sub.10-C.sub.20
alkyl sulfates ("AS"), C.sub.10-C.sub.18 secondary (2,3) alkyl
sulfates of the formula
CH.sub.3(CH.sub.2).sub.x(CHOSO.sub.3.sup.-M.sup.+) CH.sub.3 and
CH.sub.3 (CH.sub.2).sub.y(CHOSO.sub.3.sup.-M.sup.+)
CH.sub.2CH.sub.3 where x and (y+1) are integers of at least about
7, preferably at least about 9, and M is a water-solubilizing
cation, especially sodium, unsaturated sulfates such as oleyl
sulfate, the C.sub.10-C.sub.18 alpha-sulfonated fatty acid esters,
the C.sub.10-C.sub.18 sulfated alkyl polyglycosides, the
C.sub.10-C.sub.18 alkyl alkoxy sulfates ("AE.sub.xS") wherein x is
from 1-30, and C.sub.10-C.sub.18 alkyl alkoxy carboxylates, for
example comprising 1-5 ethoxy units, mid-chain branched alkyl
sulfates as discussed in U.S. Pat. Nos. 6,020,303 and 6,060,443;
mid-chain branched alkyl alkoxy sulfates as discussed in U.S. Pat.
Nos. 6,008,181 and 6,020,303; modified alkylbenzene sulfonate
(MLAS) as discussed in WO 99/05243, WO 99/05242 and WO 99/05244;
methyl ester sulfonate (MES); and alpha-olefin sulfonate (AOS).
[0156] Other suitable anionic surfactants that may be used are
alkyl ester sulfonate surfactants including sulfonated linear
esters of C.sub.8-C.sub.20 carboxylic acids (i.e., fatty acids).
Other suitable anionic surfactants that may be used include salts
of soap, C.sub.8-C.sub.22 primary of secondary alkanesulfonates,
C.sub.8-C.sub.24 olefinsulfonates, sulfonated polycarboxylic acids,
C.sub.8-C.sub.24 alkylpolyglycolethersulfates (containing up to 10
moles of ethylene oxide); alkyl glycerol sulfonates, fatty acyl
glycerol sulfonates, fatty oleoyl glycerol sulfates, alkyl phenol
ethylene oxide ether sulfates, paraffin sulfonates, alkyl
phosphates, isethionates such as the acyl isethionates, N-acyl
taurates, alkyl succinamates and sulfosuccinates, monoesters of
sulfosuccinates (for example saturated and unsaturated
C.sub.12-C.sub.18 monoesters) and diesters of sulfosuccinates (for
example saturated and unsaturated C.sub.6-C.sub.12 diesters),
sulfates of alkylpolysaccharides such as the sulfates of
alkylpolyglucoside, and alkyl polyethoxy carboxylates such as those
of the formula RO(CH.sub.2CH.sub.2O).sub.k--CH.sub.2COO--M+ wherein
R is a C.sub.8-C.sub.22 alkyl, k is an integer from 0 to 10, and M
is a soluble salt-forming cation.
[0157] Other exemplary anionic surfactants are the alkali metal
salts of C.sub.10-C.sub.16 alkyl benzene sulfonic acids, preferably
C.sub.11-C.sub.14 alkyl benzene sulfonic acids. In one example, the
alkyl group is linear. Such linear alkyl benzene sulfonates are
known as "LAS". Such surfactants and their preparation are
described for example in U.S. Pat. Nos. 2,220,099 and 2,477,383. IN
another example, the linear alkyl benzene sulfonates include the
sodium and/or potassium linear straight chain alkylbenzene
sulfonates in which the average number of carbon atoms in the alkyl
group is from about 11 to 14. Sodium C.sub.11-C.sub.14 LAS, e.g.,
C.sub.12 LAS, is a specific example of such surfactants.
[0158] Another exemplary type of anionic surfactant comprises
linear or branched ethoxylated alkyl sulfate surfactants. Such
materials, also known as alkyl ether sulfates or alkyl
polyethoxylate sulfates, are those which correspond to the formula:
R'--O--(C.sub.2H.sub.4O).sub.n--SO.sub.3M wherein R' is a
C.sub.8-C.sub.20 alkyl group, n is from about 1 to 20, and M is a
salt-forming cation. In a specific embodiment, R' is
C.sub.10-C.sub.18 alkyl, n is from about 1 to 15, and M is sodium,
potassium, ammonium, alkylammonium, or alkanolammonium. In more
specific embodiments, R' is a C.sub.12-C.sub.16, n is from about 1
to 6 and M is sodium. The alkyl ether sulfates will generally be
used in the form of mixtures comprising varying R' chain lengths
and varying degrees of ethoxylation. Frequently such mixtures will
inevitably also contain some non-ethoxylated alkyl sulfate
materials, i.e., surfactants of the above ethoxylated alkyl sulfate
formula wherein n=0. Non-ethoxylated alkyl sulfates may also be
added separately to the compositions of this invention and used as
or in any anionic surfactant component which may be present.
Specific examples of non-alkoyxylated, e.g., non-ethoxylated, alkyl
ether sulfate surfactants are those produced by the sulfation of
higher C.sub.8-C.sub.20 fatty alcohols. Conventional primary alkyl
sulfate surfactants have the general formula: R''OSO.sub.3.sup.-M+
wherein R'' is typically a C.sub.8-C.sub.20 alkyl group, which may
be straight chain or branched chain, and M is a water-solubilizing
cation. In specific embodiments, R'' is a Cm-Cis alkyl group, and M
is alkali metal, more specifically R'' is C.sub.12-C.sub.14 alkyl
and M is sodium. Specific, non-limiting examples of anionic
surfactants useful herein include: a) C.sub.11-C.sub.18 alkyl
benzene sulfonates (LAS); b) C.sub.10-C.sub.20 primary,
branched-chain and random alkyl sulfates (AS); c) C.sub.10-C.sub.18
secondary (2,3)-alkyl sulfates having following formulae:
##STR00001##
wherein M is hydrogen or a cation which provides charge neutrality,
and all M units, whether associated with a surfactant or adjunct
ingredient, can either be a hydrogen atom or a cation depending
upon the form isolated by the artisan or the relative pH of the
system wherein the compound is used, with non-limiting examples of
suitable cations including sodium, potassium, ammonium, and
mixtures thereof, and x is an integer of at least 7 and/or at least
about 9, and y is an integer of at least 8 and/or at least 9; d)
C.sub.10-C.sub.18 alkyl alkoxy sulfates (AE.sub.zS) wherein z, for
example, is from 1-30; e) C.sub.10-C.sub.18 alkyl alkoxy
carboxylates preferably comprising 1-5 ethoxy units; f) mid-chain
branched alkyl sulfates as discussed in U.S. Pat. Nos. 6,020,303
and 6,060,443; g) mid-chain branched alkyl alkoxy sulfates as
discussed in U.S. Pat. Nos. 6,008,181 and 6,020,303; h) modified
alkylbenzene sulfonate (MLAS) as discussed in WO 99/05243, WO
99/05242, WO 99/05244, WO 99/05082, WO 99/05084, WO 99/05241, WO
99/07656, WO 00/23549, and WO 00/23548.; i) methyl ester sulfonate
(MES); and j) alpha-olefin sulfonate (AOS).
[0159] b. Cationic Surfactants
[0160] Non-limiting examples of suitable cationic surfactants
include, but are not limited to, those having the formula (I):
##STR00002##
in which R.sup.1, R.sup.2, R.sup.3, and R.sup.4 are each
independently selected from (a) an aliphatic group of from 1 to 26
carbon atoms, or (b) an aromatic, alkoxy, polyoxyalkylene,
alkylamido, hydroxyalkyl, aryl or alkylaryl group having up to 22
carbon atoms; and X is a salt-forming anion such as those selected
from halogen, (e.g. chloride, bromide), acetate, citrate, lactate,
glycolate, phosphate, nitrate, sulphate, and alkylsulphate
radicals. In one example, the alkylsulphate radical is methosulfate
and/or ethosulfate.
[0161] Suitable quaternary ammonium cationic surfactants of general
formula (I) may include cetyltrimethylammonium chloride,
behenyltrimethylammonium chloride (BTAC), stearyltrimethylammonium
chloride, cetylpyridinium chloride, octadecyltrimethylammonium
chloride, hexadecyltrimethylammonium chloride,
octyldimethylbenzylammonium chloride, decyldimethylbenzylammonium
chloride, stearyldimethylbenzylammonium chloride,
didodecyldimethylammonium chloride, didecyldimehtylammonium
chloride, dioctadecyldimethylammonium chloride,
distearyldimethylammonium chloride, tallowtrimethylammonium
chloride, cocotrimethylammonium chloride,
2-ethylhexylstearyldimethylammonum chloride,
dipalmitoylethyldimethylammonium chloride, PEG-2 oleylammonium
chloride and salts of these, where the chloride is replaced by
halogen, (e.g., bromide), acetate, citrate, lactate, glycolate,
phosphate nitrate, sulphate, or alkylsulphate.
[0162] Non-limiting examples of suitable cationic surfactants are
commercially available under the trade names ARQUAD.RTM. from Akzo
Nobel Surfactants (Chicago, Ill.).
[0163] In one example, suitable cationic surfactants include
quaternary ammonium surfactants, for example that have up to 26
carbon atoms include: alkoxylate quaternary ammonium (AQA)
surfactants as discussed in U.S. Pat. No. 6,136,769; dimethyl
hydroxyethyl quaternary ammonium as discussed in 6,004,922;
dimethyl hydroxyethyl lauryl ammonium chloride; polyamine cationic
surfactants as discussed in WO 98/35002, WO 98/35003, WO 98/35004,
WO 98/35005, and WO 98/35006; cationic ester surfactants as
discussed in U.S. Pat. Nos. 4,228,042, 4,239,660 4,260,529 and U.S.
Pat. No. 6,022,844; and amino surfactants as discussed in U.S. Pat.
No. 6,221,825 and WO 00/47708, for example amido propyldimethyl
amine (APA).
[0164] Other suitable cationic surfactants include salts of
primary, secondary, and tertiary fatty amines. In one embodiment,
the alkyl groups of such amines have from about 12 to about 22
carbon atoms, and can be substituted or unsubstituted. These amines
are typically used in combination with an acid to provide the
cationic species.
[0165] The cationic surfactant may include cationic ester
surfactants having the formula:
##STR00003##
wherein R.sub.1 is a C.sub.5-C.sub.31 linear or branched alkyl,
alkenyl or alkaryl chain or
M.sup.-.N.sup.+(R.sub.6R.sub.7R.sub.8)(CH.sub.2).sub.s; X and Y,
independently, are selected from the group consisting of COO, OCO,
O, CO, OCOO, CONH, NHCO, OCONH and NHCOO wherein at least one of X
or Y is a COO, OCO, OCOO, OCONH or NHCOO group; R.sub.2, R.sub.3,
R.sub.4, R.sub.6, R.sub.7 and R.sub.8 are independently selected
from the group consisting of alkyl, alkenyl, hydroxyalkyl,
hydroxyalkenyl and alkaryl groups having from 1 to 4 carbon atoms;
and R.sub.5 is independently H or a C.sub.1-C.sub.3 alkyl group;
wherein the values of m, n, s and t independently lie in the range
of from 0 to 8, the value of b lies in the range from 0 to 20, and
the values of a, u and v independently are either 0 or 1 with the
proviso that at least one of u or v must be 1; and wherein M is a
counter anion. In one example, R.sub.2, R.sub.3 and R.sub.4 are
independently selected from CH.sub.3 and --CH.sub.2CH.sub.2OH. In
another example, M is selected from the group consisting of halide,
methyl sulfate, sulfate, nitrate, chloride, bromide, or iodide.
[0166] The cationic surfactants of the present invention may be
chosen for use in personal cleansing applications. In one example,
such cationic surfactants may be included in the filament and/or
fiber at a total level by weight of from about 0.1% to about 10%
and/or from about 0.5% to about 8% and/or from about 1% to about 5%
and/or from about 1.4% to about 4%, in view of balance among
ease-to-rinse feel, rheology and wet conditioning benefits. A
variety of cationic surfactants including mono- and di-alkyl chain
cationic surfactants can be used in the compositions of the present
invention. In one example, the cationic surfactants include
mono-alkyl chain cationic surfactants in view of providing desired
gel matrix and wet conditioning benefits. The mono-alkyl cationic
surfactants are those having one long alkyl chain which has from 12
to 22 carbon atoms and/or from 16 to 22 carbon atoms and/or from 18
to 22 carbon atoms in its alkyl group, in view of providing
balanced wet conditioning benefits. The remaining groups attached
to nitrogen are independently selected from an alkyl group of from
1 to about 4 carbon atoms or an alkoxy, polyoxyalkylene,
alkylamido, hydroxyalkyl, aryl or alkylaryl group having up to
about 4 carbon atoms. Such mono-alkyl cationic surfactants include,
for example, mono-alkyl quaternary ammonium salts and mono-alkyl
amines Mono-alkyl quaternary ammonium salts include, for example,
those having a non-functionalized long alkyl chain. Mono-alkyl
amines include, for example, mono-alkyl amidoamines and salts
thereof. Other cationic surfactants such as di-alkyl chain cationic
surfactants may also be used alone, or in combination with the
mono-alkyl chain cationic surfactants. Such di-alkyl chain cationic
surfactants include, for example, dialkyl (14-18) dimethyl ammonium
chloride, ditallow alkyl dimethyl ammonium chloride, dihydrogenated
tallow alkyl dimethyl ammonium chloride, distearyl dimethyl
ammonium chloride, and dicetyl dimethyl ammonium chloride.
[0167] In one example the cationic ester surfactants are
hydrolyzable under the conditions of a laundry wash.
[0168] c. Nonionic Surfactants
[0169] Non-limiting examples of suitable nonionic surfactants
include alkoxylated alcohols (AE's) and alkyl phenols, polyhydroxy
fatty acid amides (PFAA's), alkyl polyglycosides (APG's),
C.sub.10-C.sub.18 glycerol ethers, and the like.
[0170] In one example, non-limiting examples of nonionic
surfactants useful in the present invention include:
C.sub.12-C.sub.18 alkyl ethoxylates, such as, NEODOL.RTM. nonionic
surfactants from Shell; C.sub.6-C.sub.12 alkyl phenol alkoxylates
wherein the alkoxylate units are a mixture of ethyleneoxy and
propyleneoxy units; C.sub.12-Cis alcohol and C.sub.6-C.sub.12 alkyl
phenol condensates with ethylene oxide/propylene oxide block alkyl
polyamine ethoxylates such as PLURONIC.RTM. from BASF;
C.sub.14-C.sub.22 mid-chain branched alcohols, BA, as discussed in
U.S. Pat. No. 6,150,322; C.sub.14-C.sub.22 mid-chain branched alkyl
alkoxylates, BAE.sub.x, wherein x is from 1-30, as discussed in
U.S. Pat. Nos. 6,153,577, 6,020,303 and 6,093,856;
alkylpolysaccharides as discussed in U.S. Pat. No. 4,565,647
Llenado, issued Jan. 26, 1986; specifically alkylpolyglycosides as
discussed in U.S. Pat. Nos. 4,483,780 and 4,483,779; polyhydroxy
detergent acid amides as discussed in U.S. Pat. No. 5,332,528; and
ether capped poly(oxyalkylated) alcohol surfactants as discussed in
U.S. Pat. No. 6,482,994 and WO 01/42408.
[0171] Examples of commercially available nonionic surfactants
suitable for the present invention include: Tergitol.RTM. 15-S-9
(the condensation product of C.sub.11-C.sub.15 linear alcohol with
9 moles ethylene oxide) and Tergitol.RTM. 24-L-6 NMW (the
condensation product of C.sub.12-C.sub.14 primary alcohol with 6
moles ethylene oxide with a narrow molecular weight distribution),
both marketed by Dow Chemical Company; Neodol.RTM. 45-9 (the
condensation product of C.sub.14-C.sub.15 linear alcohol with 9
moles of ethylene oxide), Neodol.RTM. 23-3 (the condensation
product of C.sub.12-C.sub.13 linear alcohol with 3 moles of
ethylene oxide), Neodol.RTM. 45-7 (the condensation product of
C.sub.14-C.sub.15 linear alcohol with 7 moles of ethylene oxide)
and Neodol.RTM. 45-5 (the condensation product of C.sub.14-C.sub.15
linear alcohol with 5 moles of ethylene oxide) marketed by Shell
Chemical Company; Kyro.RTM. EOB (the condensation product of
C.sub.13-C.sub.15 alcohol with 9 moles ethylene oxide), marketed by
The Procter & Gamble Company; and Genapol LA 030 or 050 (the
condensation product of C.sub.12-C.sub.14 alcohol with 3 or 5 moles
of ethylene oxide) marketed by Hoechst. The nonionic surfactants
may exhibit an HLB range of from about 8 to about 17 and/or from
about 8 to about 14. Condensates with propylene oxide and/or
butylene oxides may also be used.
[0172] Non-limiting examples of semi-polar nonionic surfactants
useful in the present invention include: water-soluble amine oxides
containing one alkyl moiety of from about 10 to about 18 carbon
atoms and 2 moieties selected from the group consisting of alkyl
moieties and hydroxyalkyl moieties containing from about 1 to about
3 carbon atoms; water-soluble phosphine oxides containing one alkyl
moiety of from about 10 to about 18 carbon atoms and 2 moieties
selected from the group consisting of alkyl moieties and
hydroxyalkyl moieties containing from about 1 to about 3 carbon
atoms; and water-soluble sulfoxides containing one alkyl moiety of
from about 10 to about 18 carbon atoms and a moiety selected from
the group consisting of alkyl moieties and hydroxyalkyl moieties of
from about 1 to about 3 carbon atoms. See WO 01/32816, U.S. Pat.
Nos. 4,681,704, and 4,133,779.
[0173] Another class of nonionic surfactants that may be used in
the present invention includes polyhydroxy fatty acid amide
surfactants of the following formula:
##STR00004##
wherein R.sup.1 is H, or C.sub.1-4 hydrocarbyl, 2-hydroxy ethyl,
2-hydroxy propyl or a mixture thereof, R.sub.2 is C.sub.5-31
hydrocarbyl, and Z is a polyhydroxyhydrocarbyl having a linear
hydrocarbyl chain with at least 3 hydroxyls directly connected to
the chain, or an alkoxylated derivative thereof. In one example,
R.sup.1 is methyl, R.sub.2 is a straight C.sub.11-15 alkyl or
C.sub.15-17 alkyl or alkenyl chain such as coconut alkyl or
mixtures thereof, and Z is derived from a reducing sugar such as
glucose, fructose, maltose, lactose, in a reductive amination
reaction. Typical examples include the C.sub.12-C.sub.18 and
C.sub.12-C.sub.14 N-methylglucamides.
[0174] Alkylpolyaccharide surfactants may also be used as a
nonionic surfactant in the present invention.
[0175] Polyethylene, polypropylene, and polybutylene oxide
condensates of alkyl phenols are also suitable for use as a
nonionic surfactant in the present invention. These compounds
include the condensation products of alkyl phenols having an alkyl
group containing from about 6 to about 14 carbon atoms, in either a
straight-chain or branched-chain configuration with the alkylene
oxide. Commercially available nonionic surfactants of this type
include Igepal.RTM. CO-630, marketed by the GAF Corporation; and
Triton.RTM. X-45, X-114, X-100 and X-102, all marketed by the Dow
Chemical Company.
[0176] For automatic dishwashing applications, low foaming nonionic
surfactants may be used. Suitable low foaming nonionic surfactants
are disclosed in U.S. Pat. No. 7,271,138 col. 7, line 10 to col. 7,
line 60.
[0177] Examples of other suitable nonionic surfactants are the
commercially-available Pluronic.RTM. surfactants, marketed by BASF,
the commercially available Tetronic.RTM. compounds, marketed by
BASF, and the commercially available Plurafac.RTM. surfactants,
marketed by BASF.
[0178] d. Zwitterionic Surfactants
[0179] Non-limiting examples of zwitterionic or ampholytic
surfactants include: derivatives of secondary and tertiary amines,
derivatives of heterocyclic secondary and tertiary amines, or
derivatives of quaternary ammonium, quaternary phosphonium or
tertiary sulfonium compounds. See U.S. Pat. No. 3,929,678 at column
19, line 38 through column 22, line 48, for examples of
zwitterionic surfactants; betaines, including alkyl dimethyl
betaine and cocodimethyl amidopropyl betaine, C.sub.8 to C.sub.18
(for example from C.sub.12 to C.sub.18) amine oxides and sulfo and
hydroxy betaines, such as N-alkyl-N,N-dimethylammino-1-propane
sulfonate where the alkyl group can be C.sub.8 to C.sub.18 and in
certain embodiments from C.sub.10 to C.sub.14.
[0180] e. Amphoteric Surfactants
[0181] Non-limiting examples of amphoteric surfactants include:
aliphatic derivatives of secondary or tertiary amines, or aliphatic
derivatives of heterocyclic secondary and tertiary amines in which
the aliphatic radical can be straight- or branched-chain and
mixtures thereof. One of the aliphatic substituents may contain at
least about 8 carbon atoms, for example from about 8 to about 18
carbon atoms, and at least one contains an anionic
water-solubilizing group, e.g. carboxy, sulfonate, sulfate. See
U.S. Pat. No. 3,929,678 at column 19, lines 18-35, for suitable
examples of amphoteric surfactants.
[0182] f. Co-Surfactants
[0183] In addition to the surfactants described above, the
filaments may also contain co-surfactants. In the case of laundry
detergents and/or dishwashing detergents, they typically contain a
mixture of surfactant types in order to obtain broad-scale cleaning
performance over a variety of soils and stains and under a variety
of usage conditions. A wide range of these co-surfactants can be
used in the filaments of the present invention. A typical listing
of anionic, nonionic, ampholytic and zwitterionic classes, and
species of these co-surfactants, is given herein above, and may
also be found in U.S. Pat. No. 3,664,961. In other words, the
surfactant systems herein may also include one or more
co-surfactants selected from nonionic, cationic, anionic,
zwitterionic or mixtures thereof. The selection of co-surfactant
may be dependent upon the desired benefit. The surfactant system
may comprise from 0% to about 10%, or from about 0.1% to about 5%,
or from about 1% to about 4% by weight of the composition of other
co-surfactant(s).
[0184] g. Amine-Neutralized Anionic Surfactants
[0185] The anionic surfactants and/or anionic co-surfactants of the
present invention may exist in an acid form, which may be
neutralized to form a surfactant salt. In one example, the
filaments may comprise a surfactant salt form. Typical agents for
neutralization include a metal counterion base such as hydroxides,
eg, NaOH or KOH. Other agents for neutralizing the anionic
surfactants and anionic co-surfactants in their acid forms include
ammonia, amines, or alkanolamines. In one example, the neutralizing
agent comprises an alkanolamine, for example an alkanolamine
selected from the group consisting of: monoethanolamine,
diethanolamine, triethanolamine, and other linear or branched
alkanolamines known in the art; for example, 2-amino-1-propanol,
1-aminopropanol, monoisopropanolamine, or 1-amino-3-propanol. Amine
neutralization may be done to a full or partial extent, e.g. part
of the anionic surfactant mix may be neutralized with sodium or
potassium and part of the anionic surfactant mix may be neutralized
with amines or alkanolamines
Perfumes
[0186] One or more perfume and/or perfume raw materials such as
accords and/or notes may be incorporated into one or more of the
filaments of the present invention. The perfume may comprise a
perfume ingredient selected from the group consisting of: aldehyde
perfume ingredients, ketone perfume ingredients, and mixtures
thereof.
[0187] One or more perfumes and/or perfumery ingredients may be
included in the filaments of the present invention. A wide variety
of natural and synthetic chemical ingredients useful as perfumes
and/or perfumery ingredients include but not limited to aldehydes,
ketones, esters, and mixtures thereof. Also included are various
natural extracts and essences which can comprise complex mixtures
of ingredients, such as orange oil, lemon oil, rose extract,
lavender, musk, patchouli, balsamic essence, sandalwood oil, pine
oil, cedar, and the like. Finished perfumes can comprise extremely
complex mixtures of such ingredients. In one example, a finished
perfume typically comprises from about 0.01% to about 2%, by weight
on a dry filament basis and/or dry web material basis.
Perfume Delivery Systems
[0188] Certain perfume delivery systems, methods of making certain
perfume delivery systems and the uses of such perfume delivery
systems are disclosed in USPA 2007/0275866 A1. Non-limiting
examples of perfume delivery systems include the following:
[0189] I. Polymer Assisted Delivery (PAD):
[0190] This perfume delivery technology uses polymeric materials to
deliver perfume materials. Classical coacervation, water soluble or
partly soluble to insoluble charged or neutral polymers, liquid
crystals, hot melts, hydrogels, perfumed plastics, microcapsules,
nano- and micro-latexes, polymeric film formers, and polymeric
absorbents, polymeric adsorbents, etc. are some examples. PAD
includes but is not limited to:
[0191] a.) Matrix Systems:
[0192] The fragrance is dissolved or dispersed in a polymer matrix
or particle. Perfumes, for example, may be 1) dispersed into the
polymer prior to formulating into the product or 2) added
separately from the polymer during or after formulation of the
product. Diffusion of perfume from the polymer is a common trigger
that allows or increases the rate of perfume release from a
polymeric matrix system that is deposited or applied to the desired
surface (situs), although many other triggers are know that may
control perfume release. Absorption and/or adsorption into or onto
polymeric particles, films, solutions, and the like are aspects of
this technology. Nano- or micro-particles composed of organic
materials (e.g., latexes) are examples. Suitable particles include
a wide range of materials including, but not limited to polyacetal,
polyacrylate, polyacrylic, polyacrylonitrile, polyamide,
polyaryletherketone, polybutadiene, polybutylene, polybutylene
terephthalate, polychloroprene, poly ethylene, polyethylene
terephthalate, polycyclohexylene dimethylene terephthalate,
polycarbonate, polychloroprene, polyhydroxyalkanoate, polyketone,
polyester, polyethylene, polyetherimide, polyethersulfone,
polyethylenechlorinates, polyimide, polyisoprene, polylactic acid,
polymethylpentene, polyphenylene oxide, polyphenylene sulfide,
polyphthalamide, polypropylene, polystyrene, polysulfone, polyvinyl
acetate, polyvinyl chloride, as well as polymers or copolymers
based on acrylonitrile-butadiene, cellulose acetate, ethylene-vinyl
acetate, ethylene vinyl alcohol, styrene-butadiene, vinyl
acetate-ethylene, and mixtures thereof.
[0193] "Standard" systems refer to those that are "pre-loaded" with
the intent of keeping the pre-loaded perfume associated with the
polymer until the moment or moments of perfume release. Such
polymers may also suppress the neat product odor and provide a
bloom and/or longevity benefit depending on the rate of perfume
release. One challenge with such systems is to achieve the ideal
balance between 1) in-product stability (keeping perfume inside
carrier until you need it) and 2) timely release (during use or
from dry situs). Achieving such stability is particularly important
during in-product storage and product aging. This challenge is
particularly apparent for aqueous-based, surfactant-containing
products, such as heavy duty liquid laundry detergents. Many
"Standard" matrix systems available effectively become
"Equilibrium" systems when formulated into aqueous-based products.
One may select an "Equilibrium" system or a Reservoir system, which
has acceptable in-product diffusion stability and available
triggers for release (e.g., friction). "Equilibrium" systems are
those in which the perfume and polymer may be added separately to
the product, and the equilibrium interaction between perfume and
polymer leads to a benefit at one or more consumer touch points
(versus a free perfume control that has no polymer-assisted
delivery technology). The polymer may also be pre-loaded with
perfume; however, part or all of the perfume may diffuse during
in-product storage reaching an equilibrium that includes having
desired perfume raw materials (PRMs) associated with the polymer.
The polymer then carries the perfume to the surface, and release is
typically via perfume diffusion. The use of such equilibrium system
polymers has the potential to decrease the neat product odor
intensity of the neat product (usually more so in the case of
pre-loaded standard system). Deposition of such polymers may serve
to "flatten" the release profile and provide increased longevity.
As indicated above, such longevity would be achieved by suppressing
the initial intensity and may enable the formulator to use more
high impact or low odor detection threshold (ODT) or low Kovats
Index (KI) PRMs to achieve FMOT benefits without initial intensity
that is too strong or distorted. It is important that perfume
release occurs within the time frame of the application to impact
the desired consumer touch point or touch points. Suitable
micro-particles and micro-latexes as well as methods of making same
may be found in USPA 2005/0003980 A1. Matrix systems also include
hot melt adhesives and perfume plastics. In addition,
hydrophobically modified polysaccharides may be formulated into the
perfumed product to increase perfume deposition and/or modify
perfume release. All such matrix systems, including for example
polysaccarides and nanolatexes may be combined with other PDTs,
including other PAD systems such as PAD reservoir systems in the
form of a perfume microcapsule (PMC). Polymer Assisted Delivery
(PAD) matrix systems may include those described in the following
references: US Patent Applications 2004/0110648 A1; 2004/0092414
A1; 2004/0091445 A1 and 2004/0087476 A1; and U.S. Pat. Nos.
6,531,444; 6,024,943; 6,042,792; 6,051,540; 4,540,721 and
4,973,422.
[0194] Silicones are also examples of polymers that may be used as
PDT, and can provide perfume benefits in a manner similar to the
polymer-assisted delivery "matrix system". Such a PDT is referred
to as silicone-assisted delivery (SAD). One may pre-load silicones
with perfume, or use them as an equilibrium system as described for
PAD. Suitable silicones as well as making same may be found in WO
2005/102261; USPA 20050124530A1; USPA 20050143282A1; and WO
2003/015736. Functionalized silicones may also be used as described
in USPA 2006/003913 A1. Examples of silicones include
polydimethylsiloxane and polyalkyldimethylsiloxanes. Other examples
include those with amine functionality, which may be used to
provide benefits associated with amine-assisted delivery (AAD)
and/or polymer-assisted delivery (PAD) and/or amine-reaction
products (ARP). Other such examples may be found in U.S. Pat. No.
4,911,852; USPA 2004/0058845 A1; USPA 2004/0092425 A1 and USPA
2005/0003980 A1.
[0195] b.) Reservoir Systems:
[0196] Reservoir systems are also known as a core-shell type
technology, or one in which the fragrance is surrounded by a
perfume release controlling membrane, which may serve as a
protective shell. The material inside the microcapsule is referred
to as the core, internal phase, or fill, whereas the wall is
sometimes called a shell, coating, or membrane. Microparticles or
pressure sensitive capsules or microcapsules are examples of this
technology. Microcapsules of the current invention are formed by a
variety of procedures that include, but are not limited to,
coating, extrusion, spray-drying, interfacial, in-situ and matrix
polymerization. The possible shell materials vary widely in their
stability toward water. Among the most stable are
polyoxymethyleneurea (PMU)-based materials, which may hold certain
PRMs for even long periods of time in aqueous solution (or
product). Such systems include but are not limited to
urea-formaldehyde and/or melamine-formaldehyde. Stable shell
materials include polyacrylate-based materials obtained as reaction
product of an oil soluble or dispersible amine with a
multifunctional acrylate or methacrylate monomer or oligomer, an
oil soluble acid and an initiator, in presence of an anionic
emulsifier comprising a water soluble or water dispersible acrylic
acid alkyl acid copolymer, an alkali or alkali salt. Gelatin-based
microcapsules may be prepared so that they dissolve quickly or
slowly in water, depending for example on the degree of
cross-linking. Many other capsule wall materials are available and
vary in the degree of perfume diffusion stability observed. Without
wishing to be bound by theory, the rate of release of perfume from
a capsule, for example, once deposited on a surface is typically in
reverse order of in-product perfume diffusion stability. As such,
urea-formaldehyde and melamine-formaldehyde microcapsules for
example, typically require a release mechanism other than, or in
addition to, diffusion for release, such as mechanical force (e.g.,
friction, pressure, shear stress) that serves to break the capsule
and increase the rate of perfume (fragrance) release. Other
triggers include melting, dissolution, hydrolysis or other chemical
reaction, electromagnetic radiation, and the like. The use of
pre-loaded microcapsules requires the proper ratio of in-product
stability and in-use and/or on-surface (on-situs) release, as well
as proper selection of PRMs. Microcapsules that are based on
urea-formaldehyde and/or melamine-formaldehyde are relatively
stable, especially in near neutral aqueous-based solutions. These
materials may require a friction trigger which may not be
applicable to all product applications. Other microcapsule
materials (e.g., gelatin) may be unstable in aqueous-based products
and may even provide reduced benefit (versus free perfume control)
when in-product aged. Scratch and sniff technologies are yet
another example of PAD. Perfume microcapsules (PMC) may include
those described in the following references: US Patent
Applications: 2003/0125222 A1; 2003/215417 A1; 2003/216488 A1;
2003/158344 A1; 2003/165692 A1; 2004/071742 A1; 2004/071746 A1;
2004/072719 A1; 2004/072720 A1; 2006/0039934 A1; 2003/203829 A1;
2003/195133 A1; 2004/087477 A1; 2004/0106536 A1; and U.S. Pat. Nos.
6,645,479 B1; 6,200,949 B1; 4,882,220; 4,917,920; 4,514,461;
6,106,875 and U.S. Pat. No. 4,234,627, 3,594,328 and US RE 32713,
PCT Patent Application: WO 2009/134234 A1, WO 2006/127454 A2, WO
2010/079466 A2, WO 2010/079467 A2, WO 2010/079468 A2, WO
2010/084480 A2.
[0197] II. Molecule-Assisted Delivery (MAD):
[0198] Non-polymer materials or molecules may also serve to improve
the delivery of perfume. Without wishing to be bound by theory,
perfume may non-covalently interact with organic materials,
resulting in altered deposition and/or release. Non-limiting
examples of such organic materials include but are not limited to
hydrophobic materials such as organic oils, waxes, mineral oils,
petrolatum, fatty acids or esters, sugars, surfactants, liposomes
and even other perfume raw material (perfume oils), as well as
natural oils, including body and/or other soils. Perfume fixatives
are yet another example. In one aspect, non-polymeric materials or
molecules have a CLogP greater than about 2. Molecule-Assisted
Delivery (MAD) may also include those described in U.S. Pat. Nos.
7,119,060 and 5,506,201.
[0199] III. Fiber-Assisted Delivery (FAD):
[0200] The choice or use of a situs itself may serve to improve the
delivery of perfume. In fact, the situs itself may be a perfume
delivery technology. For example, different fabric types such as
cotton or polyester will have different properties with respect to
ability to attract and/or retain and/or release perfume. The amount
of perfume deposited on or in fibers may be altered by the choice
of fiber, and also by the history or treatment of the fiber, as
well as by any fiber coatings or treatments. Fibers may be woven
and non-woven as well as natural or synthetic. Natural fibers
include those produced by plants, animals, and geological
processes, and include but are not limited to cellulose materials
such as cotton, linen, hemp jute, flax, ramie, and sisal, and
fibers used to manufacture paper and cloth. Fiber-Assisted Delivery
may consist of the use of wood fiber, such as thermomechanical pulp
and bleached or unbleached kraft or sulfite pulps. Animal fibers
consist largely of particular proteins, such as silk, sinew, catgut
and hair (including wool). Polymer fibers based on synthetic
chemicals include but are not limited to polyamide nylon, PET or
PBT polyester, phenol-formaldehyde (PF), polyvinyl alcohol fiber
(PVOH), polyvinyl chloride fiber (PVC), polyolefins (PP and PE),
and acrylic polymers. All such fibers may be pre-loaded with a
perfume, and then added to a product that may or may not contain
free perfume and/or one or more perfume delivery technologies. In
one aspect, the fibers may be added to a product prior to being
loaded with a perfume, and then loaded with a perfume by adding a
perfume that may diffuse into the fiber, to the product. Without
wishing to be bound by theory, the perfume may absorb onto or be
adsorbed into the fiber, for example, during product storage, and
then be released at one or more moments of truth or consumer touch
points.
[0201] IV. Amine Assisted Delivery (AAD):
[0202] The amine-assisted delivery technology approach utilizes
materials that contain an amine group to increase perfume
deposition or modify perfume release during product use. There is
no requirement in this approach to pre-complex or pre-react the
perfume raw material(s) and amine prior to addition to the product.
In one aspect, amine-containing AAD materials suitable for use
herein may be non-aromatic; for example, polyalkylimine, such as
polyethyleneimine (PEI), or polyvinylamine (PVAm), or aromatic, for
example, anthranilates. Such materials may also be polymeric or
non-polymeric. In one aspect, such materials contain at least one
primary amine. This technology will allow increased longevity and
controlled release also of low ODT perfume notes (e.g., aldehydes,
ketones, enones) via amine functionality, and delivery of other
PRMs, without being bound by theory, via polymer-assisted delivery
for polymeric amines Without technology, volatile top notes can be
lost too quickly, leaving a higher ratio of middle and base notes
to top notes. The use of a polymeric amine allows higher levels of
top notes and other PRMS to be used to obtain freshness longevity
without causing neat product odor to be more intense than desired,
or allows top notes and other PRMs to be used more efficiently. In
one aspect, AAD systems are effective at delivering PRMs at pH
greater than about neutral. Without wishing to be bound by theory,
conditions in which more of the amines of the AAD system are
deprotonated may result in an increased affinity of the
deprotonated amines for PRMs such as aldehydes and ketones,
including unsaturated ketones and enones such as damascone. In
another aspect, polymeric amines are effective at delivering PRMs
at pH less than about neutral. Without wishing to be bound by
theory, conditions in which more of the amines of the AAD system
are protonated may result in a decreased affinity of the protonated
amines for PRMs such as aldehydes and ketones, and a strong
affinity of the polymer framework for a broad range of PRMs. In
such an aspect, polymer-assisted delivery may be delivering more of
the perfume benefit; such systems are a subspecies of AAD and may
be referred to as Amine-Polymer-Assisted Delivery or APAD. In some
cases when the APAD is employed in a composition that has a pH of
less than seven, such APAD systems may also be considered
Polymer-Assisted Delivery (PAD). In yet another aspect, AAD and PAD
systems may interact with other materials, such as anionic
surfactants or polymers to form coacervate and/or coacervates-like
systems. In another aspect, a material that contains a heteroatom
other than nitrogen, for example sulfur, phosphorus or selenium,
may be used as an alternative to amine compounds. In yet another
aspect, the aforementioned alternative compounds can be used in
combination with amine compounds. In yet another aspect, a single
molecule may comprise an amine moiety and one or more of the
alternative heteroatom moieties, for example, thiols, phosphines
and selenols. Suitable AAD systems as well as methods of making
same may be found in US Patent Applications 2005/0003980 A1;
2003/0199422 A1; 2003/0036489 A1; 2004/0220074 A1 and U.S. Pat. No.
6,103,678.
[0203] V. Cyclodextrin Delivery System (CD):
[0204] This technology approach uses a cyclic oligosaccharide or
cyclodextrin to improve the delivery of perfume. Typically a
perfume and cyclodextrin (CD) complex is formed. Such complexes may
be preformed, formed in-situ, or formed on or in the situs. Without
wishing to be bound by theory, loss of water may serve to shift the
equilibrium toward the CD-Perfume complex, especially if other
adjunct ingredients (e.g., surfactant) are not present at high
concentration to compete with the perfume for the cyclodextrin
cavity. A bloom benefit may be achieved if water exposure or an
increase in moisture content occurs at a later time point. In
addition, cyclodextrin allows the perfume formulator increased
flexibility in selection of PRMs. Cyclodextrin may be pre-loaded
with perfume or added separately from perfume to obtain the desired
perfume stability, deposition or release benefit. Suitable CDs as
well as methods of making same may be found in USPA 2005/0003980 A1
and 2006/0263313 A1 and U.S. Pat. Nos. 5,552,378; 3,812,011;
4,317,881; 4,418,144 and 4,378,923.
[0205] VI. Starch Encapsulated Accord (SEA):
[0206] The use of a starch encapsulated accord (SEA) technology
allows one to modify the properties of the perfume, for example, by
converting a liquid perfume into a solid by adding ingredients such
as starch. The benefit includes increased perfume retention during
product storage, especially under non-aqueous conditions. Upon
exposure to moisture, a perfume bloom may be triggered. Benefits at
other moments of truth may also be achieved because the starch
allows the product formulator to select PRMs or PRM concentrations
that normally cannot be used without the presence of SEA. Another
technology example includes the use of other organic and inorganic
materials, such as silica to convert perfume from liquid to solid.
Suitable SEAs as well as methods of making same may be found in
USPA 2005/0003980 A1 and U.S. Pat. No. 6,458,754 B1.
[0207] VII. Inorganic Carrier Delivery System (ZIC):
[0208] This technology relates to the use of porous zeolites or
other inorganic materials to deliver perfumes. Perfume-loaded
zeolite may be used with or without adjunct ingredients used for
example to coat the perfume-loaded zeolite (PLZ) to change its
perfume release properties during product storage or during use or
from the dry situs. Suitable zeolite and inorganic carriers as well
as methods of making same may be found in USPA 2005/0003980 A1 and
U.S. Pat. Nos. 5,858,959; 6,245,732 B1; 6,048,830 and 4,539,135.
Silica is another form of ZIC. Another example of a suitable
inorganic carrier includes inorganic tubules, where the perfume or
other active material is contained within the lumen of the nano- or
micro-tubules. In one aspect, the perfume-loaded inorganic tubule
(or Perfume-Loaded Tubule or PLT) is a mineral nano- or
micro-tubule, such as halloysite or mixtures of halloysite with
other inorganic materials, including other clays. The PLT
technology may also comprise additional ingredients on the inside
and/or outside of the tubule for the purpose of improving
in-product diffusion stability, deposition on the desired situs or
for controlling the release rate of the loaded perfume. Monomeric
and/or polymeric materials, including starch encapsulation, may be
used to coat, plug, cap, or otherwise encapsulate the PLT. Suitable
PLT systems as well as methods of making same may be found in U.S.
Pat. No. 5,651,976.
[0209] VIII. Pro-Perfume (PP):
[0210] This technology refers to perfume technologies that result
from the reaction of perfume materials with other substrates or
chemicals to form materials that have a covalent bond between one
or more PRMs and one or more carriers. The PRM is converted into a
new material called a pro-PRM (i.e., pro-perfume), which then may
release the original PRM upon exposure to a trigger such as water
or light. Pro-perfumes may provide enhanced perfume delivery
properties such as increased perfume deposition, longevity,
stability, retention, and the like. Pro-perfumes include those that
are monomeric (non-polymeric) or polymeric, and may be pre-formed
or may be formed in-situ under equilibrium conditions, such as
those that may be present during in-product storage or on the wet
or dry situs. Nonlimiting examples of pro-perfumes include Michael
adducts (e.g., beta-amino ketones), aromatic or non-aromatic imines
(Schiff bases), oxazolidines, beta-keto esters, and orthoesters.
Another aspect includes compounds comprising one or more beta-oxy
or beta-thio carbonyl moieties capable of releasing a PRM, for
example, an alpha, beta-unsaturated ketone, aldehyde or carboxylic
ester. The typical trigger for perfume release is exposure to
water; although other triggers may include enzymes, heat, light, pH
change, autoxidation, a shift of equilibrium, change in
concentration or ionic strength and others. For aqueous-based
products, light-triggered pro-perfumes are particularly suited.
Such photo-pro-perfumes (PPPs) include but are not limited to those
that release coumarin derivatives and perfumes and/or pro-perfumes
upon being triggered. The released pro-perfume may release one or
more PRMs by means of any of the above mentioned triggers. In one
aspect, the photo-pro-perfume releases a nitrogen-based pro-perfume
when exposed to a light and/or moisture trigger. In another aspect,
the nitrogen-based pro-perfume, released from the
photo-pro-perfume, releases one or more PRMs selected, for example,
from aldehydes, ketones (including enones) and alcohols. In still
another aspect, the PPP releases a dihydroxy coumarin derivative.
The light-triggered pro-perfume may also be an ester that releases
a coumarin derivative and a perfume alcohol. In one aspect the
pro-perfume is a dimethoxybenzoin derivative as described in USPA
2006/0020459 A1. In another aspect the pro-perfume is a 3',
5'-dimethoxybenzoin (DMB) derivative that releases an alcohol upon
exposure to electromagnetic radiation. In yet another aspect, the
pro-perfume releases one or more low ODT PRMs, including tertiary
alcohols such as linalool, tetrahydrolinalool, or dihydromyrcenol.
Suitable pro-perfumes and methods of making same can be found in
U.S. Pat. Nos. 7,018,978 B2; 6,987,084 B2; 6,956,013 B2; 6,861,402
B1; 6,544,945 B1; U.S. Pat. Nos. 6,093,691; 6,277,796 B1;
6,165,953; 6,316,397 B1; 6,437,150 B1; 6,479,682 B1; U.S. Pat. Nos.
6,096,918; 6,218,355 B1; U.S. Pat. Nos. 6,133,228; 6,147,037;
7,109,153 B2; 7,071,151 B2; 6,987,084 B2; 6,610,646 B2 and
5,958,870, as well as can be found in USPA 2005/0003980 A1 and USPA
2006/0223726 A1.
[0211] a.) Amine Reaction Product (ARP): [0212] For purposes of the
present application, ARP is a subclass or species of PP. One may
also use "reactive" polymeric amines in which the amine
functionality is pre-reacted with one or more PRMs to form an amine
reaction product (ARP). Typically the reactive amines are primary
and/or secondary amines, and may be part of a polymer or a monomer
(non-polymer). Such ARPs may also be mixed with additional PRMs to
provide benefits of polymer-assisted delivery and/or amine-assisted
delivery. Nonlimiting examples of polymeric amines include polymers
based on polyalkylimines, such as polyethyleneimine (PEI), or
polyvinylamine (PVAm). Nonlimiting examples of monomeric
(non-polymeric) amines include hydroxyl amines, such as
2-aminoethanol and its alkyl substituted derivatives, and aromatic
amines such as anthranilates. The ARPs may be premixed with perfume
or added separately in leave-on or rinse-off applications. In
another aspect, a material that contains a heteroatom other than
nitrogen, for example oxygen, sulfur, phosphorus or selenium, may
be used as an alternative to amine compounds. In yet another
aspect, the aforementioned alternative compounds can be used in
combination with amine compounds. In yet another aspect, a single
molecule may comprise an amine moiety and one or more of the
alternative heteroatom moieties, for example, thiols, phosphines
and selenols. The benefit may include improved delivery of perfume
as well as controlled perfume release. Suitable ARPs as well as
methods of making same can be found in USPA 2005/0003980 A1 and
U.S. Pat. No. 6,413,920 B1.
Bleaching Agents
[0213] The filaments of the present invention may comprise one or
more bleaching agents. Non-limiting examples of suitable bleaching
agents include peroxyacids, perborate, percarbonate, chlorine
bleaches, oxygen bleaches, hypohalite bleaches, bleach precursors,
bleach activators, bleach catalysts, hydrogen peroxide, bleach
boosters, photobleaches, bleaching enzymes, free radical
initiators, peroxygen bleaches, and mixtures thereof.
[0214] One or more bleaching agents may be included in the
filaments of the present invention may be included at a level from
about 1% to about 30% and/or from about 5% to about 20% by weight
on a dry filament basis and/or dry web material basis. If present,
bleach activators may be present in the filaments of the present
invention at a level from about 0.1% to about 60% and/or from about
0.5% to about 40% by weight on a dry filament basis and/or dry web
material basis.
[0215] Non-limiting examples of bleaching agents include oxygen
bleach, perborate bleach, percarboxylic acid bleach and salts
thereof, peroxygen bleach, persulfate bleach, percarbonate bleach,
and mixtures thereof. Further, non-limiting examples of bleaching
agents are disclosed in U.S. Pat. No. 4,483,781, U.S. patent
application Ser. No. 740,446, European Patent Application 0 133
354, U.S. Pat. Nos. 4,412,934, and 4,634,551.
[0216] Non-limiting examples of bleach activators (e.g., acyl
lactam activators) are disclosed in U.S. Pat. Nos. 4,915,854;
4,412,934; 4,634,551; and 4,966,723.
[0217] In one example, the bleaching agent comprises a transition
metal bleach catalyst, which may be encapsulated. The transition
metal bleach catalyst typically comprises a transition metal ion,
for example a transition metal ion from a transition metal selected
from the group consisting of: Mn(II), Mn(III), Mn(IV), Mn(V),
Fe(II), Fe(III), Fe(IV), Co(I), Co(II), Co(III), Ni(I), Ni(II),
Ni(III), Cu(I), Cu(II), Cu(III), Cr(II), Cr(III), Cr(IV), Cr(V),
Cr(VI), V(III), V(IV), V(V), Mo(IV), Mo(V), Mo(VI), W(IV), W(V),
W(VI), Pd(II), Ru(II), Ru(III), and Ru(IV). In one example, the
transition metal is selected from the group consisting of: Mn(II),
Mn(III), Mn(IV), Fe(II), Fe(III), Cr(II), Cr(III), Cr(IV), Cr(V),
and Cr(VI). The transition metal bleach catalyst typically
comprises a ligand, for example a macropolycyclic ligand, such as a
cross-bridged macropolycyclic ligand. The transition metal ion may
be coordinated with the ligand. Further, the ligand may comprise at
least four donor atoms, at least two of which are bridgehead donor
atoms. Non-limiting examples of suitable transition metal bleach
catalysts are described in U.S. Pat. Nos. 5,580,485, 4,430,243;
4,728,455; 5,246,621; 5,244,594; 5,284,944; 5,194,416; 5,246,612;
5,256,779; 5,280,117; 5,274,147; 5,153,161; 5,227,084; 5,114,606;
5,114,611, EP 549,271 A1; EP 544,490 A1; EP 549,272 A1; and EP
544,440 A2. In one example, a suitable transition metal bleach
catalyst comprises a manganese-based catalyst, for example
disclosed in U.S. Pat. No. 5,576,282. In another example, suitable
cobalt bleach catalysts are described, in U.S. Pat. Nos. 5,597,936
and 5,595,967. Such cobalt catalysts are readily prepared by known
procedures, such as taught for example in U.S. Pat. Nos. 5,597,936,
and 5,595,967. In yet another, suitable transition metal bleach
catalysts comprise a transition metal complex of ligand such as
bispidones described in WO 05/042532 A1.
[0218] Bleaching agents other than oxygen bleaching agents are also
known in the art and can be utilized herein (e.g., photoactivated
bleaching agents such as the sulfonated zinc and/or aluminum
phthalocyanines (U.S. Pat. No. 4,033,718, incorporated herein by
reference)), and/or pre-formed organic peracids, such as
peroxycarboxylic acid or salt thereof, and/or peroxysulphonic acids
or salts thereof. In one example, a suitable organic peracid
comprises phthaloylimidoperoxycaproic acid or salt thereof. When
present, the photoactivated bleaching agents, such as sulfonated
zinc phthalocyanine, may be present in the filaments of the present
invention at a level from about 0.025% to about 1.25% by weight on
a dry filament basis and/or dry web material basis.
Brighteners
[0219] Any optical brighteners or other brightening or whitening
agents known in the art may be incorporated in the filaments of the
present invention at levels from about 0.01% to about 1.2% by
weight on a dry filament basis and/or dry web material basis.
Commercial optical brighteners which may be useful in the present
invention can be classified into subgroups, which include, but are
not necessarily limited to, derivatives of stilbene, pyrazoline,
coumarin, carboxylic acid, methinecyanines,
dibenzothiophene-5,5-dioxide, azoles, 5- and 6-membered-ring
heterocycles, and other miscellaneous agents. Examples of such
brighteners are disclosed in "The Production and Application of
Fluorescent Brightening Agents", M. Zahradnik, Published by John
Wiley & Sons, New York (1982). Specific nonlimiting examples of
optical brighteners which are useful in the present compositions
are those identified in U.S. Pat. Nos. 4,790,856 and 3,646,015.
Fabric Hueing Agents
[0220] The filaments of the present invention my include fabric
hueing agents. Non-limiting examples of suitable fabric hueing
agents include small molecule dyes and polymeric dyes. Suitable
small molecule dyes include small molecule dyes selected from the
group consisting of dyes falling into the Colour Index (C.I.)
classifications of Direct Blue, Direct Red, Direct Violet, Acid
Blue, Acid Red, Acid Violet, Basic Blue, Basic Violet and Basic
Red, or mixtures thereof. In another example, suitable polymeric
dyes include polymeric dyes selected from the group consisting of
fabric-substantive colorants sold under the name of Liquitint.RTM.
(Milliken, Spartanburg, S.C., USA), dye-polymer conjugates formed
from at least one reactive dye and a polymer selected from the
group consisting of polymers comprising a moiety selected from the
group consisting of a hydroxyl moiety, a primary amine moiety, a
secondary amine moiety, a thiol moiety and mixtures thereof. In
still another aspect, suitable polymeric dyes include polymeric
dyes selected from the group consisting of Liquitint.RTM.
(Milliken, Spartanburg, S.C., USA) Violet CT, carboxymethyl
cellulose (CMC) conjugated with a reactive blue, reactive violet or
reactive red dye such as CMC conjugated with C.I. Reactive Blue 19,
sold by Megazyme, Wicklow, Ireland under the product name
AZO-CM-CELLULOSE, product code S-ACMC, alkoxylated
triphenyl-methane polymeric colourants, alkoxylated thiophene
polymeric colourants, and mixtures thereof.
[0221] Non-limiting examples of useful hueing dyes include those
found in U.S. Pat. Nos. 7,205,269; 7,208,459; and 7,674,757 B2. For
example, fabric hueing dyes may be selected from the group
consisting of: triarylmethane blue and violet basic dyes, methine
blue and violet basic dyes, anthraquinone blue and violet basic
dyes, azo dyes basic blue 16, basic blue 65, basic blue 66 basic
blue 67, basic blue 71, basic blue 159, basic violet 19, basic
violet 35, basic violet 38, basic violet 48, oxazine dyes, basic
blue 3, basic blue 75, basic blue 95, basic blue 122, basic blue
124, basic blue 141, Nile blue A and xanthene dye basic violet 10,
an alkoxylated triphenylmethane polymeric colorant; an alkoxylated
thiopene polymeric colorant; thiazolium dye; and mixtures
thereof.
[0222] In one example, a fabric hueing dye includes the whitening
agents found in WO 08/87497 A1. These whitening agents may be
characterized by the following structure (I):
##STR00005##
wherein R.sub.1 and R.sub.2 can independently be selected from:
[0223] a) [(CH.sub.2CR''HO).sub.x(CH.sub.2CR''HO).sub.yH] [0224]
wherein R' is selected from the group consisting of H, CH.sub.3,
CH.sub.2O(CH.sub.2CH.sub.2O).sub.zH, and mixtures thereof; wherein
R'' is selected from the group consisting of H,
CH.sub.2O(CH.sub.2CH.sub.2O).sub.zH, and mixtures thereof; wherein
x+y.ltoreq.5; wherein y.gtoreq.1; and wherein z=0 to 5; [0225] b)
R.sub.1=alkyl, aryl or aryl alkyl and
R.sub.2=[(CH.sub.2CR'HO).sub.x(CH.sub.2CR''HO).sub.yH] [0226]
wherein R' is selected from the group consisting of H, CH.sub.3,
CH.sub.2O(CH.sub.2CH.sub.2O).sub.zH, and mixtures thereof; wherein
R'' is selected from the group consisting of H,
CH.sub.2O(CH.sub.2CH.sub.2O).sub.zH, and mixtures thereof; wherein
x+y.ltoreq.10; wherein y.gtoreq.1; and wherein z=0 to 5; [0227] c)
R.sub.1=[CH.sub.2CH.sub.2(OR.sub.3)CH.sub.2OR.sub.4] and
R.sub.2=[CH.sub.2CH.sub.2(O R.sub.3)CH.sub.2O R.sub.4] [0228]
wherein R.sub.3 is selected from the group consisting of H,
(CH.sub.2CH.sub.2O).sub.zH, and mixtures thereof; and wherein z=0
to 10; [0229] wherein R.sub.4 is selected from the group consisting
of (C.sub.1-C.sub.16)alkyl, aryl groups, and mixtures thereof; and
[0230] d) wherein R1 and R2 can independently be selected from the
amino addition product of styrene oxide, glycidyl methyl ether,
isobutyl glycidyl ether, isopropylglycidyl ether, t-butyl glycidyl
ether, 2-ethylhexylgycidyl ether, and glycidylhexadecyl ether,
followed by the addition of from 1 to 10 alkylene oxide units.
[0231] In another example, a suitable whitening agent may be
characterized by the following structure (II):
##STR00006##
wherein R' is selected from the group consisting of H, CH.sub.3,
CH.sub.2O(CH.sub.2CH.sub.2O).sub.zH, and mixtures thereof; wherein
R'' is selected from the group consisting of H,
CH.sub.2O(CH.sub.2CH.sub.2O).sub.zH, and mixtures thereof; wherein
x+y.ltoreq.5; wherein y.gtoreq.1; and wherein z=0 to 5.
[0232] In yet another example, a suitable whitening agent may be
characterized by the following structure (III):
##STR00007## [0233] This whitening agent is commonly referred to as
"Violet DD". Violet DD is typically a mixture having a total of 5
EO groups. This structure is arrived by the following selection in
Structure I of the following pendant groups shown in Table I below
in "part a" above:
TABLE-US-00001 [0233] TABLE I R1 R2 . R' R'' X y R' R'' x y a H H 3
1 H H 0 1 b H H 2 1 H H 1 1 c = b H H 1 1 H H 2 1 d = a H H 0 1 H H
3 1
[0234] Further whitening agents of use include those described in
US2008/34511 A1 (Unilever). In one example, the whitening agent
comprises "Violet 13".
Dye Transfer Inhibiting Agents
[0235] The filaments of the present invention may include one or
more dye transfer inhibiting agents that inhibit transfer of dyes
from one fabric to another during a cleaning process. Generally,
such dye transfer inhibiting agents include polyvinyl pyrrolidone
polymers, polyamine N-oxide polymers, copolymers of
N-vinylpyrrolidone and N-vinylimidazole, manganese phthalocyanine,
peroxidases, and mixtures thereof. If used, these agents typically
comprise from about 0.01% to about 10% and/or from about 0.01% to
about 5% and/or from about 0.05% to about 2% by weight on a dry
filament basis and/or dry web material basis.
Chelating Agents
[0236] The filaments of the present invention may contain one or
more chelating agents, for example one or more iron and/or
manganese and/or other metal ion chelating agents. Such chelating
agents can be selected from the group consisting of: amino
carboxylates, amino phosphonates, polyfunctionally-substituted
aromatic chelating agents and mixtures thereof. If utilized, these
chelating agents will generally comprise from about 0.1% to about
15% and/or from about 0.1% to about 10% and/or from about 0.1% to
about 5% and/or from about 0.1% to about 3% by weight on a dry
filament basis and/or dry web material basis.
[0237] The chelating agents may be chosen by one skilled in the art
to provide for heavy metal (e.g. Fe) sequestration without
negatively impacting enzyme stability through the excessive binding
of calcium ions. Non-limiting examples of chelating agents of use
in the present invention are found in U.S. Pat. Nos. 7,445,644,
7,585,376 and US 2009/0176684A1.
[0238] Useful chelating agents include heavy metal chelating
agents, such as diethylenetriaminepentaacetic acid (DTPA) and/or a
catechol including, but not limited to, Tiron. In embodiments in
which a dual chelating agent system is used, the chelating agents
may be DTPA and Tiron.
[0239] DTPA has the following core molecular structure:
##STR00008##
[0240] Tiron, also known as 1,2-diydroxybenzene-3,5-disulfonic
acid, is one member of the catechol family and has the core
molecular structure shown below:
##STR00009##
[0241] Other sulphonated catechols are of use. In addition to the
disulfonic acid, the term "tiron" may also include mono- or
di-sulfonate salts of the acid, such as, for example, the disodium
sulfonate salt, which shares the same core molecular structure with
the disulfonic acid.
[0242] Other chelating agents suitable for use herein can be
selected from the group consisting of: aminocarboxylates,
aminophosphonates, polyfunctionally-substituted aromatic chelating
agents and mixtures thereof. In one example, the chelating agents
include but are not limited to: HEDP
(hydroxyethanedimethylenephosphonic acid); MGDA
(methylglycinediacetic acid); GLDA (glutamic-N,N-diacetic acid);
and mixtures thereof.
[0243] Without intending to be bound by theory, it is believed that
the benefit of these materials is due in part to their exceptional
ability to remove heavy metal ions from washing solutions by
formation of soluble chelates; other benefits include inorganic
film or scale prevention. Other suitable chelating agents for use
herein are the commercial DEQUEST series, and chelants from
Monsanto, DuPont, and Nalco, Inc.
[0244] Aminocarboxylates useful as chelating agents include, but
are not limited to, ethylenediaminetetracetates,
N-(hydroxyethyl)ethylenediaminetriacetates, nitrilotriacetates,
ethylenediamine tetraproprionates,
triethylenetetraaminehexacetates, diethylenetriamine-pentaacetates,
and ethanoldiglycines, alkali metal, ammonium, and substituted
ammonium salts thereof and mixtures thereof. Aminophosphonates are
also suitable for use as chelating agents in the compositions of
the invention when at least low levels of total phosphorus are
permitted in the filaments of the present invention, and include
ethylenediaminetetrakis (methylenephosphonates). In one example,
these aminophosphonates do not contain alkyl or alkenyl groups with
more than about 6 carbon atoms. Polyfunctionally-substituted
aromatic chelating agents are also useful in the compositions
herein. See U.S. Pat. No. 3,812,044, issued May 21, 1974, to Connor
et al. Non-limiting examples of compounds of this type in acid form
are dihydroxydisulfobenzenes such as
1,2-dihydroxy-3,5-disulfobenzene.
[0245] In one example, a biodegradable chelating agent comprises
ethylenediamine disuccinate ("EDDS"), for example the [S,S] isomer
as described in U.S. Pat. No. 4,704,233. The trisodium salt of EDDS
may be used. In another example, the magnesium salts of EDDS may
also be used.
[0246] One or more chelating agents may be present in the filaments
of the present invention at a level from about 0.2% to about 0.7%
and/or from about 0.3% to about 0.6% by weight on a dry filament
basis and/or dry web material basis.
Suds Suppressors
[0247] Compounds for reducing or suppressing the formation of suds
can be incorporated into the filaments of the present invention.
Suds suppression can be of particular importance in the so-called
"high concentration cleaning process" as described in U.S. Pat.
Nos. 4,489,455 and 4,489,574, and in front-loading-style washing
machines.
[0248] A wide variety of materials may be used as suds suppressors,
and suds suppressors are well known to those skilled in the art.
See, for example, Kirk Othmer Encyclopedia of Chemical Technology,
Third Edition, Volume 7, pages 430-447 (John Wiley & Sons,
Inc., 1979). Examples of suds supressors include monocarboxylic
fatty acid and soluble salts therein, high molecular weight
hydrocarbons such as paraffin, fatty acid esters (e.g., fatty acid
triglycerides), fatty acid esters of monovalent alcohols, aliphatic
Cis-C.sub.40 ketones (e.g., stearone), N-alkylated amino triazines,
waxy hydrocarbons preferably having a melting point below about
100.degree. C., silicone suds suppressors, and secondary alcohols.
Suds supressors are described in U.S. Pat. Nos. 2,954,347;
4,265,779; 4,265,779; 3,455,839; 3,933,672; 4,652,392; 4,978,471;
4,983,316; 5,288,431; 4,639,489; 4,749,740; and 4,798,679;
4,075,118; European Patent Application No. 89307851.9; EP 150,872;
and DOS 2,124,526.
[0249] For any filaments and/or nonwovens comprising such filaments
of the present invention designed to be used in automatic laundry
washing machines, suds should not form to the extent that they
overflow the washing machine. Suds suppressors, when utilized, are
preferably present in a "suds suppressing amount. By "suds
suppressing amount" is meant that the formulator of the composition
can select an amount of this suds controlling agent that will
sufficiently control the suds to result in a low-sudsing laundry
detergent for use in automatic laundry washing machines.
[0250] The filaments herein will generally comprise from 0% to
about 10% by weight on a dry filament basis and/or dry web material
basis of suds suppressors. When utilized as suds suppressors, for
example monocarboxylic fatty acids, and salts therein, may be
present in amounts up to about 5% and/or from about 0.5% to about
3% by weight on a dry filament basis and/or dry web material basis.
When utilized, silicone suds suppressors are typically used in the
filaments at a level up to about 2.0% by weight on a dry filament
basis and/or dry web material basis, although higher amounts may be
used. When utilized, monostearyl phosphate suds suppressors are
typically used in the filaments at a level from about 0.1% to about
2% by weight on a dry filament basis and/or dry web material basis.
When utilized, hydrocarbon suds suppressors are typically utilized
in the filaments at a level from about 0.01% to about 5.0% by
weight on a dry filament basis and/or dry web material basis,
although higher levels can be used. When utilized, alcohol suds
suppressors are typically used in the filaments at a level from
about 0.2% to about 3% by weight on a dry filament basis and/or dry
web material basis.
Suds Boosters
[0251] If high sudsing is desired, suds boosters such as the
C.sub.10-C.sub.16 alkanolamides can be incorporated into the
filaments, typically at a level from 0% to about 10% and/or from
about 1% to about 10% by weight on a dry filament basis and/or dry
web material basis. The C.sub.10-C.sub.14 monoethanol and diethanol
amides illustrate a typical class of such suds boosters. Use of
such suds boosters with high sudsing adjunct surfactants such as
the amine oxides, betaines and sultaines noted above is also
advantageous. If desired, water-soluble magnesium and/or calcium
salts such as MgCl.sub.2, MgSO.sub.4, CaCl.sub.2, CaSO.sub.4 and
the like, may be added to the filaments at levels from about 0.1%
to about 2% by weight on a dry filament basis and/or dry web
material basis to provide additional suds.
Softening Agents
[0252] One or more softening agents may be present in the
filaments. Non-limiting examples of suitable softening agents
include quaternary ammonium compounds for example a quaternary
ammonium esterquat compound, silicones such as polysiloxanes, clays
such as smectite clays, and mixture thereof.
[0253] In one example, the softening agents comprise a fabric
softening agent. Non-limiting examples of fabric softening agents
include impalpable smectite clays, such as those described in U.S.
Pat. No. 4,062,647, as well as other fabric softening clays known
in the art. When present, the fabric softening agent may be present
in the filaments at a level from about 0.5% to about 10% and/or
from about 0.5% to about 5% by weight on a dry filament basis
and/or dry web material basis. Fabric softening clays may be used
in combination with amine and/or cationic softening agents such as
those disclosed in U.S. Pat. Nos. 4,375,416, and 4,291,071.
Cationic softening agents may also be used without fabric softening
clays.
Conditioning Agents
[0254] The filaments of the present invention may include one or
more conditioning agents, such as a high melting point fatty
compound. The high melting point fatty compound may have a melting
point of about 25.degree. C. or greater, and may be selected from
the group consisting of: fatty alcohols, fatty acids, fatty alcohol
derivatives, fatty acid derivatives, and mixtures thereof. Such
fatty compounds that exhibit a low melting point (less than
25.degree. C.) are not intended to be included as a conditioning
agent. Non-limiting examples of the high melting point fatty
compounds are found in International Cosmetic Ingredient
Dictionary, Fifth Edition, 1993, and CTFA Cosmetic Ingredient
Handbook, Second Edition, 1992.
[0255] One or more high melting point fatty compounds may be
included in the filaments of the present invention at a level from
about 0.1% to about 40% and/or from about 1% to about 30% and/or
from about 1.5% to about 16% and/or from about 1.5% to about 8% by
weight on a dry filament basis and/or dry web material basis. The
conditioning agents may provide conditioning benefits, such as
slippery feel during the application to wet hair and/or fabrics,
softness and/or moisturized feel on dry hair and/or fabrics.
[0256] The filaments of the present invention may contain a
cationic polymer as a conditioning agent. Concentrations of the
cationic polymer in the filaments, when present, typically range
from about 0.05% to about 3% and/or from about 0.075% to about 2.0%
and/or from about 0.1% to about 1.0% by weight on a dry filament
basis and/or dry web material basis. Non-limiting examples of
suitable cationic polymers may have cationic charge densities of at
least 0.5 meq/gm and/or at least 0.9 meq/gm and/or at least 1.2
meq/gm and/or at least 1.5 meq/gm at a pH of from about 3 to about
9 and/or from about 4 to about 8. In one example, cationic polymers
suitable as conditioning agents may have cationic charge densities
of less than 7 meq/gm and/or less than 5 meq/gm at a pH of from
about 3 to about 9 and/or from about 4 to about 8. Herein,
"cationic charge density" of a polymer refers to the ratio of the
number of positive charges on the polymer to the molecular weight
of the polymer. The weight average molecular weight of such
suitable cationic polymers will generally be between about 10,000
and 10 million, in one embodiment between about 50,000 and about 5
million, and in another embodiment between about 100,000 and about
3 million.
[0257] Suitable cationic polymers for use in the filaments of the
present invention may contain cationic nitrogen-containing moieties
such as quaternary ammonium and/or cationic protonated amino
moieties. Any anionic counterions may be used in association with
the cationic polymers so long as the cationic polymers remain
soluble in water and so long as the counterions are physically and
chemically compatible with the other components of the filaments or
do not otherwise unduly impair product performance, stability or
aesthetics of the filaments. Non-limiting examples of such
counterions include halides (e.g., chloride, fluoride, bromide,
iodide), sulfates and methylsulfates.
[0258] Non-limiting examples of such cationic polymers are
described in the CTFA Cosmetic Ingredient Dictionary, 3rd edition,
edited by Estrin, Crosley, and Haynes, (The Cosmetic, Toiletry, and
Fragrance Association, Inc., Washington, D.C. (1982)).
[0259] Other suitable cationic polymers for use in the filaments of
the present invention include cationic polysaccharide polymers,
cationic guar gum derivatives, quaternary nitrogen-containing
cellulose ethers, cationic synthetic polymers, cationic copolymers
of etherified cellulose, guar and starch. When used, the cationic
polymers herein are soluble in water. Further, suitable cationic
polymers for use in the filaments of the present invention are
described in U.S. Pat. Nos. 3,962,418, 3,958,581, and U.S.
2007/0207109A1, which are all incorporated herein by reference.
[0260] The filaments of the present invention may include a
nonionic polymer as a conditioning agent. Polyalkylene glycols
having a molecular weight of more than about 1000 are useful
herein. Useful are those having the following general formula:
##STR00010##
wherein R.sup.95 is selected from the group consisting of: H,
methyl, and mixtures thereof.
[0261] Silicones may be included in the filaments as conditioning
agents. The silicones useful as conditioning agents typically
comprise a water insoluble, water dispersible, non-volatile, liquid
that forms emulsified, liquid particles. Suitable conditioning
agents for use in the composition are those conditioning agents
characterized generally as silicones (e.g., silicone oils, cationic
silicones, silicone gums, high refractive silicones, and silicone
resins), organic conditioning oils (e.g., hydrocarbon oils,
polyolefins, and fatty esters) or combinations thereof, or those
conditioning agents which otherwise form liquid, dispersed
particles in the aqueous surfactant matrix herein. Such
conditioning agents should be physically and chemically compatible
with the essential components of the composition, and should not
otherwise unduly impair product stability, aesthetics or
performance.
[0262] The concentration of the conditioning agents in the
filaments may be sufficient to provide the desired conditioning
benefits. Such concentration can vary with the conditioning agent,
the conditioning performance desired, the average size of the
conditioning agent particles, the type and concentration of other
components, and other like factors.
[0263] The concentration of the silicone conditioning agents
typically ranges from about 0.01% to about 10% by weight on a dry
filament basis and/or dry web material basis. Non-limiting examples
of suitable silicone conditioning agents, and optional suspending
agents for the silicone, are described in U.S. Reissue Pat. No.
34,584, U.S. Pat. Nos. 5,104,646; 5,106,609; 4,152,416; 2,826,551;
3,964,500; 4,364,837; 6,607,717; 6,482,969; 5,807,956; 5,981,681;
6,207,782; 7,465,439; 7,041,767; 7,217,777; US Patent Application
Nos. 2007/0286837A1; 2005/0048549A1; 2007/0041929A1; British Pat.
No. 849,433; German Patent No. DE 10036533, which are all
incorporated herein by reference; Chemistry and Technology of
Silicones, New York: Academic Press (1968); General Electric
Silicone Rubber Product Data Sheets SE 30, SE 33, SE 54 and SE 76;
Silicon Compounds, Petrarch Systems, Inc. (1984); and in
Encyclopedia of Polymer Science and Engineering, vol. 15, 2d ed.,
pp 204-308, John Wiley & Sons, Inc. (1989).
[0264] In one example, the filaments of the present invention may
also comprise from about 0.05% to about 3% by weight on a dry
filament basis and/or dry web material basis of at least one
organic conditioning oil as a conditioning agent, either alone or
in combination with other conditioning agents, such as the
silicones (described herein). Suitable conditioning oils include
hydrocarbon oils, polyolefins, and fatty esters. Also suitable for
use in the compositions herein are the conditioning agents
described by the Procter & Gamble Company in U.S. Pat. Nos.
5,674,478, and 5,750,122. Also suitable for use herein are those
conditioning agents described in U.S. Pat. Nos. 4,529,586,
4,507,280, 4,663,158, 4,197,865, 4,217, 914, 4,381,919, and 4,422,
853, which are all incorporated herein by reference.
Humectants
[0265] The filaments of the present invention may contain one or
more humectants. The humectants herein are selected from the group
consisting of polyhydric alcohols, water soluble alkoxylated
nonionic polymers, and mixtures thereof. The humectants, when used,
may be present in the filaments at a level from about 0.1% to about
20% and/or from about 0.5% to about 5% by weight on a dry filament
basis and/or dry web material basis.
Suspending Agents
[0266] The filaments of the present invention may further comprise
a suspending agent at concentrations effective for suspending
water-insoluble material in dispersed form in the compositions or
for modifying the viscosity of the composition. Such concentrations
of suspending agents range from about 0.1% to about 10% and/or from
about 0.3% to about 5.0% by weight on a dry filament basis and/or
dry web material basis.
[0267] Non-limiting examples of suitable suspending agents include
anionic polymers and nonionic polymers (e.g., vinyl polymers, acyl
derivatives, long chain amine oxides, and mixtures thereof, alkanol
amides of fatty acids, long chain esters of long chain alkanol
amides, glyceryl esters, primary amines having a fatty alkyl moiety
having at least about 16 carbon atoms, secondary amines having two
fatty alkyl moieties each having at least about 12 carbon atoms).
Examples of suspending agents are described in U.S. Pat. No.
4,741,855.
Enzymes
[0268] One or more enzymes may be present in the filaments of the
present invention. Non-limiting examples of suitable enzymes
include proteases, amylases, lipases, cellulases, carbohydrases
including mannanases and endoglucanases, pectinases,
hemicellulases, peroxidases, xylanases, phopholipases, esterases,
cutinases, keratanases, reductases, oxidases, phenoloxidases,
lipoxygenases, ligninases, pullulanases, tannases, penosanases,
malanases, glucanases, arabinosidases, hyaluraonidases,
chrondroitinases, laccases, and mixtures thereof.
[0269] Enzymes may be included in the filaments of the present
invention for a variety of purposes, including but not limited to
removal of protein-based, carbohydrate-based, or triglyceride-based
stains from substrates, for the prevention of refugee dye transfer
in fabric laundering, and for fabric restoration. In one example,
the filaments of the present invention may include proteases,
amylases, lipases, cellulases, peroxidases, and mixtures thereof of
any suitable origin, such as vegetable, animal, bacterial, fungal
and yeast origin. Selections of the enzymes utilized are influenced
by factors such as pH-activity and/or stability optima,
thermostability, and stability to other additives, such as active
agents, for example builders, present within the filaments. In one
example, the enzyme is selected from the group consisting of:
bacterial enzymes (for example bacterial amylases and/or bacterial
proteases), fungal enzymes (for example fungal cellulases), and
mixtures thereof.
[0270] When present in the filaments of the present invention, the
enzymes may be present at levels sufficient to provide a
"cleaning-effective amount". The term "cleaning effective amount"
refers to any amount capable of producing a cleaning, stain
removal, soil removal, whitening, deodorizing, or freshness
improving effect on substrates such as fabrics, dishware and the
like. In practical terms for current commercial preparations,
typical amounts are up to about 5 mg by weight, more typically 0.01
mg to 3 mg, of active enzyme per gram of the filament and/or fiber
of the present invention. Stated otherwise, the filaments of the
present invention will typically comprise from about 0.001% to
about 5% and/or from about 0.01% to about 3% and/or from about
0.01% to about 1% by weight on a dry filament basis and/or dry web
material basis.
[0271] One or more enzymes may be applied to the filament and/or
nonwoven web and/or film after the filament and/or nonwoven web
and/or film are produced.
[0272] A range of enzyme materials and means for their
incorporation into the filament-forming composition of the present
invention, which may be a synthetic detergent composition, is also
disclosed in WO 9307263 A; WO 9307260 A; WO 8908694 A; U.S. Pat.
Nos. 3,553,139; 4,101,457; and 4,507,219.
Enzyme Stabilizing System
[0273] When enzymes are present in the filaments and/or fibers of
the present invention, an enzyme stabilizing system may also be
included in the filaments. Enzymes may be stabilized by various
techniques. Non-limiting examples of enzyme stabilization
techniques are disclosed and exemplified in U.S. Pat. Nos.
3,600,319 and 3,519,570; EP 199,405, EP 200,586; and WO 9401532
A.
[0274] In one example, the enzyme stabilizing system may comprise
calcium and/or magnesium ions.
[0275] The enzyme stabilizing system may be present in the
filaments of the present invention at a level of from about 0.001%
to about 10% and/or from about 0.005% to about 8% and/or from about
0.01% to about 6% by weight on a dry filament basis and/or dry web
material basis. The enzyme stabilizing system can be any
stabilizing system which is compatible with the enzymes present in
the filaments. Such an enzyme stabilizing system may be inherently
provided by other formulation actives, or be added separately,
e.g., by the formulator or by a manufacturer of enzymes. Such
enzyme stabilizing systems may, for example, comprise calcium ion,
magnesium ion, boric acid, propylene glycol, short chain carboxylic
acids, boronic acids, and mixtures thereof, and are designed to
address different stabilization problems.
Builders
[0276] The filaments of the present invention may comprise one or
more builders. Non-limiting examples of suitable builders include
zeolite builders, aluminosilicate builders, silicate builders,
phosphate builders, citric acid, citrates, nitrilo triacetic acid,
nitrilo triacetate, polyacrylates, acrylate/maleate copolymers, and
mixtures thereof.
[0277] In one example, a builder selected from the group consisting
of: aluminosilicates, silicates, and mixtures thereof, may be
included in the filaments of the present invention. The builders
may be included in the filaments to assist in controlling mineral,
especially calcium and/or magnesium hardness in wash water or to
assist in the removal of particulate soils from surfaces. Also
suitable for use herein are synthesized crystalline ion exchange
materials or hydrates thereof having chain structure and a
composition represented by the following general Formula I an
anhydride form: x(M.sub.2O).ySiO.sub.2.zM'O wherein M is Na and/or
K, M' is Ca and/or Mg; y/x is 0.5 to 2.0 and z/x is 0.005 to 1.0 as
taught in U.S. Pat. No. 5,427,711.
[0278] Non-limiting examples of other suitable builders that may be
included in the filaments include phosphates and polyphosphates,
for example the sodium salts thereof; carbonates, bicarbonates,
sesquicarbonates and carbonate minerals other than sodium carbonate
or sesquicarbonate; organic mono-, di-, tri-, and tetracarboxylates
for example water-soluble nonsurfactant carboxylates in acid,
sodium, potassium or alkanolammonium salt form, as well as
oligomeric or water-soluble low molecular weight polymer
carboxylates including aliphatic and aromatic types; and phytic
acid. These builders may be complemented by borates, e.g., for
pH-buffering purposes, or by sulfates, for example sodium sulfate
and any other fillers or carriers which may be important to the
engineering of stable surfactant and/or builder-containing
filaments of the present invention.
[0279] Still other builders may be selected from polycarboxylates,
for example copolymers of acrylic acid, copolymers of acrylic acid
and maleic acid, and copolymers of acrylic acid and/or maleic acid
and other suitable ethylenic monomers with various types of
additional functionalities.
[0280] Builder level can vary widely depending upon end use. In one
example, the filaments of the present invention may comprise at
least 1% and/or from about 1% to about 30% and/or from about 1% to
about 20% and/or from about 1% to about 10% and/or from about 2% to
about 5% by weight on a dry fiber basis of one or more
builders.
Clay Soil Removal/Anti-Redeposition Agents
[0281] The filaments of the present invention may contain
water-soluble ethoxylated amines having clay soil removal and
anti-redeposition properties. Such water-soluble ethoxylated amines
may be present in the filaments of the present invention at a level
of from about 0.01% to about 10.0% and/or from about 0.01% to about
7% and/or from about 0.1% to about 5% by weight on a dry filament
basis and/or dry web material basis of one or more water-soluble
ethoxylates amines Non-limiting examples of suitable clay soil
removal and antiredeposition agents are described in U.S. Pat. Nos.
4,597,898; 548,744; 4,891,160; European Patent Application Nos.
111,965; 111,984; 112,592; and WO 95/32272.
Polymeric Soil Release Agent
[0282] The filaments of the present invention may contain polymeric
soil release agents, hereinafter "SRAs." If utilized, SRA's will
generally comprise from about 0.01% to about 10.0% and/or from
about 0.1% to about 5% and/or from about 0.2% to about 3.0% by
weight on a dry filament basis and/or dry web material basis.
[0283] SRAs typically have hydrophilic segments to hydrophilize the
surface of hydrophobic fibers such as polyester and nylon, and
hydrophobic segments to deposit upon hydrophobic fibers and remain
adhered thereto through completion of washing and rinsing cycles
thereby serving as an anchor for the hydrophilic segments. This can
enable stains occurring subsequent to treatment with SRA to be more
easily cleaned in later washing procedures.
[0284] SRAs can include, for example, a variety of charged, e.g.,
anionic or even cationic (see U.S. Pat. No. 4,956,447), as well as
non-charged monomer units and structures may be linear, branched or
even star-shaped. They may include capping moieties which are
especially effective in controlling molecular weight or altering
the physical or surface-active properties. Structures and charge
distributions may be tailored for application to different fiber or
textile types and for varied detergent or detergent additive
products. Non-limiting examples of SRAs are described in U.S. Pat.
Nos. 4,968,451; 4,711,730; 4,721,580; 4,702,857; 4,877,896;
3,959,230; 3,893,929; 4,000,093; 5,415,807; 4,201,824; 4,240,918;
4,525,524; 4,201,824; 4,579,681; and 4,787,989; European Patent
Application 0 219 048; 279,134 A; 457,205 A; and DE 2,335,044.
Polymeric Dispersing Agents
[0285] Polymeric dispersing agents can advantageously be utilized
in the filaments of the present invention at levels from about 0.1%
to about 7% and/or from about 0.1% to about 5% and/or from about
0.5% to about 4% by weight on a dry filament basis and/or dry web
material basis, especially in the presence of zeolite and/or
layered silicate builders. Suitable polymeric dispersing agents may
include polymeric polycarboxylates and polyethylene glycols,
although others known in the art can also be used. For example, a
wide variety of modified or unmodified polyacrylates,
polyacrylate/mealeates, or polyacrylate/methacrylates are highly
useful. It is believed, though it is not intended to be limited by
theory, that polymeric dispersing agents enhance overall detergent
builder performance, when used in combination with other builders
(including lower molecular weight polycarboxylates) by crystal
growth inhibition, particulate soil release peptization, and
anti-redeposition. Non-limiting examples of polymeric dispersing
agents are found in U.S. Pat. No. 3,308,067, European Patent
Application No. 66915, EP 193,360, and EP 193,360.
Alkoxylated Polyamine Polymers
[0286] Alkoxylated polyamines may be included in the filaments of
the present invention for providing soil suspending, grease
cleaning, and/or particulate cleaning. Such alkoxylated polyamines
include but are not limited to ethoxylated polyethyleneimines,
ethoxylated hexamethylene diamines, and sulfated versions thereof.
Polypropoxylated derivatives of polyamines may also be included in
the filaments of the present invention. A wide variety of amines
and polyaklyeneimines can be alkoxylated to various degrees, and
optionally further modified to provide the abovementioned benefits.
A useful example is 600 g/mol polyethyleneimine core ethoxylated to
20 EO groups per NH and is available from BASF.
Alkoxylated Polycarboxylate Polymers
[0287] Alkoxylated polycarboxylates such as those prepared from
polyacrylates may be included in the filaments of the present
invention to provide additional grease removal performance Such
materials are described in WO 91/08281 and PCT 90/01815.
Chemically, these materials comprise polyacrylates having one
ethoxy side-chain per every 7-8 acrylate units. The side-chains are
of the formula --(CH.sub.2CH.sub.2O).sub.m(CH.sub.2).sub.nCH.sub.3
wherein m is 2-3 and n is 6-12. The side-chains are ester-linked to
the polyacrylate "backbone" to provide a "comb" polymer type
structure. The molecular weight can vary, but is typically in the
range of about 2000 to about 50,000. Such alkoxylated
polycarboxylates can comprise from about 0.05% to about 10% by
weight on a dry filament basis and/or dry web material basis.
Amphilic Graft Co-Polymers
[0288] The filaments of the present invention may include one or
more amphilic graft co-polymers. An example of a suitable amphilic
graft co-polymer comprises (i) a polyethyelene glycol backbone; and
(ii) and at least one pendant moiety selected from polyvinyl
acetate, polyvinyl alcohol and mixtures thereof. A non-limiting
example of a commercially available amphilic graft co-polymer is
Sokalan HP22, supplied from BASF.
Dissolution Aids
[0289] The filaments of the present invention may incorporate
dissolution aids to accelerate dissolution when the filament
contains more the 40% surfactant to mitigate formation of insoluble
or poorly soluble surfactant aggregates that can sometimes form or
surfactant compositions are used in cold water. Non-limiting
examples of dissolution aids include sodium chloride, sodium
sulfate, potassium chloride, potassium sulfate, magnesium chloride,
and magnesium sulfate.
Buffer System
[0290] The filaments of the present invention may be formulated
such that, during use in an aqueous cleaning operation, for example
washing clothes or dishes, the wash water will have a pH of between
about 5.0 and about 12 and/or between about 7.0 and 10.5. In the
case of a dishwashing operation, the pH of the wash water typically
is between about 6.8 and about 9.0. In the case of washing clothes,
the pH of the was water typically is between 7 and 11. Techniques
for controlling pH at recommended usage levels include the use of
buffers, alkalis, acids, etc., and are well known to those skilled
in the art. These include the use of sodium carbonate, citric acid
or sodium citrate, monoethanol amine or other amines, boric acid or
borates, and other pH-adjusting compounds well known in the
art.
[0291] Filaments useful as "low pH" detergent compositions are
included in the present invention and are especially suitable for
the surfactant systems of the present invention and may provide
in-use pH values of less than 8.5 and/or less than 8.0 and/or less
than 7.0 and/or less than 7.0 and/or less than 5.5 and/or to about
5.0.
[0292] Dynamic in-wash pH profile filaments are included in the
present invention. Such filaments may use wax-covered citric acid
particles in conjunction with other pH control agents such that (i)
3 minutes after contact with water, the pH of the wash liquor is
greater than 10; (ii) 10 mins after contact with water, the pH of
the wash liquor is less than 9.5; (iii) 20 mins after contact with
water, the pH of the wash liquor is less than 9.0; and (iv)
optionally, wherein, the equilibrium pH of the wash liquor is in
the range of from above 7.0 to 8.5.
Release of Active Agent
[0293] One or more active agents may be released from the filament
when the filament is exposed to a triggering condition. In one
example, one or more active agents may be released from the
filament or a part of the filament when the filament or the part of
the filament loses its identity, in other words, loses its physical
structure. For example, a filament loses its physical structure
when the filament-forming material dissolves, melts or undergoes
some other transformative step such that the filament structure is
lost. In one example, the one or more active agents are released
from the filament when the filament's morphology changes.
[0294] In another example, one or more active agents may be
released from the filament or a part of the filament when the
filament or the part of the filament alters its identity, in other
words, alters its physical structure rather than loses its physical
structure. For example, a filament alters its physical structure
when the filament-forming material swells, shrinks, lenthens,
and/or shortens, but retains its filament-forming properties.
[0295] In another example, one or more active agents may be
released from the filament with the filament's morphology not
changing (not losing or altering its physical structure).
[0296] In one example, the filament may release an active agent
upon the filament being exposed to a triggering condition that
results in the release of the active agent, such as by causing the
filament to lose or alter its identity as discussed above.
Non-limiting examples of triggering conditions include exposing the
filament to solvent, a polar solvent, such as alcohol and/or water,
and/or a non-polar solvent, which may be sequential, depending upon
whether the filament-forming material comprises a polar
solvent-soluble material and/or a non-polar solvent-soluble
material; exposing the filament to heat, such as to a temperature
of greater than 75.degree. F. and/or greater than 100.degree. F.
and/or greater than 150.degree. F. and/or greater than 200.degree.
F. and/or greater than 212.degree. F.; exposing the filament to
cold, such as to a temperature of less than 40.degree. F. and/or
less than 32.degree. F. and/or less than 0.degree. F.; exposing the
filament to a force, such as a stretching force applied by a
consumer using the filament; and/or exposing the filament to a
chemical reaction; exposing the filament to a condition that
results in a phase change; exposing the filament to a pH change
and/or a pressure change and/or temperature change; exposing the
filament to one or more chemicals that result in the filament
releasing one or more of its active agents; exposing the filament
to ultrasonics; exposing the filament to light and/or certain
wavelengths; exposing the filament to a different ionic strength;
and/or exposing the filament to an active agent released from
another filament.
[0297] In one example, one or more active agents may be released
from the filaments of the present invention when a nonwoven web
comprising the filaments is subjected to a triggering step selected
from the group consisting of: pre-treating stains on a fabric
article with the nonwoven web; forming a wash liquour by contacting
the nonwoven web with water; tumbling the nonwoven web in a dryer;
heating the nonwoven web in a dryer; and combinations thereof.
Filament-Forming Composition
[0298] The filaments of the present invention are made from a
filament-forming composition. The filament-forming composition is a
polar-solvent-based composition. In one example, the
filament-forming composition is an aqueous composition comprising
one or more filament-forming materials and one or more active
agents.
[0299] The filament-forming composition of the present invention
may have a shear viscosity as measured according to the Shear
Viscosity Test Method described herein of from about 1
PascalSeconds to about 25 PascalSeconds and/or from about 2
PascalSeconds to about 20 PascalSeconds and/or from about 3
PascalSeconds to about 10 PascalSeconds, as measured at a shear
rate of 3,000 sec.sup.-1 and at the processing temperature
(50.degree. C. to 100.degree. C.).
[0300] The filament-forming composition may be processed at a
temperature of from about 50.degree. C. to about 100.degree. C.
and/or from about 65.degree. C. to about 95.degree. C. and/or from
about 70.degree. C. to about 90.degree. C. when making filaments
from the filament-forming composition.
[0301] 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.
[0302] The filament-forming composition may exhibit a Capillary
Number of at least 1 and/or at least 3 and/or at least 5 such that
the filament-forming composition can be effectively polymer
processed into a hydroxyl polymer fiber.
[0303] 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:
C a = 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.
[0304] 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).
[0305] 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).
[0306] The fluid viscosity will depend on the temperature and may
depend of the shear rate. The definition of a shear thinning fluid
includes a dependence on the shear rate. The surface tension will
depend on the makeup of the fluid and the temperature of the
fluid.
[0307] In a fiber spinning process, the filaments need to have
initial stability as they leave the die. The Capillary number is
used to characterize this initial stability criterion. At the
conditions of the die, the Capillary number should be greater than
1 and/or greater than 4.
[0308] In one example, the filament-forming composition exhibits a
Capillary Number of from at least 1 to about 50 and/or at least 3
to about 50 and/or at least 5 to about 30.
[0309] The filament-forming composition of the present invention
may have a shear viscosity of from about 1 PascalSeconds to about
25 PascalSeconds and/or from about 2 PascalSeconds to about 20
PascalSeconds and/or from about 3 PascalSeconds to about 10
PascalSeconds, as measured at a shear rate of 3,000 sec.sup.-1 and
at the processing temperature (50.degree. C. to 100.degree.
C.).
[0310] The filament-forming composition may be processed at a
temperature of from about 50.degree. C. to about 100.degree. C.
and/or from about 65.degree. C. to about 95.degree. C. and/or from
about 70.degree. C. to about 90.degree. C. when making fibers from
the filament-forming composition.
[0311] In one example, the non-volatile components of the spinning
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%. The non-volatile components may be composed of
filament-forming materials, such as backbone polymers, actives and
combinations thereof. The volatile component of the spinning
composition will comprise the remaining percentage and range from
10% to 80%.
[0312] The filament-forming composition may exhibit a Capillary
Number of at least 1 and/or at least 3 and/or at least 5 such that
the filament-forming composition can be effectively polymer
processed into a hydroxyl polymer fiber.
[0313] 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. ##EQU00004##
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.
[0314] 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 ##EQU00005##
Vol'=volumetric flowrate (units of Length.sup.3 per Time),
Area=cross-sectional area of the die exit (units of
Length.sup.2).
[0315] When the die opening is a circular hole, then the fluid
velocity can be defined as
V = Vol ' .pi. * R 2 ##EQU00006##
R is the radius of the circular hole (units of length).
[0316] The fluid viscosity will depend on the temperature and may
depend of the shear rate. The definition of a shear thinning fluid
includes a dependence on the shear rate. The surface tension will
depend on the makeup of the fluid and the temperature of the
fluid.
[0317] In a filament spinning process, the filaments need to have
initial stability as they leave the die. The Capillary number is
used to characterize this initial stability criterion. At the
conditions of the die, the Capillary number should be greater than
1 and/or greater than 4.
[0318] In one example, the filament-forming composition exhibits a
Capillary Number of from at least 1 to about 50 and/or at least 3
to about 50 and/or at least 5 to about 30.
[0319] In one example, the filament-forming composition 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 and fatty amides,
silicones, aminosilicones, fluoropolymers and mixtures thereof.
[0320] In one example, the filament-forming composition may
comprise one or more antiblocking and/or detackifying agents.
Non-limiting examples of suitable antiblocking and/or detackifying
agents include starches, modified starches, crosslinked
polyvinylpyrrolidone, crosslinked cellulose, microcrystalline
cellulose, silica, metallic oxides, calcium carbonate, talc and
mica.
[0321] Active agents of the present invention may be added to the
filament-forming composition prior to and/or during filament
formation and/or may be added to the filament after filament
formation. For example, a perfume active agent may be applied to
the filament and/or nonwoven web comprising the filament after the
filament and/or nonwoven web according to the present invention are
formed. In another example, an enzyme active agent may be applied
to the filament and/or nonwoven web comprising the filament after
the filament and/or nonwoven web according to the present invention
are formed. In still another example, one or more particulate
active agents, such as one or more ingestible active agents, such
as bismuth subsalicylate, which may not be suitable for passing
through the spinning process for making the filament, may be
applied to the filament and/or nonwoven web comprising the filament
after the filament and/or nonwoven web according to the present
invention are formed.
Extensional Aids
[0322] In one example, the filament comprises an extensional aid.
Non-limiting examples of extensional aids can include polymers,
other extensional aids, and combinations thereof.
[0323] In one example, the extensional aids have a weight-average
molecular weight of at least about 500,000 Da. In another example,
the weight average molecular weight of the extensional aid is from
about 500,000 to about 25,000,000, in another example from about
800,000 to about 22,000,000, in yet another example from about
1,000,000 to about 20,000,000, and in another example from about
2,000,000 to about 15,000,000. The high molecular weight
extensional aids are preferred in some examples of the invention
due to the ability to increase extensional melt viscosity and
reducing melt fracture.
[0324] The extensional aid, when used in a meltblowing process, is
added to the composition of the present invention in an amount
effective to visibly reduce the melt fracture and capillary
breakage of fibers during the spinning process such that
substantially continuous fibers having relatively consistent
diameter can be melt spun. Regardless of the process employed to
produce filaments, the extensional aids, when used, can be present
from about 0.001% to about 10%, by weight on a dry filament basis
and/or dry web material basis, in one example, and in another
example from about 0.005 to about 5%, by weight on a dry filament
basis and/or dry web material basis, in yet another example from
about 0.01 to about 1%, by weight on a dry filament basis and/or
dry web material basis, and in another example from about 0.05% to
about 0.5%, by weight on a dry filament basis and/or dry web
material basis.
[0325] Non-limiting examples of polymers that can be used as
extensional aids can include alginates, carrageenans, pectin,
chitin, guar gum, xanthum gum, agar, gum arabic, karaya gum,
tragacanth gum, locust bean gum, alkylcellulose,
hydroxyalkylcellulose, carboxyalkylcellulose, and mixtures
thereof.
[0326] Nonlimiting examples of other extensional aids can include
carboxyl modified polyacrylamide, polyacrylic acid, polymethacrylic
acid, polyvinyl alcohol, polyvinylacetate, polyvinylpyrrolidone,
polyethylene vinyl acetate, polyethyleneimine, polyamides,
polyalkylene oxides including polyethylene oxide, polypropylene
oxide, polyethylenepropylene oxide, and mixtures thereof.
Method for Making Filament
[0327] The filaments of the present invention may be made by any
suitable process. A non-limiting example of a suitable process for
making the filaments is described below.
[0328] In one example, a method for making a filament according to
the present invention comprises the steps of:
[0329] a. providing a filament-forming composition comprising one
or more filament-forming materials and one or more active agents;
and
[0330] b. spinning the filament-forming composition into one or
more filaments comprising the one or more filament-forming
materials and the one or more active agents that are releasable
from the filament when exposed to conditions of intended use,
wherein the total level of the one or more filament-forming
materials present in the filament is less than 65% and/or 50% or
less by weight on a dry filament basis and/or dry web material
basis and the total level of the one or more active agents present
in the filament is greater than 35% and/or 50% or greater by weight
on a dry filament basis and/or dry web material basis.
[0331] In one example, during the spinning step, any volatile
solvent, such as water, present in the filament-forming composition
is removed, such as by drying, as the filament 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
volatile solvent, such as water, is removed during the spinning
step, such as by drying the filament being produced.
[0332] The filament-forming composition may comprise any suitable
total level of filament-forming materials and any suitable level of
active agents so long as the filament produced from the
filament-forming composition comprises a total level of
filament-forming materials in the filament of from about 5% to 50%
or less by weight on a dry filament basis and/or dry web material
basis and a total level of active agents in the filament of from
50% to about 95% by weight on a dry filament basis and/or dry web
material basis.
[0333] In one example, the filament-forming composition may
comprise any suitable total level of filament-forming materials and
any suitable level of active agents so long as the filament
produced from the filament-forming composition comprises a total
level of filament-forming materials in the filament of from about
5% to 50% or less by weight on a dry filament basis and/or dry web
material basis and a total level of active agents in the filament
of from 50% to about 95% by weight on a dry filament basis and/or
dry web material basis, wherein the weight ratio of
filament-forming material to additive is 1 or less.
[0334] In one example, the filament-forming composition comprises
from about 1% and/or from about 5% and/or from about 10% to about
50% and/or to about 40% and/or to about 30% and/or to about 20% by
weight of the filament-forming composition of filament-forming
materials; from about 1% and/or from about 5% and/or from about 10%
to about 50% and/or to about 40% and/or to about 30% and/or to
about 20% by weight of the filament-forming composition of active
agents; and from about 20% and/or from about 25% and/or from about
30% and/or from about 40% and/or to about 80% and/or to about 70%
and/or to about 60% and/or to about 50% by weight of the
filament-forming composition of a volatile solvent, such as water.
The filament-forming composition may comprise minor amounts of
other active agents, such as less than 10% and/or less than 5%
and/or less than 3% and/or less than 1% by weight of the
filament-forming composition of plasticizers, pH adjusting agents,
and other active agents.
[0335] The filament-forming composition is spun into one or more
filaments by any suitable spinning process, such as meltblowing
and/or spunbonding. In one example, the filament-forming
composition is spun into a plurality of filaments by meltblowing.
For example, the filament-forming composition may be pumped from an
extruder to a meltblown spinnerette. Upon exiting one or more of
the filament-forming holes in the spinnerette, the filament-forming
composition is attenuated with air to create one or more filaments.
The filaments may then be dried to remove any remaining solvent
used for spinning, such as the water.
[0336] The filaments of the present invention may be collected on a
belt, such as a patterned belt to form a nonwoven web comprising
the filaments.
Web Material
[0337] The web materials comprising one or more active agents of
the present invention exhibits novel properties, features, and/or
combinations thereof compared to known web materials comprising one
or more active agents. This is shown by the data set forth in Table
II below.
TABLE-US-00002 TABLE II Active Agents in Filaments/ Basis GM Plate
Dry Web Web Fibers Weight Thickness Density Modulus Stiffness Burst
Material (Y/N) (Y/N) (g/m.sup.2) (mm) (g/cm.sup.3) (g/cm.sup.2)
(N*mm) (g) Dizolve .RTM. N -- 354 0.885 0.40 18630 8.1+ 310
Sheet.sup.1 A Dizolve .RTM. N -- 434 0.943 0.46 95613 25.5+ 302
Sheet.sup.1 B Dizolve .RTM. N -- 420 1.00 0.42 68236 19.1+ 257
Sheet.sup.1 C Purex .RTM. Y N ~800 ~1.95 ~0.41 -- 51.9+ >5000
Complete 3-in 1 Laundry Sheets.sup.2 Invention Y Y 155 0.375 0.41
1537 .ltoreq.2.6 .ltoreq.572 A Invention Y Y 117 0.426 0.27 3039
.ltoreq.4.7 .ltoreq.2019 B Invention Y Y 79 0.351 0.22 1649 -- -- C
Active Agents in MD CD Filaments/ MD Peak CD Peak Dry Dry
Disintegration Dissolution Web Web Fibers Elongation Elongation
Tensile Tensile Time Time Material (Y/N) (Y/N) (%) (%) (g/in)
(g/in) (s/g) (s/g) Dizolve .RTM. N -- 7.60 8.62 432 378 59.8 978
Sheet.sup.1 A Dizolve .RTM. N -- 1.42 2.00 1487 1231 -- --
Sheet.sup.1 B Dizolve .RTM. N -- 2.03 2.96 1064 908 -- --
Sheet.sup.1 C Purex .RTM. Y N -- -- -- -- -- -- Complete 3-in 1
Laundry Sheets.sup.2 Invention Y Y 26 28 455 319 167 5008 A
Invention Y Y 56 76 805 723 16.9 498 B Invention Y Y 58 81 733 716
-- -- C .sup.1Dizolve .RTM. Laundry Detergent Sheets commercially
available from Dizolve Group Corp. .sup.2Commercially available
from The Dial Corporation
Nonwoven Web
[0338] One or more, and/or a plurality of filaments of the present
invention may form a nonwoven web by any suitable process known in
the art. The nonwoven web may be used to deliver the active agents
from the filaments of the present invention when the nonwoven web
is exposed to conditions of intended use of the filaments and/or
nonwoven web.
[0339] Even though the filament and/or nonwoven web and/or film of
the present invention are in solid form, the filament-forming
composition used to make the filaments of the present invention may
be in the form of a liquid.
[0340] In one example, the nonwoven web comprises a plurality of
identical or substantially identical from a compositional
perspective filaments according to the present invention. In
another example, the nonwoven web may comprise two or more
different filaments according to the present invention.
Non-limiting examples of differences in the filaments may be
physical differences such as differences in diameter, length,
texture, shape, rigidness, elasticity, and the like; chemical
differences such as crosslinking level, solubility, melting point,
Tg, active agent, filament-forming material, color, level of active
agent, level of filament-forming material, presence of any coating
on filament, biodegradable or not, hydrophobic or not, contact
angle, and the like; differences in whether the filament loses its
physical structure when the filament is exposed to conditions of
intended use; differences in whether the filament's morphology
changes when the filament is exposed to conditions of intended use;
and differences in rate at which the filament releases one or more
of its active agents when the filament is exposed to conditions of
intended use. In one example, two or more filaments within the
nonwoven web may comprise the same filament-forming material, but
have different active agents. This may be the case where the
different active agents may be incompatible with one another, for
example an anionic surfactant (such as a shampoo active agent) and
a cationic surfactant (such as a hair conditioner active
agent).
[0341] In another example, as shown in FIG. 4, the nonwoven web 20
may comprise two or more different layers 22, 24 (in the
z-direction of the nonwoven web 20 of filaments 16 of the present
invention that form the nonwoven web 20. The filaments 16 in layer
22 may be the same as or different from the filaments 16 of layer
24. Each layer 22, 24 may comprise a plurality of identical or
substantially identical or different filaments. For example,
filaments that may release their active agents at a faster rate
than others within the nonwoven web may be positioned to an
external surface of the nonwoven web.
[0342] In another example, the nonwoven web may exhibit different
regions, such as different regions of basis weight, density and/or
caliper. In yet another example, the nonwoven web may comprise
texture on one or more of its surfaces. A surface of the nonwoven
web may comprise a pattern, such as a non-random, repeating
pattern. The nonwoven web may be embossed with an emboss pattern.
In another example, the nonwoven web may comprise apertures. The
apertures may be arranged in a non-random, repeating pattern.
[0343] In one example, the nonwoven web may comprise discrete
regions of filaments that differ from other parts of the nonwoven
web.
[0344] Non-limiting examples of use of the nonwoven web of the
present invention include, but are not limited to a laundry dryer
substrate, washing machine substrate, washcloth, hard surface
cleaning and/or polishing substrate, floor cleaning and/or
polishing substrate, as a component in a battery, baby wipe, adult
wipe, feminine hygiene wipe, bath tissue wipe, window cleaning
substrate, oil containment and/or scavenging substrate, insect
repellant substrate, swimming pool chemical substrate, food, breath
freshener, deodorant, waste disposal bag, packaging film and/or
wrap, wound dressing, medicine delivery, building insulation, crops
and/or plant cover and/or bedding, glue substrate, skin care
substrate, hair care substrate, air care substrate, water treatment
substrate and/or filter, toilet bowl cleaning substrate, candy
substrate, pet food, livestock bedding, teeth whitening substrates,
carpet cleaning substrates, and other suitable uses of the active
agents of the present invention.
[0345] The nonwoven web of the present invention may be used as is
or may be coated with one or more active agents.
[0346] In another example, the nonwoven web of the present
invention may be pressed into a film, for example by applying a
compressive force and/or heating the nonwoven web to convert the
nonwoven web into a film. The film would comprise the active agents
that were present in the filaments of the present invention. The
nonwoven web may be completely converted into a film or parts of
the nonwoven web may remain in the film after partial conversion of
the nonwoven web into the film. The films may be used for any
suitable purposes that the active agents may be used for including,
but not limited to the uses exemplified for the nonwoven web.
[0347] In one example, the nonwoven web of the present invention
exhibits an average disintegration time per g of sample of less
than 120 and/or less than 100 and/or less than 80 and/or less than
55 and/or less than 50 and/or less than 40 and/or less than 30
and/or less than 20 seconds/gram (s/g) as measured according to the
Dissolution Test Method described herein.
[0348] In another example, the nonwoven web of the present
invention exhibits an average dissolution time per g of sample of
less than 950 and/or less than 900 and/or less than 800 and/or less
than 700 and/or less than 600 and/or less than 550 s/g as measured
according to the Dissolution Test Method described herein.
[0349] In one example, the nonwoven web of the present invention
exhibits a thickness of greater than 0.01 mm and/or greater than
0.05 mm and/or greater than 0.1 mm and/or to about 20 mm and/or to
about 10 mm and/or to about 5 mm and/or to about 2 mm and/or to
about 0.5 mm and/or to about 0.3 mm as measured by the Thickness
Test Method described herein.
Automatic Dishwashing Articles
[0350] Automatic dishwashing articles comprise one or more
filaments and/or fibers and/or nonwoven webs and/or films of the
present invention and a surfactant system, and optionally one or
more optional ingredients known in the art of cleaning, for example
useful in cleaning dishware in an automatic dishwashing machine.
Examples of these optional ingredients include: anti-scalants,
bleaching agents, perfumes, dyes, antibacterial agents, enzymes
(e.g., protease, amylase), cleaning polymers (e.g., alkoxylated
polyethyleneimine polymer), anti-redeposition polymers,
hydrotropes, suds inhibitors, carboxylic acids, thickening agents,
preservatives, disinfecting agents, glass and metal care agents, pH
buffering means so that the automatic dishwashing liquor generally
has a pH of from 3 to 14 (alternatively 8 to 11), or mixtures
thereof. Examples of automatic dishwashing actives are described in
U.S. Pat. Nos. 5,679,630; 5,703,034; 5,703,034; 5,705,464;
5,962,386; 5,968,881; 6,017,871; 6,020,294.
[0351] Scale formation can be a problem. It can result from
precipitation of alkali earth metal carbonates, phosphates, and
silicates. Examples of anti-scalants include polyacrylates and
polymers based on acrylic acid combined with other moieties.
Sulfonated varieties of these polymers are particular effective in
nil phosphate formulation executions. Examples of anti-scalants
include those described in U.S. Pat. No. 5,783,540, col. 15, 1.
20-col. 16, 1. 2; and EP 0 851 022 A2, pg. 12, 1. 1-20.
[0352] In one embodiment, an automatic dishwashing article is
provided comprising a filament and/or fiber and/or nonwoven web of
the present invention, a nonionic surfactant, a sulfonated polymer,
optionally a chelant, optionally a builder, and optionally a
bleaching agent, and mixtures thereof. A method of cleaning
dishware is provided comprising the step of dosing an automatic
dishwashing article of the present invention into an automatic
dishwashing machine.
Hand Dishwashing Articles
[0353] Hand dish washing articles comprise one or more filaments
and/or fibers and/or nonwoven webs and/or films of the present
invention and a surfactant system, and optionally one or more
optional ingredients known in the art of cleaning and hand care,
for example useful in cleaning dishware by hand. Examples of these
optional ingredients include: perfume, dyes, pearlescent agents,
antibacterial agents, enzymes (e.g., protease), cleaning polymers
(e.g., alkoxylated polyethyleneimine polymer), cationic polymers,
hydrotropes, humectants, emollients, hand care agents, polymeric
suds stabilizers, bleaching agent, diamines, carboxylic acids,
thickening agents, preservatives, disinfecting agents, pH buffering
means so that the dish washing liquor generally has a pH of from 3
to 14 (preferably from 8 to 11), or mixtures thereof. Examples of
hand dishwashing actives are described in U.S. Pat. Nos. 5,990,065;
and 6,060,122.
[0354] In one embodiment, the surfactant of the hand dishwashing
article comprises an alkyl sulfate, an alkoxy sulfate, an alkyl
sulfonate, an alkoxy sulfonate, an alkyl aryl sulfonate, an amine
oxide, a betaine or a derivative of aliphatic or heterocyclic
secondary and ternary amine, a quaternary ammonium surfactant, an
amine, a singly or multiply alkoxylated alcohol, an alkyl
polyglycoside, a fatty acid amide surfactant, a C.sub.8-C.sub.20
ammonia amide, a monoethanolamide, a diethanolamide, an
isopropanolamide, a polyhydroxy fatty acid amide, or a mixture
thereof.
[0355] A method of washing dishware is provided comprising the step
of dosing a hand dishwashing article of the present invention in a
sink or basin suitable for containing soiled dishware. The sink or
basin may contain water and/or soiled dishware.
Hard Surface Cleaning Article
[0356] Hard surface cleaning articles comprise one or more
filaments and/or fibers and/or nonwoven webs and/or films of the
present invention and optionally one or more optional ingredients
known in the art of cleaning, for example useful in cleaning hard
surfaces, such as an acid constituent, for example an acid
constituent that provides good limescale removal performance (e.g.,
formic acid, citric acid, sorbic acid, acetic acid, boric acid,
maleic acid, adipic acid, lactic acid malic acid, malonic acid,
glycolic acid, or mixtures thereof). Examples of ingredients that
may be included an acidic hard surface cleaning article may include
those described in U.S. Pat. No. 7,696,143. Alternatively the hard
surface cleaning article comprises an alkalinity constituent (e.g.,
alkanolmine, carbonate, bicarbonate compound, or mixtures thereof).
Examples of ingredients that may be included in an alkaline hard
surface cleaning article may include those described in US
2010/0206328 A1. A method of cleaning a hard surface includes using
or dosing a hard surface cleaning article in a method to clean a
hard surface. In one embodiment, the method comprises dosing a hard
surface cleaning article in a bucket or similar container,
optionally adding water to the bucket before or after dosing the
article to the bucket. In another embodiment, the method comprising
dosing a hard surface cleaning article in a toilet bowl, optionally
scrubbing the surface of the toilet bowl after the article has
dissolved in the water contained in the toilet bowl.
Toilet Bowl Cleaning Head
[0357] A toilet bowl cleaning head for a toilet bowl cleaning
implement comprising one or more filaments and/or fibers and/or
nonwoven webs and/or films of the present invention is provided.
The toilet bowl cleaning head may be disposable. The toilet bowl
cleaning head may be removably attached to a handle, so that the
user's hands remain remote from the toilet bowl. In one embodiment,
the toilet bowl cleaning head may contain a water dispersible
shell. In turn, the water dispersible shell may comprise one or
more filaments and/or fibers and/or nonwoven webs and/or films of
the present invention. This water dispersible shell may encase a
core. The core may comprise at least one granular material. The
granular material of the core may comprise surfactants, organic
acids, perfumes, disinfectants, bleaches, detergents, enzymes,
particulates, or mixtures thereof. Optionally, the core may be free
from cellulose, and may comprise one or more filaments and/or
fibers and/or nonwoven webs and/or films of the present invention.
Examples a suitable toilet bowl cleaning head may be made according
to commonly assigned U.S. patent application Ser. No. 12/901,804
(P&G Case 11892). A suitable toilet bowl cleaning head
containing starch materials may be made according to commonly
assigned U.S. patent application Ser. No. 13/073,308 (P&G case
12048), Ser. No. 13/073,274 (P&G case 12049) and/or Ser. No.
13/07,3346 (P&G case 12054). A method of cleaning a toilet bowl
surface is provided comprising the step of contacting the toilet
bowl surface with a toilet bowl cleaning head of the present
invention.
Methods of Use
[0358] The nonwoven webs or films comprising one or more fabric
care active agents according the present invention may be utilized
in a method for treating a fabric article. The method of treating a
fabric article may comprise one or more steps selected from the
group consisting of: (a) pre-treating the fabric article before
washing the fabric article; (b) contacting the fabric article with
a wash liquor formed by contacting the nonwoven web or film with
water; (c) contacting the fabric article with the nonwoven web or
film in a dryer; (d) drying the fabric article in the presence of
the nonwoven web or film in a dryer; and (e) combinations
thereof.
[0359] In some embodiments, the method may further comprise the
step of pre-moistening the nonwoven web or film prior to contacting
it to the fabric article to be pre-treated. For example, the
nonwoven web or film can be pre-moistened with water and then
adhered to a portion of the fabric comprising a stain that is to be
pre-treated. Alternatively, the fabric may be moistened and the web
or film placed on or adhered thereto. In some embodiments, the
method may further comprise the step of selecting of only a portion
of the nonwoven web or film for use in treating a fabric article.
For example, if only one fabric care article is to be treated, a
portion of the nonwoven web or film may be cut and/or torn away and
either placed on or adhered to the fabric or placed into water to
form a relatively small amount of wash liquor which is then used to
pre-treat the fabric. In this way, the user may customize the
fabric treatment method according to the task at hand. In some
embodiments, at least a portion of a nonwoven web or film may be
applied to the fabric to be treated using a device. Exemplary
devices include, but are not limited to, brushes and sponges. Any
one or more of the aforementioned steps may be repeated to achieve
the desired fabric treatment benefit.
Process for Making a Film
[0360] The nonwoven web of the present invention may be converted
into a film. An example of a process for making a film from a
nonwoven web according to the present invention comprises the steps
of:
[0361] a. providing a nonwoven web comprising a plurality of
filaments comprising a filament-forming material, for example a
polar solvent-soluble filament-forming material; and
[0362] b. converting the nonwoven web into a film.
[0363] In one example of the present invention, a process for
making a film from a nonwoven web comprises the steps of providing
a nonwoven web and converting the nonwoven web into a film.
[0364] The step of converting the nonwoven web into a film may
comprise the step of subjecting the nonwoven web to a force. The
force may comprise a compressive force. The compressive force may
apply from about 0.2 MPa and/or from about 0.4 MPa and/or from
about 1 MPa and/or to about 10 MPa and/or to about 8 MPa and/or to
about 6 MPa of pressure to the nonwoven web.
[0365] The nonwoven web may be subjected to the force for at least
20 milliseconds and/or at least 50 milliseconds and/or at least 100
milliseconds and/or to about 800 milliseconds and/or to about 600
milliseconds and/or to about 400 milliseconds and/or to about 200
milliseconds. In one example, the nonwoven web is subjected to the
force for a time period of from about 400 milliseconds to about 800
milliseconds.
[0366] The nonwoven web may be subjected to the force at a
temperature of at least 50.degree. C. and/or at least 100.degree.
C. and/or at least 140.degree. C. and/or at least 150.degree. C.
and/or at least 180.degree. C. and/or to about 200.degree. C. In
one example, the nonwoven web is subjected to the force at a
temperature of from about 140.degree. C. to about 200.degree.
C.
[0367] The nonwoven web may be supplied from a roll of nonwoven
web. The resulting film may be wound into a roll of film.
Non-Limiting Examples
[0368] Non-limiting examples of filaments according to the present
invention are produced by using a small-scale apparatus 26, a
schematic representation of which is shown in FIGS. 5 and 6. A
pressurized tank 28 suitable for batch operations is filled with a
filament-forming composition 30, for example a filament-forming
composition that is suitable for making filaments useful as fabric
care compositions and/or dishwashing compositions.
[0369] In a first example as set forth in Example 1 below, a
filament-forming composition 30 according to the present invention
is made as follows: two separate parts are combined to produce the
filament-forming composition 30. A first part, Part A, containing
15% by weight solids solution of polyvinyl alcohol is made by
mixing dry polyvinyl alcohol with 85% by weight deionized water and
heating the mixture to about 90.degree. C. and adding mechanical
mixing, if needed, until all or substantially all of the polyvinyl
alcohol is dissolved in the deionized water. This material is then
allowed to cool to about 73.degree. F..+-.4.degree. F. (about
23.degree. C..+-.2.2.degree. C.). Next, a second part, Part B,
containing 24.615% by weight deionized water and the balance
additives, including active agents such as surfactants, pH
adjusting agents and chelating agents that exhibit a combined total
weight % of greater than 50% is then added to Part A. The resulting
mixture is hand mixed to form the filament-forming composition.
This filament-forming is suitable for spinning into filaments
according to the present invention.
[0370] In a second example as set forth in Example 2 below, a
filament-forming composition 30 combines Part A and Part B at the
indicated weight percentages set forth in Table 2A below. The
weight percent of ingredients of a filament resulting from the
filament-forming composition of Table 2A is shown in Table 2B
below.
[0371] In a third example as set forth in Example 3 below, a
filament-forming composition combines Part A and Part B at the
indicated weight percentages set forth in Table 3A below. The
weight percent of ingredients of a filament resulting from the
filament-forming composition of Table 3A is shown in Table 3B
below.
[0372] In a fourth example as set forth in Example 4 below, a
filament-forming composition contains the ingredients as set forth
in Table 4 below.
[0373] In a fifth example as set forth in Example 5 below, a
filament-forming composition contains the ingredients as set forth
in Table 5 below.
[0374] In a sixth example as set forth in Example 6 below, a
filament-forming composition contains the ingredients as set forth
in Table 6 below.
[0375] In a seventh example as set forth in Example 7 below, a
filament-forming composition contains the ingredients as set forth
in Table 7 below.
[0376] Additional examples are set forth in Examples 8-12
below.
[0377] A pump 32 (for example a Zenith.RTM., type PEP II pump
having a capacity of 5.0 cubic centimeters per revolution (cc/rev),
manufactured by Parker Hannifin Corporation, Zenith Pumps division,
of Sanford, N.C., USA) is used to pump the filament-forming
composition 30 to a die 34. The filament-forming composition's
material flow to a die 34 is controlled by adjusting the number of
revolutions per minute (rpm) of the pump 32. Pipes 36 are connected
the tank 28, the pump 32, and the die 34 in order to transport (as
represented by the arrows) the filament-forming composition 30 from
the tank 28 to the pump 32 and into the die 34. The die 34 as shown
in FIG. 6 has two or more rows of circular extrusion nozzles 38
spaced from one another at a pitch P of about 1.524 millimeters
(about 0.060 inches). The nozzles 38 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 38 is encircled by an annular
and divergently flared orifice 40 to supply attenuation air to each
individual nozzle 38. The filament-forming composition 30 that is
extruded through the nozzles 38 is surrounded and attenuated by
generally cylindrical, humidified air streams supplied through the
orifices 40 encircling the nozzles 38 to produce the filaments 42.
Attenuation air is 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. An appropriate quantity of steam is added to
the attenuation air to saturate or nearly saturate the heated air
at the conditions in the electrically heated, thermostatically
controlled delivery pipe. Condensate is removed in an electrically
heated, thermostatically controlled, separator. The filaments 42
are dried by a drying air stream having a temperature of from about
149.degree. C. (about 300.degree. F.) to about 315.degree. C.
(about 600.degree. F.) by an electrical resistance heater (not
shown) supplied through drying nozzles (not shown) and discharged
at an angle of about 90.degree. relative to the general orientation
of the filaments 42 being spun.
[0378] The filaments may be collected on a collection device, 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 nonwoven web formed as a result of collecting the filaments on
the belt or fabric.
Example 1
[0379] An example of a filament and/or nonwoven web of the present
invention suitable for providing a beauty benefit is shown in Table
1 below.
TABLE-US-00003 TABLE 1 % by weight Filament (i.e., of filament-
Filament- components % by weight forming Forming remaining on a dry
filament composition Composition upon drying) basis and/or dry
(i.e., premix) (g) (g) web material basis PART A Polyvinyl 15.000
178.170 178.170 24.7% alcohol.sup.1 Deionized 85.000 1009.630 water
PART B Deionized 24.615 195.394 water Anionic 45.180 322.815
322.815 49.8% surfactants Nonionic 1.241 9.851 9.851 1.4%
surfactants pH adjusting 7.114 56.471 56.471 7.8% agent Chelants
2.154 17.098 17.098 2.4% Other Balance ingredients Combined A and B
Solids 720.923 36.4% Deionized 1260.701 63.6% water
.sup.1Sigma-Aldrich Catalog No. 363081, MW 85,000-124,000, 87-89%
hydrolyzed
Example 2
[0380] Table 2A below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or nonwoven web of the present invention suitable for
providing a beauty benefit.
TABLE-US-00004 TABLE 2A % by weight of filament-forming composition
(i.e., premix) PART A Glycerin 3.2 Polyvinyl alcohol.sup.1 8.1
Distilled water 88.7 PART B Sodium Lauroamphoacetate (26%
activity).sup.2 31.8 Ammonium Laureth-3 sulfate (25% activity) 4.9
Ammonium Undecyl sulfate (24% activity) 19.9 Ammonium Laureth-1
sulfate (70% activity) 8.0 Cationic cellulose.sup.3 0.5 Citric Acid
1.6 Distilled water 33.3 .sup.1Sigma-Aldrich Catalog No. 363081, MW
85,000-124,000, 87-89% hydrolyzed .sup.2McIntyre Group Ltd,
University Park, IL, Mackam HPL-28ULS .sup.3UCARE .TM. Polymer
LR-400, available from Amerchol Corporation (Plaquemine,
Louisiana)
[0381] The resulting filaments from the filament-forming
composition of Table 2A exhibits the following levels of active
agents and of filament-forming materials as set forth in Table 2B
below.
TABLE-US-00005 TABLE 2B Estimated Value % by weight on a dry
filament basis Solid Fibers Compositional Parameter and/or dry web
material basis Active Agents (Surfactants) 60.6 wt. %
Filament-forming Material (Polyvinylalcohol) 23.7 wt. % Weight
Ratio of Filament-forming Material to 0.39 Active Agent
Example 3
[0382] Table 3A below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or nonwoven web of the present invention suitable for
providing a beauty benefit.
TABLE-US-00006 TABLE 3A % by weight of filament-forming composition
(i.e., premix) PART A Glycerin 13.5 Polyvinyl alcohol.sup.1 8.1
Distilled water 78.4 PART B Sodium Lauroamphoacetate (26%
activity).sup.2 38.2 Ammonium Laureth-3 sulfate (70% activity) 2.9
Ammonium Undecyl sulfate (70% activity) 9.8 Ammonium Laureth-1
sulfate (70% activity) 9.8 Cationic cellulose.sup.3 0.5
Poly(ethylene oxide).sup.4 2.0 Distilled water 36.8
.sup.1Sigma-Aldrich Catalog No. 363081, MW 85,000-124,000, 87-89%
hydrolyzed .sup.2McIntyre Group Ltd, University Park, IL, Mackam
HPL-28ULS .sup.3UCARE .TM. Polymer LR-400, available from Amerchol
Corporation (Plaquemine, Louisiana) .sup.4Average MW 8,000,000,
available from Sigma Aldrich, Catalog Number 372838
[0383] The resulting filaments from the filament-forming
composition of Table 3A exhibits the following levels of active
agents and of filament-forming materials as set forth in Table 3B
below.
TABLE-US-00007 TABLE 3B Estimated Value % by weight on a dry
filament basis Solid Fibers Compositional Parameter and/or dry web
material basis Active Agents (Surfactants) 49.4 wt. %
Filament-forming Material (Polyvinylalcohol) 15.5 wt. % Weight
Ratio of Filament-forming Material to 0.31 Active Agent
Example 4
[0384] Table 4 below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or a nonwoven web of the present invention suitable
for use as a laundry detergent.
TABLE-US-00008 TABLE 4 % by weight Filament (i.e., of filament-
Filament- components % by weight forming Forming remaining on a dry
filament composition Composition upon drying) basis and/or dry
(i.e., premix) (%) (%) web material basis C12-15 AES 28.45 11.38
11.38 28.07 C11.8 HLAS 12.22 4.89 4.89 12.05 MEA 7.11 2.85 2.85
7.02 N67HSAS 4.51 1.81 1.81 4.45 Glycerol 3.08 1.23 1.23 3.04
PE-20, 3.00 1.20 1.20 2.95 Polyethyleneimine Ethoxylate, PEI 600
E20 Ethoxylated/ 2.95 1.18 1.18 2.91 Propoxylated Polyethyleneimine
Brightener 15 2.20 0.88 0.88 2.17 Amine Oxide 1.46 0.59 0.59 1.44
Sasol 24,9 Nonionic 1.24 0.50 0.50 1.22 Surfactant DTPA (Chelant)
1.08 0.43 0.43 1.06 Tiron (Chelant) 1.08 0.43 0.43 1.06 Celvol 523
PVOH.sup.1 0.000 13.20 13.20 32.55 Water 31.629 59.43 Trace
.sup.1Celvol 523, Celanese/Sekisui, MW 85,000-124,000, 87-89%
hydrolyzed
Example 5
[0385] Table 5 below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or a nonwoven web of the present invention suitable
for use as a laundry detergent.
TABLE-US-00009 TABLE 5 % by weight Filament (i.e., of filament-
Filament- components % by weight forming Forming remaining on a dry
filament composition Composition upon drying) basis and/or dry
(i.e., premix) (%) (%) web material basis C12-15 AES 23.13 9.25
9.25 24.05 C11.8 HLAS 13.55 5.42 5.42 14.10 MEA 6.91 2.76 2.76 7.20
N67HSAS 3.66 1.46 1.46 3.82 Glycerol 2.97 1.19 1.19 3.09 PE-20,
2.81 1.12 1.12 3.92 Polyethyleneimine Ethoxylate, PEI 600 E20
Ethoxylated/ 2.81 1.12 1.12 2.92 Propoxylated Polyethyleneimine
Brightener 15 0.25 0.15 0.15 0.26 Amine Oxide 1.26 0.50 0.50 1.32
Sasol 24,9 Nonionic 2.17 0.87 0.87 2.26 Surfactant DTPA (Chelant)
1.01 0.40 0.40 1.06 Tiron (Chelant) 1.01 0.40 0.40 1.05 Celvol 523
PVOH.sup.1 0.00 13.80 13.80 32.92 Water 38.46 61.53 Trace
.sup.1Celvol 523, Celanese/Sekisui, MW 85,000-124,000, 87-89%
hydrolyzed
Example 6
[0386] Table 6 below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or a nonwoven web of the present invention suitable
for use as a hand dishwashing detergent.
TABLE-US-00010 TABLE 6 % by weight Filament (i.e., of filament-
Filament- components % by weight forming Forming remaining on a dry
filament composition Composition upon drying) basis and/or dry
(i.e., premix) (%) (%) web material basis NaAE0.6S 31.09 12.43
12.43 24.05 1,3-BAC Diamine 0.35 0.14 0.14 14.10 PGC Amine Oxide
7.20 2.88 2.88 7.20 Tridecylalcohol-EO9 6.00 2.40 2.40 3.82 Sodium
cumene 2.22 0.89 0.89 3.09 sulfonate GLDA 2.22 0.89 0.89 3.92
Ethanol 2.17 0.87 0.87 2.92* Sodium Chloride 1.40 0.56 0.56 0.26
Magnesium chloride 0.61 0.24 0.24 1.32 pH Trim 0.50 0.20 0.20 2.26
NaOH 0.46 0.18 0.18 1.06 Acticide 0.05 0.02 0.02 1.05 Celvol 523
PVOH.sup.1 0.000 13.20 13.20 32.92 Water 45.74 65.10 Trace
.sup.1Celvol 523, Celanese/Sekisui, MW 85,000-124,000, 87-89%
hydrolyzed *Calculated
Example 7
[0387] Table 7 below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or a nonwoven web of the present invention suitable
for use as a laundry detergent.
TABLE-US-00011 TABLE 7 % by weight Filament (i.e., of filament-
Filament- components % by weight forming Forming remaining on a dry
filament composition Composition upon drying) basis and/or dry
(i.e., premix) (%) (%) web material basis C12-15 AES 23.13 9.25
9.25 24.04 C11.8 HLAS 13.55 5.42 5.42 14.10 MEA 6.91 2.76 2.76 7.20
N67HSAS 3.66 1.46 1.46 3.80 Glycerol 2.97 1.19 1.19 3.09 PE-20,
2.81 1.12 1.12 3.92 Polyethyleneimine Ethoxylate, PEI 600 E20
Ethoxylated/ 2.81 1.12 1.12 2.92 Propoxylated Polyethyleneimine
Brightener 15 0.25 0.15 0.15 0.26 Amine Oxide 1.26 0.50 0.50 1.32
Sasol 24,9 Nonionic 2.17 0.87 0.87 2.26 Surfactant DTPA (Chelant)
1.01 0.40 0.40 1.06 Tiron (Chelant) 1.01 0.40 0.40 1.05 Suds
Suppressor 0.06 0.03 0.03 0.07 AC8016 Celvol 523 PVOH.sup.1 0.00
13.80 13.80 32.92 Water 38.46 61.51 Trace .sup.1Celvol 523,
Celanese/Sekisui, MW 85,000-124,000, 87-89% hydrolyzed
Example 8
[0388] Table 8 below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or a nonwoven web of the present invention suitable
for use as a laundry detergent.
TABLE-US-00012 TABLE 8 % by weight Filament (i.e., of filament-
Filament- components % by weight forming Forming remaining on a dry
filament composition Composition upon drying) basis and/or dry
(i.e., premix) (%) (%) web material basis C12-15 AES 23.13 9.25
9.25 24.04 C11.8 HLAS 13.55 5.42 5.42 14.10 MEA 6.91 2.76 2.76 7.20
N67HSAS 3.66 1.46 1.46 3.80 Glycerol 2.97 1.19 1.19 3.09 PE-20,
2.81 1.12 1.12 3.92 Polyethyleneimine Ethoxylate, PEI 600 E20
Ethoxylated/ 2.81 1.12 1.12 2.92 Propoxylated Polyethyleneimine
Brightener 15 0.25 0.15 0.15 0.26 Amine Oxide 1.26 0.50 0.50 1.32
Sasol 24,9 Nonionic 2.17 0.87 0.87 2.26 Surfactant DTPA (Chelant)
2.02 0.80 0.80 2.12 Suds Suppressor 0.06 0.03 0.03 0.07 AC8016
Celvol 523 PVOH.sup.1 0.00 13.80 13.80 32.92 Water 38.46 61.51
Trace .sup.1Celvol523, Celanese/Sekisui, MW 85,000-124,000, 87-89%
hydrolyzed
Example 9
[0389] Table 9 below sets forth another example of a
filament-forming composition of the present invention for making
filaments and/or a nonwoven web of the present invention suitable
for use as a laundry detergent.
TABLE-US-00013 TABLE 9 % by weight Filament (i.e., of filament-
Filament- components % by weight forming Forming remaining on a dry
filament composition Composition upon drying) basis and/or dry
(i.e., premix) (%) (%) web material basis C12-15 AES 32.77 13.11
13.11 26.93 C11.8 HLAS 19.20 7.68 7.68 15.81 Sodium Hydroxide 7.70
3.08 3.08 6.34 N67HSAS 5.19 2.08 2.08 4.27 PE-20, 3.98 1.59 1.59
3.27 Polyethyleneimine Ethoxylate, PEI 600 E20 Ethoxylated/ 3.98
1.59 1.59 3.27 Propoxylated Polyethyleneimine Brightener 15 0.36
0.21 0.21 0.44 Amine Oxide 1.79 0.71 0.71 1.47 Sasol 24,9 Nonionic
3.08 1.23 1.23 2.53 Surfactant DTPA (Chelant) 2.87 1.15 1.15 2.38
C12-18 Fatty Acid 2.51 1.00 1.00 2.07 1,2-Propanediol 2.96 1.18
1.18 2.44 Ethanol 0.34 0.14 0.14 0.28* Suds Suppressor 0.09 0.03
0.03 0.07 AC8016 Celvol 523 PVOH.sup.1 0.00 13.80 13.80 28.41 Water
17.16 51.42 Trace .sup.1Celvol 523, Celanese/Sekisui, MW
85,000-124,000, 87-89% hydrolyzed *Calculated
Example 10
[0390] Tables 10A-10F set forth another example of a
filament-forming composition according to the present invention and
the components thereof as well as the final composition of the
filaments and/or nonwoven made therefrom. Such filaments and/or
nonwoven web are suitable for use as a laundry detergent.
TABLE-US-00014 TABLE 10A Laundry Detergent Premix Activity Parts
Parts Water Material (%) (%) (%) (%) MEA:AES 100% 29.35 29.35 0.00
C16-17 AS-MEA 100% 4.71 4.71 0.00 Sasol 24,9 Nonionic 100% 1.27
1.27 0.00 Surfactant Glycerol 100% 3.24 3.24 0.00 Brightener 15 51%
2.26 4.46 2.20 DTPA (Chelant) 50% 2.20 4.41 2.20 MEA 100% 1.79 1.79
0.00 C11.8 HLAS 100% 15.22 15.22 0.00 PE-20, 80% 3.06 3.82 0.76
Polyethyleneimine Ethoxylate, PEI 600 E20 Ethoxylated/Propoxylated
100% 3.06 3.06 0.00 Polyethyleneimine Amine Oxide 32% 1.38 4.30
2.93 AF8017 Antifoam (Suds 100% 0.06 0.06 0.00 Suppressor) Water
24.30 24.30 67.60 100.00 32.40
TABLE-US-00015 TABLE 10B Polyvinyl alcohol (PVOH) Premix Activity
Parts Parts Water Material (%) (%) (%) (%) Polyvinyl alcohol 100%
23.00 23.00 0.00 (Celvol 523) Water 77.00 77.00 23.00 100.00
77.00
TABLE-US-00016 TABLE 10C Brightner 15 Premix % in Parts Active
Composition Premix delivery Basis Brightener 6.17 0.28% 12.19% 15
Powder % Nonionic 24.69 1.10% 48.78% Surfactant, Sasol 23,9 % MEA
19.75 0.88% 39.02% total 50.61 2.26% 100.00% Water 49.39 2.20%
100.00 4.46%
TABLE-US-00017 TABLE 10D Filament-Forming Composition Spun into
Filaments Activity Parts Parts Water Material (%) (%) (%) (%) PVOH
Premix 23.0% 34.11 148.32 114.21 Laundry Detergent 67.6% 58.89
87.11 28.22 Premix 93.00 235.43 142.43 Water Dried Off 0.00
(135.43) (135.43) 93.00 100.00 7.00
TABLE-US-00018 TABLE 10E Perfume Composition Added (after
formation) to Filaments/Nonwoven Web Incorporating Filaments
Activity Parts Parts Water Material (%) (%) (%) (%) Nonwoven Web
93% 92.10 99.03 6.93 Perfume 100% 0.97 0.97 0.00 93.07 100.00
TABLE-US-00019 TABLE 10F Final Composition of Filaments/Nonwoven
Web Incorporating Filaments Activity Parts Parts Water Material (%)
(%) (%) (%) MEA:AES 100% 25.32 25.32 0.00 C16-17 AS-MEA 100% 4.07
4.07 0.00 Sasol 24,9 Nonionic 100% 2.04 2.04 0.00 Surfactant
Glycerol 100% 2.79 2.79 0.00 Brightener 15 100% 0.24 0.24 0.00 DTPA
(Chelant) 100% 1.90 1.90 0.00 MEA 100% 2.31 2.31 0.00 C11.8 HLAS
100% 13.13 13.13 0.00 PE-20, 100% 2.64 2.64 0.00 Polyethyleneimine
Ethoxylate, PEI 600 E20 Ethoxylated/Propoxylated 100% 2.64 2.64
0.00 Polyethyleneimine Amine Oxide 100% 1.19 1.19 0.00 AF8017
Antifoam (Suds 100% 0.05 0.05 0.00 Suppressor) Celvol 523 100%
33.78 33.78 0.00 Perfume 100% 0.97 0.97 0.00 Water 6.93 6.93 Total
93.07 100.00 6.93
Example 11
[0391] Table 11A sets forth an example of an enzyme composition;
namely an enzyme prill, that can be added to a filament and/or
nonwoven web comprising filaments of the present invention. Table
11B sets for an example of a nonwoven web according to the present
invention comprising the enzyme prill of Table 11A.
TABLE-US-00020 TABLE 11A Enzyme Composition Weight (g) Protease
enzyme 0.0065 First Amylase enzyme 0.0065 Second Amylase enzyme
0.0126 Mannanase enzyme 0.0331
TABLE-US-00021 TABLE 11B Enzyme Composition Weight (g) Weight (%)
Nonwoven web 6.20 99.06 Protease enzyme 0.0065 0.10 First Amylase
enzyme 0.0065 0.10 Second Amylase enzyme 0.0126 0.20 Mannanase
enzyme 0.0331 0.53 TOTAL 6.26 100
Example 12
[0392] Table 12 sets forth an example of a nonwoven web according
to the present invention comprising a cellulase enzyme that is
added to the nonwoven web or one or more filaments making up the
nonwoven web after the filaments and/or nonwoven web are
formed.
TABLE-US-00022 TABLE 12 Enzyme Composition Weight (g) Weight (%)
Nonwoven web 6.20 99.9 Cellulase enzyme 0.0062 0.1 TOTAL 6.2062
100
Test Methods
[0393] Unless otherwise indicated, 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 73.degree.
F..+-.4.degree. F. (about 23.degree. C..+-.2.2.degree. C.) and a
relative humidity of 50%.+-.10% for 2 hours prior to the test
unless otherwise indicated. Samples conditioned as described herein
are considered dry samples (such as "dry filaments") for purposes
of this invention. Further, all tests are conducted in such
conditioned room.
Water Content Test Method
[0394] The water (moisture) content present in a filament and/or
fiber and/or nonwoven web is measured using the following Water
Content Test Method.
[0395] A filament and/or nonwoven or portion thereof ("sample") is
placed in a conditioned room at a temperature of 73.degree.
F..+-.4.degree. F. (about 23.degree. C..+-.2.2.degree. C.) and a
relative humidity of 50%.+-.10% for at least 24 hours prior to
testing. The weight of the sample is recorded when no further
weight change is detected for at least a 5 minute period. Record
this weight as the "equilibrium weight" of the sample. Next, place
the sample in a drying oven for 24 hours at 70.degree. C. with a
relative humidity of about 4% to dry the sample. After the 24 hours
of drying, immediately weigh the sample. Record this weight as the
"dry weight" of the sample. The water (moisture) content of the
sample is calculated as follows:
% Water ( moisture ) in sample = 100 % .times. ( Equilbrium weight
of sample - Dry weight of sample ) Dry weight of sample
##EQU00007##
[0396] The % Water (moisture) in sample for 3 replicates is
averaged to give the reported % Water (moisture) in sample.
Dissolution Test Method
[0397] Apparatus and Materials:
[0398] 600 mL Beaker
[0399] Magnetic Stirrer (Labline Model No. 1250 or equivalent)
[0400] Magnetic Stirring Rod (5 cm)
[0401] Thermometer (1 to 100.degree. C.+/-1.degree. C.)
[0402] Template, Stainless Steel (3.8 cm.times.3.2 cm)
[0403] Timer (0-300 seconds, accurate to the nearest second)
[0404] 35 mm Slide Mount having an open area of 3.8 cm.times.3.2 cm
(commercially available from Polaroid Corporation)
[0405] 35 mm Slide Mount Holder
[0406] City of Cincinnati Water or equivalent having the following
properties: Total Hardness=155 mg/L as CaCO.sub.3; Calcium
content=33.2 mg/L; Magnesium content=17.5 mg/L; Phosphate
content=0.0462
[0407] Sample Preparation: [0408] 1. Cut 3 test samples from a film
or a nonwoven web to be tested ("sample") using the template to
ensure that the sample fits within the 35 mm slide mount with open
area dimensions 24.times.36 mm (i.e. 3.8 cm.times.3.2 cm specimen).
Cut the samples from areas of the film or nonwoven web equally
spaced along the transverse direction of the film or nonwoven web.
As one of ordinary skill in the art would know, the basis weight of
the sample is measured and the sample weight is determined by
utilizing the open area dimensions. [0409] 2. Lock each of the 3
samples in a separate 35 mm slide mount. [0410] 3. Place magnetic
stirring rod into the 600 mL Beaker. [0411] 4. Obtain 500 mL or
greater of Cincinnati city water and measure water temperature with
thermometer and, if necessary, adjust the temperature of the water
to maintain it at the testing temperature; namely, 5.degree. C.
Once the water temperature is at 5.degree. C., fill the 600 mL
beaker with 500 mL of the water. [0412] 5. Next, place the beaker
on the magnetic stirrer. Turn the stirrer on, and adjust stir speed
until a vortex develops in the water and the bottom of the vortex
is at the 400 mL mark on the 600 mL beaker. [0413] 6. Secure the 35
mm slide mount with sample locked therein in a holder designed to
lower the 35 mm slide mount into the water in the beaker, for
example an alligator clamp of a 35 mm slide mount holder designed
to position the 35 mm slide mount into the water present in the 600
mL beaker. The 35 mm slide mount is held by the alligator clamp in
the middle of one long end of the 35 mm slide mount such that the
long ends of the 35 mm slide mount are parallel to the surface of
the water present in the 600 mL beaker. This set up will position
the film or nonwoven surface perpendicular to the flow of the
water. A slightly modified example of an arrangement of a 35 mm
slide mount and slide mount holder are shown in FIGS. 1-3 of U.S.
Pat. No. 6,787,512. [0414] 7. In one motion, the 35 mm slide mount
holder, which positions the 35 mm slide mount above the center of
the water in the beaker, is dropped resulting in the 35 mm slide
mount becoming submerged in the water sufficiently such that the
water contacts the entire exposed surface area of the film or
nonwoven sample locked in the 35 mm slide mount. As soon as the
water contacts the entire exposed surface area of the film or
nonwoven start the timer. Disintegration occurs when the film or
nonwoven breaks apart. When all of the visible film or nonwoven is
released from the slide mount, raise the 35 mm slide mount out of
the water while continuing to monitor the water for undissolved
film or nonwoven fragments. Dissolution occurs when all film or
nonwoven fragments are no longer visible in the water. [0415] 8.
Three replicates of each sample are run. [0416] 9. Each
disintegration and dissolution time is normalized by weight of the
sample to obtain values of the disintegration and dissolution times
per g of sample tested, which is in units of seconds/gram of sample
(s/g). The average disintegration and dissolution times per g of
sample tested of the three replicates are recorded. As one of
ordinary skill in the art would know, the disintegration time and
dissolution time for each sample is also recorded.
Diameter Test Method
[0417] The diameter of a discrete filament or a filament within a
nonwoven web or film 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 filaments 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 filament
in the electron beam. A manual procedure for determining the
filament 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 filament is sought and then
measured across its width (i.e., perpendicular to filament
direction at that point) to the other edge of the filament. A
scaled and calibrated image analysis tool provides the scaling to
get actual reading in .mu.m. For filaments within a nonwoven web or
film, several filament are randomly selected across the sample of
the nonwoven web or film using the SEM or the optical microscope.
At least two portions the nonwoven web or film (or web inside a
product) 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 filament diameters, standard deviation of the
filament diameters, and median of the filament diameters.
[0418] Another useful statistic is the calculation of the amount of
the population of filaments that is below a certain upper limit. To
determine this statistic, the software is programmed to count how
many results of the filament 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
filament as di.
[0419] In case the filaments have non-circular cross-sections, the
measurement of the filament diameter is determined as and set equal
to the hydraulic diameter which is four times the cross-sectional
area of the filament divided by the perimeter of the cross-section
of the filament (outer perimeter in case of hollow filaments). The
number-average diameter, alternatively average diameter is
calculated as:
d num = i = 1 n d i n ##EQU00008##
Thickness Method
[0420] Thickness of a nonwoven web or film is measured by cutting 5
samples of a nonwoven web or film sample such that each cut sample
is larger in size than a load foot loading surface of a VIR
Electronic Thickness Tester Model II available from Thwing-Albert
Instrument Company, Philadelphia, Pa. Typically, the load foot
loading surface has a circular surface area of about 3.14 in.sup.2.
The sample is confined between a horizontal flat surface and the
load foot loading surface. The load foot loading surface applies a
confining pressure to the sample of 15.5 g/cm.sup.2. The caliper of
each sample is the resulting gap between the flat surface and the
load foot loading surface. The caliper is calculated as the average
caliper of the five samples. The result is reported in millimeters
(mm).
Shear Viscosity Test Method
[0421] The shear viscosity of a filament-forming composition of the
present invention is measured using a capillary rheometer,
Goettfert Rheograph 6000, manufactured by Goettfert USA of Rock
Hill S.C., USA. The measurements are conducted using a capillary
die having a diameter D of 1.0 mm and a length L of 30 mm (i.e.,
L/D=30). The die is attached to the lower end of the rheometer's 20
mm barrel, which is held at a die test temperature of 75.degree. C.
A preheated to die test temperature, 60 g sample of the
filament-forming composition is loaded into the barrel section of
the rheometer. Rid the sample of any entrapped air. Push the sample
from the barrel through the capillary die at a set of chosen rates
1,000-10,000 seconds.sup.-1. An apparent shear viscosity can be
calculated with the rheometer's software from the pressure drop the
sample experiences as it goes from the barrel through the capillary
die and the flow rate of the sample through the capillary die. The
log (apparent shear viscosity) can be plotted against log (shear
rate) and the plot can be fitted by the power law, according to the
formula .eta.=K.gamma..sup.n-1, wherein K is the material's
viscosity constant, n is the material's thinning index and .gamma.
is the shear rate. The reported apparent shear viscosity of the
filament-forming composition herein is calculated from an
interpolation to a shear rate of 3,000 sec.sup.-1 using the power
law relation.
Basis Weight Test Method
[0422] Basis weight of a fibrous structure sample is measured by
selecting twelve (12) individual fibrous structure samples and
making two stacks of six individual samples each. If the individual
samples are connected to one another vie perforation lines, the
perforation lines must be aligned on the same side when stacking
the individual samples. A precision cutter is used to cut each
stack into exactly 3.5 in..times.3.5 in. squares. The two stacks of
cut squares are combined to make a basis weight pad of twelve
squares thick. The basis weight pad is then weighed on a top
loading balance with a minimum resolution of 0.01 g. The top
loading balance must be protected from air drafts and other
disturbances using a draft shield. Weights are recorded when the
readings on the top loading balance become constant. The Basis
Weight is calculated as follows:
Basis Weight ( lbs / 3000 ft 2 ) = Weight of basis weight pad ( g )
.times. 3000 ft 2 453.6 g / lbs .times. 12 samples .times. [ 12.25
in 2 ( Area of basis weight pad ) / 144 in 2 ] ##EQU00009## Basis
Weight ( g / m 2 ) = Weight of basis weight pad ( g ) .times. 10 ,
000 cm 2 / m 2 79.0321 cm 2 ( Area of basis weight pad ) .times. 12
samples ##EQU00009.2##
Weight Average Molecular Weight
[0423] 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