EP4640573A1

EP4640573A1 - Packaged laundry product

Info

Publication number: EP4640573A1
Application number: EP24171647.1A
Authority: EP
Inventors: Girish Muralidharan
Original assignee: Unilever IP Holdings BV
Current assignee: Unilever IP Holdings BV
Priority date: 2024-04-22
Filing date: 2024-04-22
Publication date: 2025-10-29

Abstract

The present invention relates to a packaged product with a container enclosing a laundry article. More particularly, the present invention relates to a packaged product having a flexible solid laundry article enclosed in a recyclable or biodegradable material. There is a need to create, a recyclable or biodegradable package that encloses flexible solid laundry article that are easily dissolvable in water even after long period of storage in particular under high humidity conditions and where the package is capable of protecting the laundry article from the exposure to the external conditions and holds its structure through transport and storage. The present invention provides a packaged laundry product where a flexible solid laundry is packaged in a container comprising a recyclable and/or biodegradable material. The packaged product has an increased overall amount of recyclable and/or biodegradable material and is environmentally friendly without compromising on the product attributes. Further, the flexible solid laundry article remains storage stable, and has good dissolution properties even after long storage periods.

Description

Field of the Invention

The present invention relates to a packaged product with a container enclosing a laundry article. More particularly, the present invention relates to a packaged product having a flexible solid laundry article enclosed in a recyclable or biodegradable material.

Background of the Invention

Flexible solid laundry article provide consumers the convenience and efficiency to use the laundry composition.
Consumers desire for convenience while opening and closing the package and nowadays more and more consumers desire for package which are environmentally friendly and free of nonrenewable, or petroleum based raw materials. To provide these benefits through packaging while ensuring that the package minimize moisture ingress into the laundry article has remained a challenge.
In addition to this, it is desirable to limit access to the flexible solid laundry article particularly with respect to children, by incorporating child resistent features into the packaging.
Current flexible solid laundry article are generally packaged in a carton box. Compostable or biodegradable material offers environmental advantages, however due to its very nature (is tendancy to biodegrade) the use of such materials is problematic. Pulp based or fibrous package are often prone to high water transmission properties. This means that he likelihood of water ingress and/or egress is much higher and so there is an impact on the physical performance of the flexible solid laundry article inside such a fibre or pulp based package.
A particular characteristic is that flexible solid laundry article containing detergent composition having from 5 wt.% to 10 wt.% water tend to stick to the inside surface of such package on storage, particularly in high humidity conditions. This sticking is caused by the exterior surface being negatively affected by the water transmission when stored in a biodegradable material, particularly paper-based package.
As such, there remains a need to create, a recyclable or biodegradable package that encloses flexible solid laundry article that are easily dissolvable in water even after long period of storage in particular under high humidity conditions and where the package is capable of protecting the laundry article from the exposure to the external conditions and holds its structure through transport and storage.

Summary of the Invention

The present inventors have surprisingly found that when a flexible solid laundry article according to the present invention is packaged in a container comprising a recyclable and/or biodegradable material the packaged product has an increased overall amount of recyclable and/or biodegradable material and is environmentally friendly without compromising on the product attributes. In particular, the flexible solid laundry article remains storage stable, and has good dissolution properties even after long storage periods.
According to the first aspect, the present invention provides packaged laundry product comprising a container and a flexible solid laundry article, said flexible solid laundry article is enclosed in the container, wherein the container comprises a recyclable or biodegradable material and wherein the flexible solid laundry article comprises (i) a water-soluble polymer comprising a cellulose ether derivative; (ii) a water-insoluble disintegrant and wherein the flexible solid laundry article is free of PVOH or a copolymer of PVOH.

Detailed Description of the Invention

According to a first aspect of the present invention provided is a packaged laundry product comprising a container and a flexible solid laundry article.
According to the first aspect of the present invention the packaged laundry product comprises a container. Preferably the packaged laundry product according to the first aspect, has the flexible solid laundry article which are stacked in one, two- or three-dimensional array, preferably a three-dimensional array inside the container. Preferably the container is the primary package or the secondary package. Preferably the container has a compartment for containing the plurality of laundry article and a closure for the container, wherein the closure has a locking means. Preferably the container has dividing means for dividing the container compartment into subcompartments. Preferably the container has child resistant means for deterring a child from opening the container. Preferably the container is shaped in the form of a tub, tray, box, or combinations thereof. Preferably the container comprises: (i) a container body; (ii) a top panel engaged with the container body, (iii) an opening flap connected with a hinge to the top panel; (iv) a locking means integral with the opening flap and detachably attachable to the container body. Preferably the opening panel is separable from the top panel when the package is opened for the first time by means of a weakened portion provided on the top panel. Preferably the unseparated portion of the top panel after the opening panel is separated form a flush seat for the opening panel in the closed position.

Container material

Preferably the container is made of a recyclable, compostable or a biodegradable material. Still preferably a compostable or a biodegradable material.
The term "biodegradable" means the complete breakdown of a substance by microorganisms to carbon dioxide water biomass, and inorganic materials. The term "compostable" means a material that meets the following three requirements: (i) is capable of being processed in a composting facility for solid waste; (ii) if so processed will end up in the final compost; and (iii) if the compost is used in the soil the material will ultimately biodegrade in the soil.
The container may comprise entirely biodegradable material such that the container in its entirety can be completely broken down of a substance by microorganisms such as bacteria, fungi, yeasts, and algae; environmental heat, moisture, or other environmental factors to carbon dioxide water biomass, and inorganic material. Preferably from 90 to 99.9% wt. of the container, more preferably from 96 to 99.9% wt. consists of pulp or fibrous materials such as paper, card or board. The remainder comprising barrier materials and/or information labels. However, it is preferred that any label also comprises biodegradable materials as described herein preferably paper or other fibrous or pulp based material.
Suitable biodegradable materials comprises paper, cardboard from cellulose or derivatves; and may optionally comprise lignin, or derivatives; biodegradable plastics, such as bioplastics which are preferably oxo-biodegradable plastics wherein biodegradation results from oxidative and cell-mediated phenomena, either simultaneously or successively (as distinct from oxodegradation which is degradation resulting from "oxidative cleavage of macromolecules" such that the plastic fragments but does not biodegrade except over a very long time). The material may also be compostable.
The biodegradable material comprises a bio polymer such as polylactic acid (PLA) which may be from e.g. corn starch, cassava, sugarcan etc; polyhydroxyalkanoate (PHA) including include poly-3-hydroxybutyrate (PHB or PH3B), polyhydroxyvalerate (PHV), and polyhydroxyhexanoate (PHH). A PHA copolymer called poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV); biodegradable polyesters e.g. polycaprolactone (PCL), Polybutylensuccinat (PBS) polyvinylalcohol (PVA); polybutylenadipate-terephthalate (PBAT); cellulose based materials e.g. ethyl cellulose, cellulose acetate (true) Cellophane (made from wood, cotton or hemp); starch or starch based materials (from potato, rice, corn etc); sugar cane bagasse, and any combination or mixture thereof. For example PCL may be mixed with starch to improve biodegradability of the PCL.
The biodegradable material may comprise any biodegradable polyolefin.
Biodegradable petroleum based plastics inlcude: polyglycolic acid (PGA), a thermoplastic polymer and an aliphatic polyester; polybutylene succinate (PBS), which is a thermoplastic polymer resin that has properties comparable to propylene; polycaprolactone (PCL), as this has hydrolysable ester linkages offering biodegradable properties. It has been shown that firmicutes and proteobacteria can degrade PCL. Penicillium sp. strain 26-1 can degrade high density PCL; though not as quickly as thermotolerant Aspergillus sp. strain ST-01. Species of clostridium can degrade PCL under anaerobic conditions; Polybutylene adipate terephthalate (PBAT) which is a biodegradable random copolymer.
The most preferred biodegradable materials include paper, card or board from cellulose or derivatves.
Preferably the biodegradable material is bio-based according to ¹⁴C or radiocarbon method (EU: EN 16640 or CEN/TS 16137, International: ISO 16620-2, US: ASTM 6866).
Preferably the biodegradable material is made from a renewable resource.
The container material may comprise an outer layer to provide additional protection or sheen (for biodegradable materials with a matt finish such as paper board) . This layer preferably comprises a biodegradable polymer coating or varnish or film. Preferably the outer layer comprises any of the bio polymers described above. Preferaby the outer layer is at least present on some or all of the internal surfaces of the receptable.
The term fibrous or pulp material includes paper or paperboard: specifically. Preferably, the fibrous or pulp material is in the form of a sheet and is formed as a blank which is folded to form a closeable container. The closeable container can be formed from a one-piece blank or may contain multiple pieces.
The material useable for making the container can exhibit a grammage from 100 and 500 g/m², preferably from 200 and 400 g/m². The sheet paper material used for making the container can, in an embodiment variant thereof, be covered, for at least part of the first and/or second prevalent development surfaces, by a coating, for example a film, whose aim is to balance water transfer between the interior and the exterior of the container with leakage protection. Advantageously but not in a limiting way, the coating could comprise and extrusion coating on one or both sides (inner side and/or outer side) of the paper material defining the container, with values which can for example range between 10 and 50 micrometer of the coating material. The coating plastic material can be for example selected among the following materials: LDPE, HDPE, PP, PE.
Preferred barrier materials include polymeric materials selected from polylactic acid, polyhydroxyalkanoate, a polyester, polybutylenadipate terephthalate, a cellulose based material, a starch based material, a sugare cane based material and mixtures thereof.
In a preferred embodiment the biodegradable material comprises at least two layers, more preferably at least three.
The biodegradable material preferably comprises a bleached layer and which bleached layer comprises an outer layer of the biodegradable material. By outer layer is meant that the bleached layer is physically outermost. A second layer comprises a non-bleached layer which is also exterior but opposite the bleached layer. The biodegradable material thus preferably comprises a bleached and un-bleached layer on opposing sides. Between the bleached and unbleached layer is preferably a filler layer comprised of post-consumer recycled material and which is preferably paper-based also.

Container structure

The container preferably has a minimum compression strength of 300N. The thickness (or caliper) of material will be chosen to provide the necessary structural rigidity to the container.
The container may comprise any suitable rigid structure, such as a tub, tray, or carton or box, or tubular structure. However, preferred container will be formed from a blank which is formed into a container. Preferably, the container comprises a base, opposing pairs of walls and a closable lid. Preferably, the lid is integral with the base or formed from a separate component.
The walls of such structures may be foamed or moulded. It may comprise laminate structures (e.g. built up in layers ). It may comprise fibrous material such as fibres/pulp which is glued, compressed and/or enclosed in stiff walls. Fluting may be incorporated e.g. corrugated paper board. For paperboard, the grammage is preferably at least 200gsm (grams per square meter) preferably at least 225 gsm.
The structure may be foldable between an erected structure to provide a functioning receptacle and a flattened structure which assists in transporation and ease of disposal later so that mulitple packs could be flattened and stacked ready for transport to a biodegradation site.
The biodegradable container may comprise a combination of a fibrous and/or pulp material and a polymeric material. One example may be a material comprises one or more fibrous and/or pulp layers in combination with one or more polymeric materials (all materials being biodegradable). There may be one or more layers of fibre and/or pulp sandwiched between layers of polymeric material. The material may be virgin or recycled.
Dimensionally, it is preferred that the container comprises a top surface which, when in a closed configuration, is from 9 to 25 cm wide, still preferably 9 to 20 cm, still more preferably 9 to 15 cm. This width is an average across the full length of the top surface. This width is preferred because the biodegradable packaging tends to flex more easily than the more rigid plastic packaging containers and we have found that this dimension correlates with the optimal consumer behaviour when opening the container to access the contents by using appropriate force and so not damaging the biodegradable container or the contents within. This is particular the case when the child resistant closure requires simultaneous pressing of unlocking zones on opposing side walls. Such opposing pressures may damage the contents of the container by pressurising capsules which are already under water transmission stress.
Where the container comprises a separate lid and base it is preferred that the lid comprises a top sheet and depending pairs of opposing walls such that it resembles five sides of a cube. Similarly, it is preferred that the base comprises a bottom sheet and upstanding pairs of opposing walls such that it also resembles five sides of a cube.
In this way, the lid and the base co-operate to form a closed container with the pairs of opposing walls for each of the lid and the base providing double protection against the exterior as the lid and base co-operate telescopically. Preferably, the lid provides the outermost surface when the base and lid are telescopically engaged to close the container.
Preferably, the lid comprises a bleached layer on the outermost layer and an unbleached layer on the innermost layer. In such a configuration the bleached layer presents the outermost surface of the container for the five sides that the lid makes up. Preferably, this outermost layer comprises printed parts. Preferably, the bleached layer also comprises a barrier material as described below.
Preerably the container comprises a containing drawer which is open at the top permitting access to the contents of the container, and which is slidable engagable with an exterior case which closes access when the drawer is fully engaged within the case. In such an embodiment the case would correspond to the lid described above and the drawer to the base.
In a preferred embodiment the container has a hinged opening flap that is mechanically engageable with another portion of the container when the opening flap is in a closed position. Opening flap remains connected to some other part of the container and this is a desirable are opening feature since when opened, the opening flap is not misplaced.
Packages typically employ an opening flap in one of two arrangements. In the first arrangement, the opening flap is an entire planar surface of the container, and the opening flap is pivotably connected to the remainder of the container body. This arrangement advantageously provides for a wide opening into the container and can make it convenient to access the contents of the container. To open the user must apply sufficient force to dislodge the channel in the opening flap from the rim of the remainder of the container. For paper, card or board containers, the opening flap is commonly provided with one or more flaps that are tucked into the inner periphery of the remainder of the container.
In the second arrangement, the opening flap is part of a planar surface of the container. When the user opens the flap, a portion or portions of the surface remain connected to the remainder of the container body. Typically, the opening flap is a partial cutout of the planar surface with the boundary between the opening flap and planar surface from which it is cut being a through cut of the planar surface made orthogonal to the planar surface of the container. This arrangement advantageously provides for an opening that can be sized and dimensioned to provide easy access to the contents of the container, can be easy to manufacture, and can be sized and dimensioned as required.
Preferably the container having an opening flap comprises a top panel, a hinge; an opening flap connected to said hinge, and a container body engaged with said top panel, wherein said top panel, said opening flap, and said container body together define an interior space. To provide for securely closing the opening flap, the container preferably comprises a locking feature. The locking means may be connected to the opening flap. The hinge can be a fold line between the material constituting the opening flap and the top panel, the hinge can also be a fold line between the material constituting the opening flap and the rear panel. The hinge can coincide with the fold line between the top panel and the rear panel. The hinged portion preferably comprises the entirety of the portion of the opening flap that moves pivotably about the hinge. The hinged portion may comprise a hinge or the entirety of the hinged portion can be a hinge. The opening flap can pivot about the one or more hinges. The opening flap may be separated from the top panel when it is first opened by a weakened portion which is thinner than portions of the opening flap adjacent to the weakened portion. The weakened portion can be a through cut, a frangible line, a score line, a perforated line, partial die cut, partial die cut on opposing surfaces, zipper cut, or the like.
The container according to the present invention preferably encloses a plurality of flexible solid laundry article. Preferably, for consumer value and convenience, packages contain sufficient numbers of flexible solid laundry article, which is 10 or more, more preferably 20 or more, even more preferably 30 or more, even more preferably 40 or more and more preferably 50 or more flexible solid laundry article. There may be no more than 70 flexible solid laundry article in the container, preferably no more than 60 flexible solid laundry article.
Preferably when the flexible laundry article is in the form of a 3D structure, the container preferably has outer shell structure and an inner shell structure. The inner structure comprises one or more divided sections enabled to hold product. The inner structure may be integral to the outer shell and formed as part of or connected to the outer shell or the inner structure can be distinct from the outer shell. The outer shell preferably includes a child-resistant opening. The outer shell structure, the inner shell structure or both are preferably made from non-plastic, biodegradable material.

Barrier material

The container preferably comprises a barrier material for improved performance. Barrier materials are preferably employed to provide humidity control and are usually applied on the board surface on one or both sides, depending on the end use.
Dispersion barrier:Dispersion is a new barrier option without the traditional coating layers. The surface is finished with water-based dispersion technology. That makes the board liquid and grease resistant during its use while it breaks down in a recycling process like paper, providing high yield of recovered fiber when products are recycled.
Green PE coating: PE Green is a fully renewable option to traditional PE (polyethylene) and provides excellent humidity protection. PE Green is made of renewable, plant-based raw material, which provides barrier packaging that is 100% renewable as well as recyclable. In converting, it performs the same way as PE and is therefore easy to introduce to production by customers.
PE coating: PE, or polyethylene, is the most commonly used barrier coating. Polyolefin barriers, such as LDPE and HDPE polymers, provide excellent humidity protection.
Biodegradable coating: Biodegradable coatings are tailor-made polymers offering humidity, oxygen and grease barriers and sealability. Our biodegradable coatings are compostable. However, the biopolymer-coated paperboard can be easily recycled, too, which is usually the preferred end-of-life option.
Biopolymers can be produced from natural crops or from fossil raw materials. But the key is that in the end the biopolymer-coated paperboard breaks down to humus and CO2. If you choose our biopolymer-coated paperboard, you get a product that is recyclable or it can be collected among other compostable waste that goes into industrial composting.
PET coating: PET provides a barrier and performs other functions. Black or white PET coatings that provide heat resistance act as an excellent grease barrier and possess solid WVTR (water vapour transmission rate) properties.
PP coating: PP or polypropylene coating offers heat resistance for microwave oven and is also suitable for deep freezing. Good sealing properties secure performance in use.
However, it is preferred that the barrier material comprises less than 5 wt.% more preferably less than 1 wt.% and preferably substantially zero PE, PP or PET.
Metal barrier coating: Preferably the barrier material may be a vapor deposition metal, still preerably where the barrier material is vapor deposited aluminium.
In a preferred embodiment the barrier comprises a water-based dispersion.
Water-based barrier coatings seal the substrate surface and protect the packaging from external and internal influences. The packaging remains attractive and can fulfil its functionality without restrictions. Depending on the product, our barrier coatings offer adequate protection against fat, water, water vapor, dairy products, alcohol, oil or alkali for the lifetime of the packaging. Due to their versatility, they are used for a wide range of applications. Barrier coatings are available for packaging converters and printers or the paper industry.
Preferably, the base of the package comprises a layer of water-based dispersion barrier.
Preferably, the barrier material on the base is applied to an inner surface.
Preferably, the lid or top panel component comprises less than 1 wt.% of the barrier material, more preferably a water-based dispersion barrier.
More preferably, the dispersion barrier component comprises a thermoplastic elastomer (TPE). Said TPE is preferably dispersed in the barrier component.
The advantage of a TPE containing barrier material is that it is dispersed in the barrier component such that layers are not required. The dispersion is applied in one go.
An alternative barrier component may comprise a multi-layer approach. Such barriers include those commercially available from Weilburger under the Senolith^® brand. Examples are described in WO 2018/069413 . Preferably, these would be applied by digital print, ink duct damping unit, flexo printing, inline - offline coating unit, and web offset as well as gravure.
Such barrier materials might be applied as a wet layer primarily. The dispersion is preferably an aqueous dispersion, in particular a PTFE dispersion, perfluoroalkoxy (PFA) polymer dispersion, and/or fluorinated ethylene-propylene (FEP), copolymer of hexafluoropropylene.
When a layer is applied in a moist form, a surface film is formed which can then be cured. A first layer can have a resin in order to improve adhesion to a substrate. Exemplary suitable resins are, without limitation, polyamideimide, polyphenylene sulfide (PPS), polyether sulfone (PES), polyether ether ketone (PEEK), silicone resin and / or polysulfone. The proportion of such a resin in a moist composition to be applied as a layer, in particular a dispersion, is preferably about 3 to 8 percent by weight of the composition.
The second polymer is applied to the first layer in a liquid. The dispersion can contain further constituents mentioned herein. The dispersion is preferably an aqueous dispersion, in particular a PTFE dispersion, perfluoroalkoxy (PFA) polymer dispersion, and / or fluorinated ethylene-propylene (FEP, copolymer of hexafluoropropylene and tetrafluoroethylene) dispersion. The proportion of the second polymer in a moist composition to be applied as a layer, in particular a dispersion, is preferably about 40-60 percent by weight. The first layer may have been dried, partially dried or not dried prior to application of the second layer. In an advantageous variant, the second layer is applied to the first layer as long as the first layer is still moist, in particular as long as the first layer is still moist.
Preferably, both the lid and the base comprise multi-layer barrier material such as those described above.
Preferably, the barrier material is applied to the exterior of lid, top panel and/or base. More preferably, the barrier material is applied to at least 50%, more preferably, from 70%, especially preferably from 90% and most preferably from 95% of the exterior surface of the lid.
More preferably, the barrier material is applied to at least 50%, more preferably, from 70%, especially preferably from 90% and most preferably from 95% of the exterior surface of the base.
More preferably, the base comprises barrier material on the exterior and the interior surface.

Adhesive

Preferably, the container is folded into shape and maintained in shape with the help of adhesives. Adhesives are common in the art but preferably we mean hot melt adhesive, reactive hot melt adhesive, thermosetting adhesive, pressure sensitive adhesive, contact glue adhesive. Preferably, the adhesive is a hot melt pressure sensitive adhesive.
Preferably, the hot melt pressure sensitive adhesive is suitable to tackify and bond to a range of materials making up the packaging.
Preferably, the barrier material and adhesive comprises from 0.1 wt.% to 5 wt.% of the total container plus adhesive and barrier material, i.e. without the flexible solid laundry article. More preferably, the barrier material and adhesive comprises from 1 to 3% wt. and most preferably from 1.5 to 2.5% wt. of the total container plus adhesive and barrier material.
Preferably the container includes a printed image thereon. Preferably printed layer includes an ink layer and still preferably an overprint varnish on the ink layer. Preferably the ink layer is deposited on a layer comprising the paper-based material. Preferably disposed on the ink layer is an overprint varnish coating. A surface of the layer on which the print layer is deposited is preferably machine glazed to provide for a smooth surface. The smoothness of the surface provides for good printability. The ink layer preferably in presence of the overprint varnish coating is referred herein as the print layer. The ink layer preferably includes a colorant, preferably the colorant includes one or more pigments. Ink layer can be either solvent-based or water-based. The printing ink may be a gravure printing ink or a flexographic printing ink. In some embodiments, the ink layer is high abrasive resistant. The ink suitable for the present invention may be from a petroleum source, more preferably the ink is derived from a renewable biobased resource, such as plant based. Non-limiting examples of inks include ECO-SUREITM from Gans Ink & Supply Co. and the solvent based VUTEk(R) and BioVuTM inks from EFI, Inks from Siegwerk which are bio based using bio ethanol as solvents, nitro cellulose based binding systems other than fossil based which are derived completely from renewable resources (e.g., corn). The natural solvent used in the ink layer includes bio sourced ethanol and vegetable oils. Pigments used may be from either a bio source or a synthetic source. The printed image is preferably a product logo, graphics, ingredient information or other printed material. The ink layer may preferably also include an over print varnish layer (OPV). The optional overprint varnish layer functions to protect the ink layer from its physical and chemical environment. Preferably the over print varnish layer is solvent based and has a cross-linking which provides scuff resistance and high gloss to the print layer. The over print varnish preferably includes a solvent and nitrocellulose. Preferably the nitrocellulose is naturally sourced, and the overprint varnish preferably includes solvent from a natural source.

Flexible solid laundry article

The flexible solid laundry article according to the first aspect of the present invention may be in the form of a sheet, multi-layered sheet having two or more sheet stacked on each other, a sealed pouch comprising the sheet which pouch encloses a solid detergent composition and any other 3D article formed by sandwiching a composition in between two or more layers of the sheet.
Preferably the flexible solid laundry article of the present invention can be provided in the form comprising one or more flexible, dissolvable, porous sheets, wherein each of said two or more sheets is characterized by being an open-celled foam, a fibrous structure, a non-fibrous structure. The porous sheet can be optionally bonded together via a bonding means (e.g., heat, moisture, ultrasonic, pressure, and the like).
The term "solid" as used herein refers to the ability of an article to substantially retain its shape (i.e., without any visible change in its shape) at 20°C and under the atmospheric pressure, when no external force is applied thereto.
The term "flexible" as used herein refers to the ability of an article to withstand stress without breakage or significant fracture when it is bent at 90° along a center line perpendicular to its longitudinal direction Preferably, such article can undergo significant elastic deformation and is characterized by a Young's Modulus of no more than 5 GPa, preferably no more than 1 GPa, more preferably no more than 0.5 GPa, most preferably no more than 0.2 GPa.
The flexible solid laundry article is provided in unit dose format. The term" unit dose" herein refers to a dose of a product suitable for single time use.
The flexible solid laundry article according to the present invention is preferably a dissolvable solid article. By the term dissolvable it is meant that the article is capable of dissolving in the liquid, especially aqueous carrier, more specifically water. Water can be added to 1 to 100 parts of the article, preferably from 5 to 50 parts, more preferably from 10 to 40 parts. The flexible solid laundry article provides a cleaning composition for laundering on dissolution in water.
The term "sheet" as used herein refers to a non-fibrous structure having a three-dimensional shape, i.e., with a thickness, a length, and a width, while the length-to-thickness aspect ratio and the width-to-thickness aspect ratio are both at least 5:1, and the length-to width ratio is at least 1:1. Preferably, the length-to-thickness aspect ratio and the width-to thickness aspect ratio are both at least 10:1, more preferably at least 15:1, most preferably at least 20:1; and the length-to-width aspect ratio is preferably at least 1.2:1, more preferably at least 1.5:1, most preferably at least 1.:1, still more preferably 1.8:1.
The flexible solid laundry article is preferably porous and has a density preferably ranging from 0.050 g/cm³ about 0.4 g/cm³, preferably from 0.06 g/cm³, 0.3 g/cm³, more preferably from 0.07 g/cm³ to 0.2 g/cm³, most preferably from 0.08 grams/ cm³ to 0.15 cm³.
The flexible solid laundry article may comprise an area of print or embossed. Preferebly one or more of the sides of the flexible solid laundry article is printed or embossed. The area of print may cover the entire article or part thereof. The area of print may comprise a single colour or maybe comprise multiple colours, even three colours. The area of print may comprise pigments, dyes, bluing agents or mixtures thereof. The print may be present as a layer on the surface of the flexible solid laundry article or may at least partially penetrate into the article. The flexible solid laundry article when present in the form of a multilayer structure may comprise at least two sheet, or even at least three sheet, wherein the sheets are sealed together. The area of print may be present on one sheet, or on more than one sheet, e.g. on two sheets, or even on three sheets.
The area of print may be achieved using standard techniques, such as flexographic printing or inkjet printing. Preferably, the area of print is achieved via flexographic printing. The area of print may be on either side of the article. The area of print may be purely aesthetic or may provide useful information to the consumer.
The embossing is preferably formed using an embossing roller and a pressing roller which cooperate with each other to form embossing. Preferably the embossing roller includes embossing protrusion formed on the outer circumferential surface and the preferably the pressing roller includes an embossing groove corresponding to the embossing protrusion and the embossing groove is preferably formed on the outer circumferential surface thereof. Preferably the flexible solid laundry article comprises plurality of emboss.
The flexible solid laundry article may be opaque, transparent, or translucent.
Preferably the final moisture content of the flexible solid laundry article ranges from 0.5 wt.% to 15 wt.%, still preferably from 1 wt.% to 12 wt.%, still more preferably from 3 wt.% to 10 wt.% by weight of the article.
Preferably the flexible solid laundry article has a thickness ranging from 0.2 mm to about 4 mm, preferably 0.4 mm to about 3.5 mm, more preferably from 0.7 mm to about 3 mm, still more preferably from about 0.8 mm to about 2 mm, also preferably from 1 mm to about 1.5 mm.
Preferably the flexible solid laundry article has a basis weight ranging from 50 grams/m² to 250 grams/m², preferably from 80 grams/m² to 220 grams/m², still more preferably from 100 grams/m² to 200 grams/m².
Preferably the flexible solid laundry article has a density ranging 0.05 grams/cm³ to 0.5 grams/cm³, preferably from 0.06 grams/cm³ to 0.4 grams/cm³, still more preferably from 0.07 grams/cm³ to 0.2 grams/cm³, most preferably from 0.08 grams/cm³ to 0.15 grams/cm³.
Preferably the flexible solid laundry article comprises a perforation line or tear line or line on frangibility. The perforation line may be provided to separate measured unit dose portions. Alternately the flexible solid laundry article may include a first part and a second part separated by a perforation line or tear line or line on frangibility. Preferably the flexible article is a sheet. Preferably, the first part comprises a first cleaning composition and the second part comprises a second cleaning composition, wherein the first and the second compositions are different from each other. For example, the first composition may be a laundry cleaning composition whereas the second composition may be a fabric conditioning or fabric treatment composition. The sheet may be provided with more than two parts separated by perforation lines or tear lines. It may possible that each part has different colorant providing a visual cue to the consumers. Preferably each part can be separated by the perforation line or tear line and use thereon.

Water-soluble polymer

The flexible solid laundry article comprises a water-soluble polymer. The water-soluble polymer acts as carrier or matrix for the format. The term water-soluble herein refer to a solubility value of at least 0.5% by weight in distilled water at 25 °C.
The water-soluble polymer comprises a cellulose ether derivative. Preferably the cellulose ether derivative suitable for the invention are readily soluble in water at 25 °C. The term "readily soluble" herein implies that the polymer dissolves in water in room temperature thereby providing a visually clear or transparent solution, without leaving any lump in the solution. Visually clear or transparent herein, refers to a solution having a turbidity value less than 50 NTU (Nephelometric turbidity unit).
Typically, cellulose ether derivatives are obtained by substituting one or more hydrogen atoms of hydroxyl groups in the anhydro-glucose units of cellulose with alkyl or substituted alkyl groups. Degree of substitution (DS) is one of the factors, that define the properties of cellulose ether derivatives, particularly, solubility in water. It is defined as the number of substituted hydroxyl groups for every glucose molecule ranging between zero and three. For example, cellulose ether derivatives with degree of substitution values between 1.2 to 2.4 are soluble in cold water.
Examples of cellulose ether derivatives suitable for the present invention includes methyl cellulose, ethyl cellulose, ethyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxy ethyl methyl cellulose, hydroxypropyl methyl cellulose, ethyl hydroxy ethyl cellulose. Certain grade of sodium carboxy methyl cellulose that are readily soluble in water at 25 °C may also be useful for the present invention.
Preferably the cellulose ether derivative is selected from cellulose alkyl ether derivative or cellulose hydroxyalkyl ether derivative. Non-ionic cellulose ether derivatives, i.e., derivatives containing non-ionic functional group, such as, hydroxy, methoxy, ethoxy, hydroxyethyl, hydroxy propyl, di-hydroxy propyl and dihydroxy butyl, are preferable for the present invention. Preferably the cellulose ether derivative is selected form hydroxypropyl methyl cellulose, hydroxy ethyl cellulose, hydroxypropyl cellulose, and combinations thereof. Most preferred cellulose ether derivative is hydroxypropyl methyl cellulose.
Typically, pure cellulose is hardly soluble in distilled water, however it forms gel by absorbing water. Hence, it may not be used as carrier or matrix for the sheet format. Non limiting examples of the water-soluble polymers which may also present in the detergent sheet includes gelatine, and polysaccharide e.g., xanthan gum, guar gum, carrageenan gum in addition to the cellulose containing compound.
Preferably the amount of water-soluble polymer in the flexible solid laundry article detergent sheet is in the range 5 to 50% by weight, more preferably 7 to 45% by weight, even more preferably 9 to 40% by weight and most preferably 10 to 35% by weight of the flexible solid laundry article.
Conventionally, a water dissolvable cleaning product or articles comprises polyvinyl alcohol (PVA) or its copolymers, which are readily available and water-soluble substrate. However, the present invention may not contain PVA as water-soluble polymer. Preferably the flexible solid laundry article described herein is free of polyvinyl alcohol or its derivative. The flexible solid laundry article according to the present invention is free of polyvinyl alcohol or a copolymer of polyvinyl alcohol. The term 'free of' herein implies that the flexible solid laundry article comprises less than 5% by weight, more preferably 4% by weight, even more preferably 3% by weight yet more preferably 2% by weight and most preferably 1% by weight of polyvinyl alcohol and/or its derivative.

Water-insoluble disintegrant

The flexible solid laundry article comprises a water-insoluble disintegrant. The term water-insoluble herein refers to ingredient having solubility less than 0.5% by weight in distilled water at 25 °. Such ingredients often are not readily soluble in water at room temperature., i.e., around 25 °C, and leave residue when added to water.
Preferably the water-insoluble disintegrant is a swellable disintegrant. Swellable disintegrant herein refers to the components which swell in contact with water and thereby accelerate dissolution of the detergent sheet. Particularly, in the present invention swellable disintegrant is referring to one which has a water absorption ratio (WAR) of greater than 1. It is observed that the swellable disintegrant in specific amount accelerates the dissolution of the detergent sheet in water and provides a cleaning composition quickly.
Water Absorption Ratio (WAR) is a measure as to how much water a material absorbs under controlled and defined conditions. The process described in ASTM D570 is used in this application.
The water-insoluble disintegrant is preferably selected from microcrystalline cellulose, alkali metal salt of starch glycolate, croscarmellose, pregelatinized starch and combinations thereof. Most preferred swellable disintegrant is microcrystalline cellulose. Microcrystalline cellulose absorbs water and swells and has WAR value more than 5.
The flexible solid laundry article comprises from 3 to 25% by weight of the disintegrant. More preferably the flexible solid laundry article comprises from 4 to 24% by weight and most preferably from 5 to 23% by weight of the swellable disintegrant.
The flexible solid laundry article may further comprise a non-swellable disintegrant. Non-swellable disintegrant herein refer to those which have water absorption ratio (WAR) less than 1. Examples of non-swellable disintegrate includes polyvinyl pyrrolidone, calcium silicate, starch, magnesium stearate. The non-swellable disintegrant may present from 0 to 10% by weight of the more preferably from 0.5 to 8% by weight and most preferably from 1 to 5% by weight of the flexible solid laundry article.

Detersive surfactant

Preferably the flexible solid laundry article comprises a detersive surfactant in addition to the cleaning ingredient. The detersive surfactant may present in the flexible laundry article in an amount 5 to 60% by weight, more preferably 7 to 55% by weight and even more preferably 9 to 50% by weight and most preferably 10 to 45% by weight.

Anionic surfactant

Preferably the detersive surfactant is an anionic surfactant. The anionic surfactant is preferably a sulphonate surfactant. Preferably the sulphonate surfactant is an alkyl aryl sulphonate surfactant. More preferably the alkyl aryl sulphonate surfactant has a linear alkyl group comprising from C₁₀ to C₂₂ alkyl group, more preferably from C₁₀ to C₁₈ alkyl group, more preferably from C₁₀ to C₁₆ alkyl group still more preferably from C₁₀ to C₁₃ alkyl group. Sulphonate surfactant: Preferably the sulphonate surfactant is an alkyl benzene sulphonate surfactant. Preferably the alkyl chain in the alkyl benzene sulphonate is straight or branched, more preferably linear. Preferably the sulphonate surfactant is a linear alkyl benzene sulphonate with a C₁₀ to C₁₈ alkyl group, still preferably C₁₀ to C₁₄ alkyl group and most preferably C₁₀ to C₁₃ linear alkyl benzene sulphonate. Preferably the higher linear alkyl benzene sulfonate is a sodium alkylbenzene sulfonate surfactant (LAS), which preferably has a straight chain alkyl radical of average length of about 11 to 13 carbon atoms. Suitable alkyl benzene sulphonate (LAS) is obtainable, preferably obtained, by sulphonating commercially available linear alkyl benzene (LAB); suitable LAB includes low 2-phenyl LAB, other suitable LAB includes high 2-phenyl LAB, such as those supplied by Sasol under the tradename Hyblene^®.
Preferably C₁₀ to C₁₅ alkyl benzene sulfonates (LAS), still preferably C₁₀ to C₁₄ alkyl benzene sulfonates (LAS), still preferably the benzene sulfonate (LAS) has at least 50 wt.% of C₁₂ alkyl benzene sulfonate, still preferably 80 wt.% C₁₂ alkyl benzene sulfonates. The alkyl benzene sulphonate is preferably in the salt form with the cation selected from alkali metal, alkaline earth metal or alkanolamine. Preferably alkali metal selected from sodium or potassium, most preferably sodium. The key intermediate compound in the manufacture of LAS is the relevant alkene. These alkenes (olefins) may be produced by any of the methods described above and may be formed from primary sugars, biomass, waste plastic, MSW, carbon capture, methane capture, marine carbon to name a few. Whereas in the processed described above the olefin is processed to form linear alcohols by hydroformylation and oxidation instead, the olefin is reacted with benzene and then sulphonate to form the LAS.
Other suitable sulphonate surfactants include methyl ester sulphonates, alpha olefin sulphonates, modified alkylbenzene sulfonate (MLAS) as discussed in WO 99/05243 , WO 99/05242 and WO 99/05244 and mixtures thereof.
Preferably the detersive surfactant is an anionic sulphate surfactant. Suitable sulphate surfactants include alkyl sulphate, preferably C₈ to C₁₈ alkyl sulphate, or predominantly C₁₂ to C₁₈ alkyl sulphate. The alkyl sulphate, alkyl alkoxylated sulphate may be linear or branched, substituted or un-substituted. The alkyl sulphate, alkyl alkoxylated sulphate and alkyl benzene sulphonate surfactant may be derived from petrochemical material, biomaterial, or a waste material.
Specific sulphated anionic surfactants which can be used in the solid laundry composition of the present invention include sulphated ethoxylated and un-ethoxylated fatty alcohols, preferably linear primary or secondary monohydric alcohols with C₁₀ to C₁₈, preferably C₁₂ to C₁₆, alkyl groups and, if ethoxylated, on average from 1 to 15, preferably 3 to 12 moles of ethylene oxide (EO) per mole of alcohol, and sulphated ethoxylated alkylphenols with C₈ to C₁₆ alkyl groups, preferably C₈ to C₉ alkyl groups, and on average from 4 to 12 moles of EO per mole of alkyl phenol. A preferred sulphate detersive surfactant is alkyl alkoxylated sulphate, preferably alkyl ethoxylated sulphate, preferably a C₈ to C₁₈ alkyl alkoxylated sulphate, preferably a C₈ to C₁₈ alkyl ethoxylated sulphate, preferably the alkyl alkoxylated sulphate has an average degree of alkoxylation of from 0.5 to 20, preferably from 0.5 to 10, preferably the alkyl alkoxylated sulphate is a C₈ to C₁₈ alkyl ethoxylated sulphate having an average degree of ethoxylation of from 0.5 to 10, preferably from 0.5 to 5, more preferably from 0.5 to 3 and most preferably from 0.5 to 1.5.
Nonlimiting examples of sulphate anionic surfactants useful herein include: C₁₀ to C₂₀ primary, branched chain and random alkyl sulfates (AS); C₁₀ to C₁₈ secondary (2,3) alkyl sulfates; C₁₀ to C₁₈ alkyl alkoxy sulfates (AES) wherein x is from 1-30; mid-chain branched alkyl sulfates as discussed in US 6,020,303 and US 6,060,443 ; mid-chain branched alkyl alkoxy sulfates as discussed in US 6,008,181 and US 6,020,303 .
Preferably the anionic surfactant is C₁₀ to C₂₀ primary sulphate surfactant, preferably lauryl sulphate. Preferably sodium lauryl sulphate. Preferably the C₁₀ to C₂₀ primary sulphate surfactant is present in an amount ranging from 20 wt.% to 49 wt.% by weight of the flexible solid laundry article.
Anionic surfactants suitable for use in the compositions include alkyl and alkyl ether sulfates. These materials have the respective formulae ROSO3M and RO(C₂H₄O)_xSO₃M, wherein R is alkyl or alkenyl of from about 8 to about 18 carbon atoms, x is an integer having a value of from 1 to 10, and M is a cation such as ammonium, alkanolamines, such as triethanolamine, monovalent metals, such as sodium and potassium, and polyvalent metal cations, such as magnesium, and calcium. Preferably, R has from 8 to 18 carbon atoms, more preferably from 10 to 16 carbon atoms, even more preferably from 11 to 14 carbon atoms, in both the alkyl and alkyl ether sulfates. The alkyl ether sulfates are typically made as condensation products of ethylene oxide and monohydric alcohols having from about 8 to about 24 carbon atoms. The alcohols can be synthetic, or they can be derived from fats, e.g., coconut oil, palm kernel oil, tallow. Synthetic alcohols may include the grades available via Shell Chemical Co under the NEODOL trade name as NEODOL 91 (C9-11 alcohols), NEODOL 23 (C12-13 alcohols), NEODOL 25 (C12-15 alcohols), NEODOL 45 (C14-15 alcohols), and NEODOL 135 (C11-C13-C15 alcohols). Lauryl alcohol and straight chain alcohols derived from coconut oil or palm kernel oil are preferred. Such alcohols are reacted with between 0 and 10, preferably from 2 to 5, or preferably 3, molar proportions of ethylene oxide, and the resulting mixture of molecular species having, for example, an average of 3 moles of ethylene oxide per mole of alcohol, is sulfated and neutralized.

Amphoteric surfactant

Preferably the cleaning ingredient is an amphoteric surfactant. Examples of amphoteric surfactants suitable for use in the present invention include, but are not limited to, amphocarboxylates such as alkylamphoacetates (mono or di); alkyl betaines; alkylamidoalkyl betaines; alkylamidoalkyl sultaines; alkylamphophosphates; phosphorylated imidazolines such as phosphobetaines and pyrophosphobetaines; carboxyalkyl alkyl polyamines; alkyliminodipropionates; alkylamphoglycinates (mono or di); alkylamphoproprionates (mono or di); N-alkyl β-amino propionic acids; alkylpolyamino carboxylates; and mixtures thereof.
Preferably the amphoteric surfactant may be alkyl betaine. Examples include Coco-Betaine, Lauryl Betaine and Oleyl Betaine. Preferably the amphoteric surfactant may be an alkylamidoalkyl betaine. Examples includes Cocamidoethyl Betaine, Cocamidopropyl Betaine, Lauramidopropyl Betaine, Myristamidopropyl Betaine (RCO=myristoyl, and x=3), Soyamidopropyl Betaine, and Oleamidopropyl Betaine. Preferably the amphoteric surfactant is Cocamidopropyl Betaine (CAPB). The cocamidopropyl Betaine is commercially available from Rhone-Poulenc as Mirataine BDJ, Galaxy, Huntsman. Preferably the amphoteric surfactant may be alkyl phosphobetaine. Examples includes sodium Coco PG-Dimonium Chloride Phosphate. Preferably the amphoteric surfactant may be alkyl sulphobetaine or alkyl Hydroxysultaines Examples include Coco-hydroxysultaine and Lauryl hydroxysultaine. Preferably the amphoteric surfactant may be alkyl sultaines. Examples include Coco-sultaine and Lauryl sultaine. Preferably the amphoteric surfactant may be alkylamidoalkyl sultaines Examples include Cocamidopropyl sultaine, Lauramidopropyl sultaine, Myristamidopropyl sultaine, soyamidopropyl sultaine, and Oleamidopropyl sultaine. Preferably the amphoteric surfactant may be alkylamidoalkyl Hydroxysultaines. Examples include Cocoamidopropyl hydroxysultaine, Lauramidopropyl hydroxysultaine, Myristamidopropyl hydroxysultaine, and Oleamidopropyl hydroxysultaine.
Preferably the amphoteric surfactant may be alkyl amine oxide. Examples include cocamine oxide and lauramine oxide. The most preferred amine oxide is coco dimethylamine oxide. Preferably the amphoteric surfactant may be alkylamidoalkyl amine oxide. Examples include cocamidopropylamine oxide (RCO =coco acyl x =3) and lauramidopropylamine oxide (RCO= lauroyl, x =3), and combinations of two or more thereof.
Preferably the amphoteric surfactant is selected from the group consisting of betaines, sultaines, amine oxide, alkyl iminoacetates, imino dialkanoates, amino alkanoates alkyl ammonium propionates, or mixtures thereof. More preferably the amphoteric surfactant are betaines or amine oxide. Preferably the betaine amphoteric surfactant is selected from alkyl betaines, alkylamidoalkyl betaines, alkyl phosphobetaines, alkyl sulphobetaines and mixtures thereof. Preferably the amine oxide amphoteric surfactant is selected from alkyl amine oxide, alkylamidoalkyl amine oxide and mixtures thereof. More preferably the betaine type amphoteric surfactant is selected from alkyl betaines, alkylamidoalkyl betaines and alkyl sulphobetaines. Preferably the amine oxide type amphoteric surfactant is selected from alkyl amine oxide, alkylamidoalkyl amine oxide or mixtures thereof. Most preferably the amphoteric surfactant is a cocamidopropyl betaine (CAPB).
Preferably amphoteric surfactant is present in the flexible solid laundry article is in an amount ranging from 0.2 wt.% to 5 wt.% by weight of the article.
Preferably the cleaning ingredient is a mixture of amphoteric surfactant and a N-acylated lactam compound.

Nonionic alkoxylated surfactant

Preferably the non-ionic alkoxylated surfactant is selected from the group consisting of polyoxyethylene-polyoxypropylene block copolymer, or a mixture of polyoxyethylene-polyoxypropylene block copolymer and monomeric surfactant with an average degree of alkoxylation of from 10 to 50.
Preferably the nonionic alkoxylated surfactant is a polyoxyethylene-polyoxypropylene block copolymer selected from the group consisting of:

(i) a polyoxyethylene-polyoxypropylene block copolymer represented by the general formula (I)

R-(EO)_n-(PO)_m-(EO)_n-R' .............. Formula (I)

wherein m is an integer from 10 to 130, each n is independently an integer from 2 to 60; and where R and R' are each independently selected from the group consisting of H, OH, C₁ to C₁₈ alkyl or C₁ to C₁₈ hydroxyalkyl or,
(ii) a polyoxyethylene-polyoxypropylene block copolymer represented by the general formula (II)

R-(PO)_n-(EO)_m-(PO)_n-R' ............ Formula (II)

wherein m is an integer of 15 to 150 and n at each end are independently integers of about 2 to 60 and where R and R' are each independently selected from the group consisting of H, OH, C₁ to C₁₈ alkyl or C₁ to C₁₈ hydroxyalkyl; or,
(iii) a polyoxyethylene-polyoxypropylene block copolymer represented by the general formula (III)

R-(PO)_a-(EO)_b-(PO)_c-(EO)_d-(PO)_e-R' ..... Formula (III)

where EO is ethylene oxide unit and PO is propylene oxide unit and a, b, and c, d and e each represent the number of ethylene oxide or propylene oxide units in each of the blocks, and where R and R' are independently H, C₁ to C₁₈ alkyl, C₁ to C₁₈ hydroxyalkyl or mixtures thereof.

Preferably the monomeric nonionic alkoxylated surfactant with an average degree of alkoxylation of from 10 to 50 represented by the general formula (IV)

R¹-O-(CH₂-CHR⁵-O-) _r (CH₂-CH₂-O-) _n (CH₂-CHR⁶-O-) _s (CH₂-CHR²-O-) _m H ........ Formula (IV)

where, R¹ is linear or at least singly branched C₄ to C₂₂ alkyl or -alkylphenol, R² is C₃ to C₄ alkyl, preferably propyl, in particular n-propyl, R⁵ is C₁ to C₄ alkyl, R⁶ is methyl or ethyl, n has a mean value of from 10 to 50. m has a mean value of from 0 to 20, preferably m being at least 0.5 if R is methyl or ethyl or r has the value 0, r has a mean value of from 0 to 50, preferably 0 and, s has a mean value of from 0 to 50, preferably 0.
Also, preferably the monomeric nonionic alkoxylated surfactant with an average degree of alkoxylation of from 10 to 50 represented by the general formula (V)

R³-O-(CH₂-CH₂-O-) _p (CH₂-CHR⁴-O-) _q H ........ Formula (V)

where, R³ is branched or straight chain C₄ to C₂₂ alkyl or -alkylphenol, R⁴ is C₃ to C₄ alkyl, p has a mean value of from 10 to 50, and q has a mean value of from 0.5 to 20, preferably from 0.5 to 4, more preferably from 0.5 to 2.
Preferably nonionic alkoxylated surfactant is present in the flexible solid laundry article in an amount ranging from 0.2 wt.% to 5 wt.%. of the composition. Preferably the nonionic alkoxylated surfactant are those with Formula (I). Useful R- (EO)n-(PO)m-(EO)n -R' block copolymer described herein are commercially available under the tradename PLURONIC^® and includes the series PE 3100, PE 3500, PE 4300, PE 6100, PE 61200, PE 6200, PE 6400, PE 6800, PE 8100, PE 9200, PE 9400, PE 10100, PE 10400, PE 10500 more preferably PE6400, PE6800, PE9200, PE4300 15 and PE8100 (BASF SE). Preferably the cleaning ingredient is a mixture of R- (EO)n-(PO)m-(EO)n -R' block copolymer and CAPB.
Preferably the cleaning ingredient is a mixture of the polyoxyethylene-polyoxypropylene block copolymer and solid release polymer.
Preferably the cleaning ingredient is a mixture of amphoteric surfactant and a silicone surfactant.

Rhamnolipids

Preferably the solid laundry composition includes a rhamnolipid biosurfactant. Preferably the rhamnolipid is a mono-rhamnolipids, di-rhamnolipids or mixtures thereof. Preferably the mono-rhamnolipids has a single rhamnose sugar ring. Preferably the di-rhamnolipids have two rhamnose sugar rings.
In the case of rhamnolipids, throughout this patent specification, the prefixes mono- and di-are used to indicate respectively to indicate mono-rhamnolipids (having a single rhamnose sugar ring) and di-rhamnolipids (having two rhamnose sugar rings) respectively. If abbreviations are used Rha is mono-rhamnolipid and Rha2 is di-rhamnolipid.
The mono-rhamnolipid may be L-rhamnosyl-β-hydroxydecanoyl-β-hydroxydecanoate (Rha-C₁₀-C₁₀ with a formula of C₂₆H₄₈O₉) produced by P. aeruginosa.
A typical di-rhamnolipid is L-rhamnosyl-L-rhamnosyl- β -hydroxydecanoyl- β -hydroxydecanoate (Rha2C₁₀C₁₀ with a formula of C₃₂H₅₈O₁₃).
In practice a variety of other minor components with different alkyl chain length combinations, depending upon carbon source and bacterial strain, exist in combination with the above more common rhamnolipids. The ratio of mono-rhamnolipid and di-rhamnolipid may be controlled by the production method.
The following rhamnolipids are sources of mono- and di- rhamnolipids encompassed within the invention (C12:1, C14:1 indicates fatty acyl chains with double bonds): Rha-C₈-C₁₀, Rha-C₁₀-C₈, Rha-C₁₀-C₁₀, Rha-C₁₀-C₁₂, Rha-C₁₀-C_12:1, Rha-C₁₂-C₁₀, Rha-C_12:1-C₁₀, Rha-C₁₂-C₁₂, Rha-C_12:1-C₁₂, Rha-C₁₄-C₁₀, Rha-C_14:1-C₁₀, Rha2-C₈-C₁₀, Rha2-C₈-C_12:1, Rha2-C₁₀-C₈, Rha2-C₁₀-C₁₀, Rha2-C₁₀-C_12:1, Rha2-C₁₀-C₁₂, Rha2-C₁₂-C₁₀, Rha2-C_12:1-C₁₂, Rha2-C₁₀-C_14:1, Rha2-C₁₄-C₁₄ and mixtures thereof.
Preferably, the rhamnolipid comprises at least 50 wt.% di-rhamnolipid, more preferably at least 60 wt.% di-rhamnolipid, even more preferably 70 wt.% di-rhamnolipid, most preferably at least 80 wt.% di-rhamnolipid. Preferably the rhamnolipid is a di-rhamnolipid of formula: Rha2-C_8-12-C_8-12. The preferred alkyl chain length is from C₈ to C₁₂, the alkyl chain may be saturated or unsaturated. Preferably the solid laundry composition includes from 1 wt.% to 20 wt.% alkyl aryl sulphonate surfactant.

Surfactant combinations

Preferably the detersive surfactant includes a combination of one or more surfactant. Preferably the detersive surfactant includes a mixture of (i) a lauryl sulfate alkali metal salt (preferably sodium or potassium salt, most preferably sodium salt) and (ii) a heptaoxyethylated lauryl alcohol (LA7), a nonaoxyethylated lauryl alcohol (LA9) or a mixture thereof. Preferably, lauryl sulfate alkali metal salt (preferably sodium or potassium salt, most preferably sodium salt) is present as the main detersive surfactant and (b) a heptaoxyethylated lauryl alcohol (LA7), a nonaoxyethylated lauryl alcohol (LA9) as a co-surfactant.

Plasticizer

The flexible solid laundry article according to the present invention may preferably include a plasticizing agent. Preferably the plasticizing agent is water soluble. The water-soluble plasticizer can be included in the article at a level of from 0.1 wt.% to about 25 wt.% by weight of the article. Non -limiting examples of suitable plasticizing agents include polyols, copolyols, and polyesters. Examples of useful polyols include, but are not limited to, glycerin, di-glycerin, propylene glycol, ethylene glycol, butylene glycol, pentylene glycol, polyethylene glycol (200-600), polyhydric low molecular weight alcohols (e.g., C₂ to C₈ alcohols); mono di- and oligosaccharides such as fructose, glucose, sucrose, maltose, lactose, and high fructose corn syrup solids. More preferably the plasticizing agent is selected from the group consisting of glycerin, propylene glycol, ethylene glycol, polyethylene glycol and combinations thereof. More preferably, the plasticizing agent is glycerin. Preferably the plasticizer is not PVOH or copolymer of PVOH.

Bittering agent

The flexible solid laundry article may comprise an aversive agent, for example a bittering agent. Suitable bittering agent include but not limited to naringin, sucrose octa acetate, quinine hydrochloride, denatonium benzoate, or mixtures thereof. Any suitable level of aversive agent may be used in the flexible solid laundry article. Suitable levels include, but are limited to, 1 to 5000 ppm, or even 100 to 2500 ppm, or even 250 to 2000 ppm.

Graphene or derivative thereof

The flexible solid laundry article may comprise 0.01 to 1.0% by weight graphene or derivative thereof. Most common graphene derivatives are graphene oxide (GO) and reduced graphene oxide (rGO).
Graphene is an allotrope, formed by a single layer carbon atoms arranged in hexagonal lattice structure. It is reported that graphene or derivative thereof has good thermal and electrical conductivity, commonly used in various sector of electrical and electronics, e.g., semiconductor, communication, sensors, etc.
Graphene is hydrophobic and can be obtained in two manners. The first is by peeling layers from graphite until you achieve a graphene monolayer. The second is known as Chemical Vapor Deposition (CVD) and where large-scale uniformity can be obtained and controlled.
Preferably the graphene derivative suitable for the invention is graphene oxide. Graphene oxide (GO) is hydrophilic and can be manufactured through Hummer's method. One of the ways to prepare reduced graphene oxide (rGO) is by thermal and/or chemical reduction of graphene oxide. More details on graphene and derivative thereof may be found in literatures, e.g., " Review on graphene and its derivatives: Synthesis methods and potential industrial implementation" Lee et.al., Journal of the Taiwan Institute of Chemical Engineers, Volume 98, May 2019, Pages 163-180, Elsevier. Graphene oxide (GO) is also commercially available and may be procured from suppliers such as Platonic Nanotech.
Preferably the flexible solid laundry article comprises 0.01 to 0.8% by weight, more preferably comprises 0.02 to 0.8% by weight, furthermore preferably 0.05 to 0.7% by weight, yet more preferably 0.08 to 0.6% by weight and most preferably 0.09 to 0.5% by weight of the graphene or derivative thereof.

Slip additive

The flexible solid laundry article may further comprise 1.0 to 10% by weight of a slip additive. Without bound by the theory, it is believed that slip additive reduces the coefficient of friction on the surfaces the flexible solid laundry article, thus helps providing non-sticky films.
Preferably The flexible solid laundry article comprises 1.0 to 8% by weight, more preferably 1.0 to 7% by weight, even more preferably 1.0 to 6% by weight, furthermore preferably 1.0 to 5% by weight, yet more preferably 1.0 to 4% by weight and most preferably 1.0 to 3% by weight of the slip additive.
Preferably, the slip additive comprises a fatty acid amide. Preferably the slip additive comprises fatty acid amide with 10 to 30 carbon atoms, more preferably 11 to 28 carbon atoms, even more preferably 12 to 26 and yet more preferably 12 to 24 and most preferably 12 to 22 carbon atoms. Preferably, the fatty acid amide is saturated or unsaturated. Where it is unsaturated it is preferred that it is mono- or di-, more preferably mono-unsaturated.
Most preferred slip additives include stearamide, erucamide and oleamide and mixture thereof.
Most preferred slip additives are C18 to C22 mono-unsaturated fatty acid amides and which includes erucamide and oleamide.

Sequestrant

the flexible solid laundry article may comprise a sequestrant. Preferably the sequestrant is selected from organic detergent builders or sequestrant materials. Examples of such sequestrants include the alkali metal, citrates, succinates, malonates, carboxymethyl succinates, carboxylates, polycarboxylates and poly acetyl carboxylates. Specific examples include sodium, potassium, and lithium salts of oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids, and citric acid. Other examples are DEQUEST^™, organic phosphonate type sequestering agents sold by Monsanto and alkanehydroxy phosphonates.
Other suitable organic builders/sequestrants include the higher molecular weight polymers and copolymers known to have builder properties. For example, such materials include appropriate polyacrylic acid, polymaleic acid, and polyacrylic/polymaleic acid copolymers and their salts, for example those sold by BASF under the name SOKALAN^™. A preferred sequestrant is Dequest^® 2066 (Diethylenetriamine penta(methylene phosphonic acid) or Heptasodium DTPMP). Other suitable sequestrant is HEDP (1 -Hydroxyethylidene -1,1, -diphosphonic acid), for example sold as Dequest 2010.
Preferably the sequestrant is selected from amino-phosphonic acid, phosphonic acid, amino carboxylic acid, and salts thereof. Preferably the sequestrant is selected from Diethylenetriamine penta (methylene phosphonic acid- heptasodium salt (DTPMPA), 1-Hydroxyethylidene 1,1-diphosphonic acid (HEDP), Trisodium salt of Methylglycinediacetic acid (MGDA), N, N-Dicarboxymethyl glutamic acid tetrasodium salt (GLDA) and combinations thereof. Most preferred sequestrant is diethylenetriamine penta (methylene phosphonic acidheptasodium salt (DTPMPA) and/or 1-hydroxyethylidene 1,1-diphosphonic acid (HEDP).
The flexible solid laundry article preferably comprises 0.1 to 10% by weight, more preferably 0.2 to 9% by weight, even more preferably 0.3 to 8% by weight and most preferably 0.4 to 7 % by weight of the sequestrant.

Perfume

According to the present invention the flexible solid laundry article preferably comprises a perfume.
Preferably the perfume is in the form of free perfume. By free perfume is meant perfume which is not encapsulated as part of a delayed or controlled release mechanism. Preferably the free perfume comprises ester perfume component having the structure where R₁ and R₂ are independently selected from C₁ to C₃₀ linear or branched, cyclic or non-cyclic, aromatic, or nonaromatic, saturated or unsaturated, substituted, or unsubstituted alkyl group. It is also preferred that the free perfume is selected from those having a functional group selected from aldehyde, carboxylic acid, and mixtures thereof. The aldehyde may be aliphatic, cycloaliphatic, aromatic, araliphatic and mixtures thereof. The term aldehyde in the context of the free perfume also includes the corresponding acetals, ester, and lactones. The esters include the aliphatic carboxylic acid esters, esters of cyclic alcohols, esters of cycloaliphatic carboxylic acids, aromatic and araliphatic carboxylic acid esters.
Preferably, the perfume comprises a component selected from the group consisting of ethyl-2-methyl valerate (manzanate), limonene, (4Z)-cyclopentadec-4-en-1-one, dihyromyrcenol, dimethyl benzyl carbonate acetate, benzyl acetate, spiro[1,3-dioxolane-2,5'-(4',4',8',8'-tetramethyl-hexahydro-3',9'-methanonaphthalene)], benzyl acetate, Rose Oxide, geraniol, methyl nonyl acetaldehyde, decanal, octanal, undecanal, verdyl acetate, tert-butylcyclohexyl acetate, cyclamal, beta ionone, hexyl salicylate, tonalid, phenafleur, octahydrotetramethyl acetophenone (OTNE), the benzene, toluene, xylene (BTX) feedstock class such as 2-phenyl ethanol, phenoxanol and mixtures thereof, the cyclododecanone feedstock class, such as habolonolide, the phenolics feedstock class such as hexyl salicylate, the C5 blocks or oxygen containing heterocycle moiety feedstock class such as gamma decalactone, methyl dihydrojasmonate and mixtures thereof, the terpenes feedstock class such as dihydromycernol, linalool, terpinolene, camphor, citronellol and mixtures thereof, the alkyl alcohols feedstock class such as ethyl-2-methylbutyrate, the diacids feedstock class such as ethylene brassylate, and mixtures of these components.
Preferably the perfume is selected from the group consisting of geraniol, phenafleur, cyclamal, betaionone, verdyl acetate dimethylbenzyl carbinol acetate, dihydromrycenol, limonene, oxazolidine compound, silicic acid ester and diricinoleates or combinations thereof.
Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15wt.% and especially preferably from 6 to 10% wt. of the perfume component ethyl-2-methyl valerate (manzanate). Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15 wt.% and especially preferably from 6 to 10% wt. of the perfume component limonene. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component (4Z)-cyclopentadec-4-en-1-one. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component dimethyl benzyl carbonate acetate. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component dihyromyrcenol. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component rose oxide. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component tert-butylcyclohexyl acetate.
Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component verdyl acetate. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component benzyl acetate. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component spiro[1,3-dioxolane-2,5'-(4',4',8',8'-tetramethyl-hexahydro-3',9'-methanonaphthalene)]. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component geraniol. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component methyl nonyl acetaldehyde. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15% and especially preferably from 6 to 10% wt. of the perfume component cyclamal.
Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15wt.% and especially preferably from 6 to 10% wt. of the perfume component beta ionone. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15wt.% and especially preferably from 6 to 10% wt. of the perfume component hexyl salicylate. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15wt.% and especially preferably from 6 to 10% wt. of the perfume component tonalid. Preferably, the perfume comprises from 0.5 to 30% wt., more preferably from 2 to 15wt.% and especially preferably from 6 to 10% wt. of the perfume component phenafleur. Preferably, the perfume comprises a component selected from the benzene, toluene, xylene (BTX) feedstock class. More preferably, the perfume component is selected from 2-phenyl ethanol, phenoxanol and mixtures thereof. Preferably, the perfume comprises a component selected from the cyclododecanone feedstock class. More preferably, the perfume component is habolonolide. Preferably, the perfume comprises a component selected from the phenolics feedstock class. More preferably, the perfume component is hexyl salicylate. Preferably, the perfume comprises a component selected from the C5 blocks or oxygen containing heterocycle moiety feedstock class. More preferably, the perfume component is selected from gamma decalactone, methyl dihydrojasmonate and mixtures thereof. Preferably, the perfume comprises a component selected from the terpene feedstock class. More preferably, the perfume component is selected from, linalool, terpinolene, camphor, citronellol and mixtures thereof.
Preferably, the perfume comprises a component selected from the alkyl alcohols feedstock class. More preferably, the perfume component is ethyl-2-methylbutyrate. Preferably, the perfume comprises a component selected from the diacids feedstock class. More preferably, the perfume component is ethylene brassylate.
Preferably, the perfume component listed above is present in the final detergent composition at from 0.0001 to 1% by wt. of the composition.
Preferably the free perfume may be in the form of a perfume oil. The perfume oil is preferably selected from the group of extracts from natural raw materials, such as essential oils, concentrates, absolutes, resins, resinoids, balsams, tinctures, and mixtures thereof.

Encapsulated perfume

Preferably the perfume is in the form of encapsulated perfume. Typically, the encapsulated perfume comprises 10 wt.% to 98 wt.% core material comprising perfume, 1 wt.% to 40 wt.% wall material and optionally 0.2 wt.% to 6 wt.% crosslinking agent.
Preferably the encapsulated perfume has at least one perfume encapsulated in an amine-aldehyde resin. More preferably the amine-aldehyde resin is melamine-formaldehyde. The amine-aldehyde resin may be crosslinked with known crosslinking agents, including but not limited to gelatine. It is also preferred that the encapsulated perfume has an encapsulation material which is an amine group-bearing polysiloxanes crosslinked by polyisocyanates. Another preferred approach is to have encapsulated perfume with silicate walls derived from alkoxysilanes. The amine-aldehyde resin wall material may be preferably strengthened by inorganic materials such as oxides. Preferably the encapsulated perfume is a starch-based capsule.
The encapsulated perfume may be microcapsules. Generally, microcapsules comprise a shell material and a core material, said shell material encapsulating said core material said core material comprising a perfume composition. Preferably the flexible solid laundry article comprises from 0.1 wt.% to 20 wt.% perfume by weight of the flexible laundry article.
The wall material or shell of the encapsulated perfume may be selected from the group consisting of polyethylenes; polysiloxanes, polyamide, polyamides; polystyrenes; polyisoprenes; polycarbonates; polyesters; polyacrylates; aminoplasts, in one aspect said aminoplast comprises a polyureas, polyurethane, and/or polyureaurethane, in one aspect said polyurea comprises polyoxymethyleneurea and/or melamine formaldehyde; polyvinylamine, polyvinyl formamide, polyolefins; polyvinyl alcohol, polysaccharides, in one aspect alginate and/or chitosan; gelatin; shellac; epoxy resins; vinyl polymers; water insoluble inorganics; silicone; and mixtures thereof. The shell material is also preferably selected from polysiloxanes, polyanhydride, polysulfone, polysaccharide, protein, polylactide (PLA), polyglycolide (PGA), polyorthoester, polyphosphazene, lipid, modified cellulose, gums, polystyrene, and polyesters or combinations of these materials. Other polymeric wall materials that are functional are ethylene maleic anhydride copolymer, styrene maleic anhydride copolymer, ethylene vinyl acetate copolymer, and lactide glycolide copolymer. The micro encapsule may have a volume weighted mean particle size from microns to 45 microns more preferably from g microns to 25 microns, or alternatively a volume weighted mean particle size from 25 microns to 60 microns, more preferably from 25 microns to 60 microns. Preferably the shell comprises melamine formaldehyde and/or cross-linked melamine formaldehyde.
Preferably the shell material may be coated. Preferably the coating may be cationic, nonionic, or anionic. Preferably the coating is a water-soluble cationic polymer selected from the group consisting of polysaccharides, cationically modified starch and cationically modified guar, polysiloxanes, dimethyl diallyl ammonium polyhalogenides, copolymers dimethyl diallyl ammonium polychloride and vinyl pyrrolidone, acrylamides, imidazoles, imidazolinium halogenides and imidazolium halogenides and polyvinyl amine and its copolymers with N-vinyl formamide. In one example, the coating that coats said shell, comprises a cationic polymer and an anionic polymer. In another example. said cationic polymer comprises hydroxyl ethyl cellulose; and said anionic polymer comprises carboxyl methyl cellulose.
Microcapsules of the current invention are preferably 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 (i.e., laundry washing and laundry rinsing). Among the most stable are polyoxymethyleneurea (PMU)-based materials, which include but are not limited to urea-formaldehyde and/or melamine-formaldehyde. Similarly, if a shell is temperature sensitive, a microcapsule might release perfume in response to elevated temperatures. Microcapsules may also release perfume in response to shear forces applied to the surface of the microcapsules.
Bioencapsulated perfume : Preferably the encapsulated perfume is bio(micro)encapsulated perfume. Biopolymers that are derived from alginate, chitosan, collagen, dextran, gelatin, gum arabic, silk and starch can also be used as the encapsulating materials. The wall material or shell material of these microcapsules preferably includes biopolymers, more preferably the shell material comprises protein polymers, polysaccharide polymers and combinations thereof. The protein and/or polysaccharide may be treated by various processes to provide derivatives, including but not limited to hydrolysis, condensation, functionalizing such as ethoxylating, crosslinking, etc. The microcapsule wall materials are preferably in an aqueous solution. The microcapsule wall preferably comprises 20 wt.% to 100 wt.% protein, polysaccharide, or combinations thereof, more preferably 30 wt.% to 98 wt.%, more preferably 35 wt.% to 95 wt.%, and most preferably 65 wt.% to 90 wt.% by weight of the microcapsule wall.
The polypeptide may exhibit an average molecular weight of from 1,000 Da to 40,000,000 Da, preferably greater than 10,000 Da, more preferably, 100,000 Da, most preferably greater than 1,000,000 Da and preferably less than 3,000,000 Da. The protein used in the microcapsule can also be derivatized or modified (e.g., derivatized or chemically modified). For example, the protein can be modified by covalently attaching sugars, lipids, cofactors, peptides, or other chemical groups including phosphate, acetate, methyl, and other natural or unnatural molecule. Suitable proteins for use in this invention include whey proteins, plant proteins and gelatin. Particularly preferred proteins include proteins selected from chickpea, pea proteins, potato proteins, brown rice proteins, white rice proteins, wheat proteins, barley proteins, pumpkin seed proteins, oat proteins, almond proteins, and combinations thereof. This includes derivatives of the aforementioned proteins.
Preferably the shell material of the microcapsules is a polysaccharide polymer. "Polysaccharide" as used herein means a natural polysaccharide, polysaccharide derivative, and/or modified polysaccharide. Suitable polysaccharides maybe selected from the group consisting of fibers, starch, sugar alcohols, sugars, and mixtures thereof.
Examples of suitable fibers include: particular cellulose, cellulose derivatives such as hydroxyethyl cellulose, in particular quaternized hydroxyethyl cellulose, carboxymethylcellulose (CMC) and microcrystalline cellulose (MCC), hemicelluloses, lichenin, chitin, chitosan, lignin, xanthan, plant fibers, in particular cereal fibers, potato fibers, apple fibers, citrus fibers, bamboo fibers, extracted sugar beet fibers; oat fibers and soluble dietary fibers, in particular inulin, especially native inulin, highly soluble inulin, granulated inulin, high performance inulin, pectins, alginates, agar, carrageenan, gum arabic (Senegal type, Seyal type), konjac gum, gellan gum, curdlan (paramylon), guar gum, locust bean gum, xanthan gum, raffinose, xylose, polydextrose and lactulose and combinations thereof. This includes derivatives of the aforementioned polysaccharides. Particularly preferred polysaccharides include gum Arabic, dextrins and maltodextrins are particularly preferred. The polysaccharide used in the microcapsule can also be derivatized or modified (e.g., derivatized or chemically modified). For example, the protein can be modified by covalently attaching sugars, lipids, cofactors, peptides, or other chemical groups including phosphate, acetate, methyl, and other natural or unnatural molecule. Examples of suitable polysaccharide derivatives include starch glycolate, carboxymethyl starch, hydroxyalkyl cellulose and cross-linked modified cellulose.
Polymeric microcapsules suitable for use in the invention will generally have an average particle size between 100 nanometers and 50 microns. Particles larger than this are entering the visible range. Examples of particles in the sub-micron range include latexes and mini-emulsions with a typical size range of 100 to 600 nanometers. The preferred particle size range is in the micron range. Examples of microcapsules in the micron range include polymeric core-shell microcapsules (such as those further described above) with a typical size range of 1 to 50 microns, preferably 5 to 30 microns. The average particle size can be determined by light scattering using a Malvern Mastersizer with the average 20 particle size being taken as the median particle size D (0.5) value. The particle size distribution can be narrow, broad, or multimodal. If necessary, the microcapsules as initially produced may be filtered or screened to produce a product of greater size uniformity. The microcapsule preferably comprises from 0.1 wt.% to 30 wt.% microcapsule wall, preferably 0.5 wt.% to 25 wt.%, more preferably 1 wt.% to 20 wt.% and 2 wt.% to 15 wt.% microcapsule wall by weight of the microcapsule.
Crosslinking agent: The microcapsule wall polymers described herein are preferably crosslinked. Suitable methods of crosslinking include isocyanate crosslinking, salt bridge cross linking, carbonyl cross linking and internal crosslinking within the microcapsule wall polymer structures (including the formation of a coacervate). Examples of carbonyl crosslinking agent includes dialdehydes such as glutaric dialdehyde, succinic dialdehyde; bis(dimethyl) acetal, bis(diethyl) acetal, polymeric dialdehyde such as oxidized starch. Also preferred are low molecular weight difunctional aldehyde such as 1,3 propane dialdehyde, 1,4 butane dialdehyde, glyoxal, 1,5 pentane dialdehyde and 1,6 hexane dialdehyde. An alternative crosslink agent suitable for use in the present invention are ionic crosslinking agents. Ionic crosslinking agents are multivalent ions which are capable of forming salt bridges with the functional groups of the protein or polysaccharide polymers. Particularly preferred are calcium salts, magnesium, sodium, potassium, strontium, barium, zinc. Internal cross linking is cross linking between the microcapsule wall polymers, without the use of a crosslinking agent. The internal crosslinking maybe crosslinking with the same polymer (i.e., a polymer with both positive and negative charges) or between two different polymers forming the microcapsule wall. When two different polymers of opposite charges are utilised, this is referred to as a coacervate formed by coacervation. Preferably a coacervate is formed between a first protein or polysaccharide of one charge and a second protein or polysaccharide of an opposite charge. The ratio between polymer with a positive charge and polymer with a negative charge is preferably between 10/0.1 to 0.1/10, more preferably between 10/1 and 1/10 and most preferably between 6/1 and 1/6.
Perfume core material: Perfume components are well known in the art. Useful perfume components may include materials of both natural and synthetic origin. They include single compounds and mixtures. Specific examples of such components may be found in the current literature, e.g., in Fenaroli's Handbook of Flavor Ingredients, 1975, CRC Press; Synthetic Food Adjuncts, 1947 by M. B. Jacobs, edited by Van Nostrand; or Perfume and Flavor Chemicals by S. Arctander 1969, Montclair, N.J. (USA). These substances are well known to the person skilled in the art of perfuming, flavouring, and/or aromatizing consumer products. Particularly preferred perfume components are blooming perfume components and substantive perfume components. Perfume perfume components are defined by a boiling point less than 250°C and a LogP greater than 2.5. Preferably encapsulated perfume compositions comprise at least 20 wt.% blooming perfume ingredients, more preferably at least 30 wt.% and most preferably at least 40 wt.% blooming perfume ingredients. Substantive perfume components are defined by a boiling point greater than 250°C and a LogP greater than 2.5. Preferably encapsulated perfume compositions comprise at least 10 wt.% substantive perfume ingredients, more preferably at least 20 wt.% and most preferably at least 30 wt.% substantive perfume ingredients. Boiling point is measured at standard pressure (760 mm Hg). Preferably a perfume composition will comprise a mixture of blooming and substantive perfume components. The perfume composition may comprise other perfume components. It is commonplace for a plurality of perfume components to be present in a microcapsule. In the compositions for use in the present invention it is envisaged that there will be three or more, preferably four or more, more preferably five or more, most preferably six or more different perfume components in a microcapsule. An upper limit of 300 perfume components may be applied.
Preferably the amount of encapsulated perfume is from 5 wt.% to 95 wt.%, preferably 10 wt.% to 90 wt.% more preferably 15 wt.% to 85 wt.%, and most 20 wt.% to 80 wt.% by weight of the microcapsule.
Deposition aid: Polymeric microcapsules suitable for use in the invention may be provided with a deposition aid at the outer surface of the microcapsules. Deposition aids serve to modify the properties of the exterior of the microcapsule, for example to make the microcapsule more substantive to a desired substrate. Desired substrates include cellulosics (including cotton) and polyesters (including those employed in the manufacture of polyester fabrics). The deposition aid may suitably be provided at the outer surface of the microparticle by means of covalent bonding, entanglement, or strong adsorption. Examples include polymeric core-shell microcapsules (such as those further described above) in which a deposition aid is attached to the outside of the shell, preferably by means of covalent bonding. While it is preferred that the deposition aid is attached directly to the outside of the shell, it may also be attached via a linking species. Deposition aids for use in the invention will generally have a weight average molecular weight (M_w) in the range of from about 5 kDa to about 500 kDa, preferably from about 10 kDa to about 500 kDa and more preferably from about 20 kDa to about 300 kDa.
Deposition aids for use in the invention may suitably be selected from polysaccharides having an affinity for cellulose. Such polysaccharides may be naturally occurring or synthetic and may have an intrinsic affinity for cellulose or may have been derivatized or otherwise modified to have an affinity for cellulose. Suitable polysaccharides have a 1-4 linked (β glycan (generalized sugar) backbone structure with at least 4, and preferably at least backbone residues which are (β 1-4 linked, such as a glucan backbone (consisting of (β 1-4 linked glucose residues), a mannan backbone (consisting of β 1-4 linked mannose residues) or a xylan backbone (consisting of (β 1-4 linked xylose residues) Examples of such (β 1-4 linked polysaccharides include xyloglucans, glucomannans, mannans, galactomannans, (β (1-3),(1-4) glucan and the xylan family incorporating glucurono-, arabino- and glucuronoarabinoxylans. Preferred (β 1-4 linked polysaccharides for use in the invention may be selected from xyloglucans which has a β 1-4 linked glucan backbone with side chains of a-D xylopyranose and (β -D-galactopyranosyl-(1-2)- α -D-xylo-pyranose, both 1-6 linked to the backbone), and galactomannans such as locust bean gum (LBG) (which has a mannan backbone of β 1-4 linked mannose residues, with single unit 20 galactose side chains linked α1-6 to the backbone). Also suitable are polysaccharides which may gain an affinity for cellulose upon hydrolysis, such as cellulose mono-acetate; or modified polysaccharides with an affinity for cellulose such as hydroxypropyl cellulose, hydroxypropyl methylcellulose, hydroxyethyl methylcellulose, hydroxypropyl guar, hydroxyethyl ethylcellulose, and methylcellulose.
Deposition aids for use in the invention may also be selected from phthalate containing polymers having an affinity for polyester. Such phthalate containing polymers may have one or more nonionic hydrophilic segments comprising oxyalkylene groups (such as oxyethylene, polyoxyethylene, oxypropylene or polyoxypropylene groups), and one or more hydrophobic segments comprising terephthalate groups. Typically, the oxyalkylene groups will have a degree of polymerization of from 1 to about 400, preferably from 100 to about 350, more preferably from 200 to about 300. A suitable example of a phthalate containing polymer of this type is a copolymer having random blocks of ethylene terephthalate and polyethylene oxide terephthalate. Preferably the deposition aid may be a deposition protein, e.g., a protein-silanol copolymer, a protein-silane copolymer, a protein-siloxane copolymer, or a cationically modified protein, is provided. More preferably, any deposition aid used is biodegradable according to the OECD Standard 301F.
Mixtures of any of the above-described materials may also be suitable.
Preferably the encapsulated perfume includes a capsule formation aid. The capsule formation aid improves the performance. The capsule formation aid may be a surfactant, dispersant, protective colloid, or emulsifier. The concentration of the capsule formation aid varies from 0.1 wt.% to 5 wt.% by weight of the capsule composition.
The encapsulated perfume may include a catalyst. A catalyst is added to induce the interfacial polymerization in the formation of the capsule wall. Preferred examples include metal carbonate, metal hydroxide, amino or organometallic compounds which includes sodium carbonate, cesium carbonate, potassium carbonate, lithium hydroxide, 1,4-diazabicyclo (2.2.2) octane (i.e., DABCO), N, N-dimethylaminoethanol, N, N-dimethylcyclohexylamine, bis-(2-dimethylaminoethyl) ether, N, N dimethylacetylamine, stannous octoate, and dibutyltin dilaurate.
One example of a particularly preferred polymeric core-shell microcapsule for use in the invention is an aminoplast microcapsule with a shell formed by the polycondensation of melamine with formaldehyde; surrounding a core containing the perfume formulation; in which a deposition aid is preferably attached to the outside of the shell by means of covalent bonding. The preferred deposition aid is selected from β 1-4 linked polysaccharides, and in particular the xyloglucans of plant origin, as are further described above.
The microcapsules may be friable or soluble in the wash liquor. Friable microcapsules survive the washing process intact and are deposited onto the fabric where they remain until the fabric garment is dried and prepared for re-wear. On wearing or handled, the friable capsules are prone to breakage thus releasing the perfume (or perfume, the terms are used interchangeably). "Friability' refers to the propensity of the microcapsules to rupture or break open when subjected to direct external pressures or shear forces. Soluble microcapsules dissolve during the washing process and release their contents, whether perfume or other benefit agent such as lipase or other enzyme during the washing process. Of course, the composition may contain a combination of microcapsules whether differing in size or performance to tailor the delivery of any contained benefit agent. Friable perfume microcapsules are distinguished from moisture-activated microcapsules such as those microcapsules comprising mostly of cyclodextrin.
The microcapsules may be provided simply as microcapsules but preferably are provided in a microcapsule composition comprising microcapsules in a slurry. The microcapsules comprise a microcapsule core comprising an active ingredient and microcapsule wall encapsulating the core. The microcapsule wall comprises a wall polymer and preferably a crosslinking agent.
Preferably the microencapsulated perfume may be present in a composition comprising the microencapsulated perfume, preferably coated with a deposition aid along with a free perfume.
Preferably the perfume is post-dosed that is after the formation of the flexible laundry article. Alternately the perfume may be added to the wet pre-mixture before the solidication of the pre-mixture to form the flexible solid laundry article. Also preferred are the addition of the perfume in both the post-dosed and along with the wet pre-mixture. If the flexible solid laundry article comprises a step of embossing then the perfume is preferably added after the embossing.

Process for preparing the flexible solid laundry article

The process for forming the flexible solid laundry article according to an aspect of the present invention involves the steps of preparing a pre-mixture of ingredients, preferably homogeneous pre-mixture is vigorously aerated to form an aerated pre-mixture, subsequently the pre-mixture is subject to solidification to form a flexible solid laundry article. Preferably the solidification is by heat drying by a batch process. (e.g., in a convection oven or a microwave oven) or by slow heating on a conveyer. Process like continuous drying (e.g., using an impingement oven) is also within the scope of the present invention. Preferably the flexible solid laundry article porous. Preferably the pores formed across different regions of the flexible laundry detergent article is uniform.
The flexible solid laundry article of the present invention is formed from a wet pre-mixture comprising the water-soluble polymer, the water-insoluble disintegrant and the cleaning ingredient.
The flexible solid laundry article according to the present invention is preferably prepared by a process which involves the following steps:

(i) dissolving or dispersing the water-soluble polymer comprising a cellulose ether derivative, water insoluble disintegrant in an aqueous medium or a suitable solvent to form a wet pre-mixture;
(ii) dosing the homogeneous wet pre-mixture in a laminar form onto a moving support to form a continuous sheet having opposing first side and second side;
(iii) drying the sheet to form a flexible solid sheet;
(iv) detaching the solid sheet from the moving support;
(v) optionally cutting the continuous flexible solid sheet into a desired size to form a flexible solid laundry article;
(vi) optionally packaging the formed flexible solid laundry article.

The process for preparing the flexible solid laundry article according to the present invention involves the below described steps which includes:

Preparing a homogeneous wet pre-mixture

The first step involves mixing the water-soluble polymer comprising a cellulose ether derivative, the water insoluble disintegrant, the cleaning ingredient, and other preferred ingredients described hereinabove in an aqueous medium or a suitable solvent to form a wet pre-mixture. Preferably the wet pre-mixture is a homogeneous mixture The wet pre-mixture may be mixed using any mixing means known to a person skilled in the art including but not limited to a mechanical mixer. Preferably when mixing the mixture may be maintained at a temperature of 20°C to 90°C, more preferably 30°C to 90°C, even more preferably 40°C to 90°C and most preferably from 50°C to 80°C.
Preferably the wet pre-mixture has a viscosity ranging from 1000 cps to 25,000 cps when measured at 40°C at 1sec^-1, more preferably from 3000 cps to 24,000 cps, even more preferably from 5000 cps to 23,000 cps, still more preferably from 10,000 cps to 20,000 cps when measured at 40°C at 1sec^-1.
The wet pre-mix may have a viscosity such that is suitable to cast on a surface to form a thin layer or cast on a mold to form an article. The liquid premix may have a viscosity in the range 10 to 2000 mPa.S, more preferably 15 to 1500 mPa.S, even more preferably 20 to 1000 mPa.S and most preferably 25 to 500 mPa.S at 20 S^-1 shear rate and 25 °C.
Preferably the solid content in the wet pre-mixture or homogeneous wet pre-mixture ranges from 15 wt.% to 70 wt.%, still preferably from 20 wt.% to 50 wt.%, still further preferably from 25 wt.% to 45 wt.% by total weight of the wet pre-mixture. By solid content it is meant to include solid ingredient, semi-solid ingredient and other liquid ingredient excluding water and volatile material when added to form the premix.
Preferably the wet pre-mixture comprises surfactant. Other preferred ingredient in the wet pre-mixture mixture includes plasticizers and laundry benefit agents.

Aeration of wet pre-mixture

Preferably the process for preparing the flexible solid laundry article involves a step of aeration. The term "aerate", "aerating" or "aeration" as used herein refers to a process of introducing a gas by mechanical and/or chemical means. Preferably the wet pre-mixture, preferably a homogeneous wet pre-mixture is aerated by introducing a gas into the wet pre-mixture.
Preferably the wet pre-mixture is pre-heated immediately prior to and/or during the aeration process at above ambient temperature but below any temperature that would cause degradation of the components therein. Preferably the wet pre-mixture is kept at temperature ranging from 40°C to about 100°C, preferably from 50°C to 95°C, more preferably from 60°C to 90°C, most preferably from 75°C to 85°C. Aeration step introduces air bubbles into the wet pre-mixture which upon drying forms open pores in the flexible solid laundry article.
Preferably, the aerated wet pre-mixture has a density ranging from about 0.05 g/mL to about 0. 5 g/ mL, preferably from about 0.08 g/ mL to about 0.4 g/ mL, more preferably from about 0.1 g/ mL to about 0.35 g/mL, still more preferably from about 0.15 g/ml to about 0.3 g/mL, most preferably from about 0.2 g/ mL to about 0.25 g/mL.
Preferably aeration is by introducing a gas into the wet pre-mixture through mechanical agitation, for example, by using any suitable mechanical processing means, including but not limited to: a rotor stator mixer, a planetary mixer, a pressurized mixer, a non-pressurized mixer, a batch mixer, a continuous mixer, a semi-continuous mixer, a high shear mixer, a low shear mixer, a submerged sparger, a continuous pressurized mixer, or any combinations thereof. Yet another method of introducing air into the wet pre-mixture is via chemical means, for example, by using chemical foaming agents to provide in-situ gas formation via chemical reaction of one or more ingredients, including formation of carbon dioxide (CO₂ gas) by an effervescent system.
Preferably the bubble size of the aerated wet pre-mixture, preferably a homogeneous aerated wet pre-mixture ranges from 5 to 500 micrometers, more preferably from 10 to 200 micrometers, even more preferably 20 to 150 micrometers and most preferably 20 to 100 micrometers. Preferably the pores formed across different regions of the flexible solid laundry article is uniform.
Preferably the homogeneous wet pre-mixture is dosed to form the flexible laundry article. The flexible solid laundry article may be formed as one or more sheets. The sheet-forming step can be conducted in any suitable manner which is known to a person skilled in the art which includes but is not limited to extrusion, casting, molding, vacuum-forming, pressing, printing, coating, and combinations thereof.
Preferably the homogeneous wet pre-mixture or the aerated wet pre-mixture can be formed into a sheet by (i) casting it into trays or sheet mould, (ii) extruding it onto a continuous belt or screen of a dryer; (iii) coating it onto the outer surface of a rotary drum drier.
Preferably the formed sheet has a thickness ranging from 0.5 mm to 4 mm, preferably from 0.6 mm to 3.5 mm, more preferably from 0.7 mm to 3 mm, still more preferably from 0.8 mm to 2 mm, most preferably from 0.9 mm to 1.5 mm.

Solidification of the formed sheet

Preferably the wet pre-mixture or aerated wet pre-mixture is subject to a solidification step to form a flexible solid laundry article, which article is preferably porous. Preferably the solidification is by heat drying by a batch process. (e.g., in a convection oven or a microwave oven). Alternatively, the wet pre-mix may be solidified by slow heating on a conveyer.
In one scenario, the convention oven is maintained at a temperature ranging from 130°C to 170°C and the drying step is carried out for a temperature of 45 minutes.
Preferably the solidification is carried out in a microwave drying arrangement which involves simultaneous heating with substantially no temperature gradient. During the heating the aqueous medium in the wet pre-mixture is heated which preferably generates bubbles. Preferably the microwave drying arrangement is maintained at a temperature ranging from 130°C to 170°C and the drying step is carried out at a low energy density microwave operated at a power of 2.0 kW and a surrounding air temperature of 54.4°C for a period of 12 minutes.
Still preferably by a continuous drying (e.g., using an impingement oven) to form a flexible solid laundry article, which article is porous. Preferably the pores formed across different regions of the flexible laundry detergent article is uniform.
Preferably the solidification is carried out in an impingement oven based drying arrangement. Preferably the impingement oven heats the wet pre-mixture from both the top and the bottom at opposing and offsetting heating directions. Preferably there is no specific temperature gradient during the drying step and the entire article is nearly simultaneously heated from both its top and bottom surface.
More preferably the solidification of the wet pre-mixture or aerated wet pre-mixture is carried out in a rotary drum-based heating/drying arrangement. Preferably the solidification involves the step of: (i) feeding a homogeneous wet-mixture or aerated homogeneous wet-mixture to a trough; (ii) heating a drum drier placed above said feeding trough, preferably where the outer surface of the drum drier has a controlled surface temperature above the room temperature. In one case the temperature can be maintained at about 130°C. The drum drier rotates along a clockwise direction to pick up the homogeneous wet-mixture or aerated homogeneous wet pre-mixture from the feeding trough. The pre-mixture forms a thin sheet over the cylindrical heated outer surface of the drum drier, which rotates and dries such sheet of aerated wet pre-mixture in approximately 1 to 60 minutes, still preferably 2 to 15 minutes. Preferably the heat from the outer heated surface of the drum drier conducts to the sheet along an outward heating direction which forms a temperature gradient in the sheet that decreases from the side of the sheet in contact with the heated surface of the drum direr to the opposing side of the sheet.
A leveling blade may be placed near the wet-mixture pickup location to ensure a consistent thickness of the sheet so formed, although it is possible to control the thickness of sheet simply by modulating the viscosity of the wet pre-mixture and the rotating speed and surface temperature of the drum drier. Once dried, the sheet can then pick up, either manually or by a scraper at the end of the drum rotation.
Preferably the heat energy is applied in a direction which is:

substantially aligned with the gravitational direction (i.e., with an offset angle of less than 90° therebetween) during most of the drying step; or,
offset from the gravitation direction, preferably the offset angle of 90° or more therebetween) during most of the drying step;
substantially aligned with the gravitational direction (i.e., with an offset angle of less than 90° in between) for less than half of the drying time and applied in a direction which is opposite or substantially opposite to the gravitation direction with an offset angle of 90° or more therebetween) for the remaining duration of the drying time, which is for more than 55%, still preferably more than 60% of the drying time.

Preferably the drying step is conducted under heating along a mostly "anti-gravity" heating direction which can be achieved by various means, which include but are not limited to the bottom conduction-based drying arrangement and the rotary drum-based drying arrangement.
Preferably the homogeneous wet-mixture or aerated homogeneous wet-mixture is filled into a mold and heated at a controlled surface temperature of the heating medium ranging from 40 to 130°C, more preferably 50 to 130°C, and most preferably 80 to 125°C for preferably a duration of around 30 minutes during the drying step. Preferably the heating direction is in a direction opposite to the gravitational direction.
Preferably the solid film is separated from the moving support by detaching means. Preferably the detaching means includes doctor blade device or similar devices known to a person skilled in the art.
Preferably the heat sensitive ingredients are added to the post-drying stage. The heat sensitive ingredients include but are not limited to enzyme and perfume ingredient.
When the flexible solid laundry article according to the present invention is in the form of a multilayer structure and includes two or more sheets, the sheets are preferably assembled together form a multilayered structure. The sheets can be combined and/or treated by any means known in the art, examples of which include but are not limited to, chemical means, mechanical means, and combinations thereof to form the multilayer flexible dissolvable solid article with a desired three-dimensional shape. Preferably the multilayered structure is formed by means of an adhesive, still preferably free of any adhesive by stacking the two or more sheets which are self-adhering.
Preferably when the flexible, solid laundry article according to the present invention is prepared from two or more flexible sheets, the process of preparing such flexible solid laundry article involves the steps of:

(i) providing two or more flexible sheets, wherein each of said two or more sheets comprises a water-soluble polymer comprising cellulose ether derivative and a water insoluble disintegrant;
(ii) arranging said two or more flexible, dissolvable, porous sheets together to form a stack; and,
(iii) cut-sealing said stack of sheets to form the flexible, solid laundry article.

Preferably the flexible solid laundry article according to the present invention having two or more flexible sheets. Preferably the two or flexible sheets are porous sheet. Preferably the contacting surfaces or said at least two adjacent sheets are essentially free of adhesive.
Still preferably the process of preparing the flexible solid laundry article according to the present invention may include a sensitive functional ingredient. Preferably the process for preparing such article involves the step of preparing two or more continuous sheets preferably free of the sensitive functional ingredient and then preferably superimposing two or more of said continuous sheet while including any sensitive functional ingredient therebetween, as an aqueous solution or dispersion of the sensitive functional ingredient applied on at least one of the opposite surfaces of said two or more continuous flexible sheet. Coupling the two or more continuous sheet into a single multilayer sheet structure.
Preferably the solid laundry sheet is cut into desired sizes. Optionally the cut unit dose article is packaged.
Flexible solid laundry article according to the present invention may be of any three-dimensional shapes, including but not limited to spherical, cubic, rectangular, polygonal, oblong, cylindrical, rod, sheet, flower-shaped, fan-shaped, star-shaped, disc-shaped, and the like. Preferably, the flexible solid laundry article of the present invention may be characterized by an aspect ratio ranging from 1 to 20, preferably from 1.4 to 18, preferably from 1.5 to 16, more preferably from 2 to 12, where the aspect ratio refers to the ratio of a longest side D of such solid article over a shortest side that may be substantially perpendicular each other.
The flexible solid laundry article of the present invention may comprise individual sheet of different colours, which are visible from an external surface of such article. The colours are aesthetically pleasing to the consumers. Two or more different colours preferably provides visual cues indicative of different benefit agents present in the individual sheet. Preferably the flexible solid laundry article may comprise a first sheet that has a first colour and includes a first benefit agent and a second sheet that has a second colour and includes a second benefit, where the first colour provides a visual cue indicative of the first benefit agent, and where the second colour provides a visual cue indicative of the second benefit agent.
Preferably the flexible solid laundry article of the present invention may include two or more sheets having different dissolution rate, such that there is a first sheet with a first dissolution rate and a second sheet with a second dissolution rate. The "dissolution rate" as used herein refers to the time (in seconds) required to completely dissolve 0.5 g of a sheet made of water-soluble polymer in accordance with the present invention in 300 mL of water.
Still preferably one or more functional ingredients may be sandwiched between the individual sheets of the flexible solid laundry article. The functional ingredient may be added by spraying, sprinkling, dusting, coating, spreading, dipping, injecting, or even vapor deposition. Preferably the functional ingredients are located within a central region between two adjacent sheets. Functional ingredients may be selected from perfumes, softening agents, polymers, enzymes, bleaches, colorants, builders, pH modifiers and mixtures thereof.
Preferably the flexible solid laundry article according to the present invention is preferably prepared by a solution casting process. Preferably in the solution casting process pre-mixture of ingredients is first formed, preferably the homogeneous mixture is then vigorously aerated to form an aerated mixture, in the next step the aerated mixture is subject to solidification to form a flexible solid laundry article, which article is porous. Preferably the solidification is by heat drying by a batch process. (e.g., in a convection oven or a microwave oven). Preferably drying the sheet for a drying time of from 1 minute to 60 minutes. Preferably the drying is at a temperature of from 40°C to 200°C to form a flexible solid sheet. Still preferably by a continuous drying (e.g., using an impingement oven) to form a flexible solid laundry article, which article is porous.
Preferably the drying is carried out on a moving support on which the homogeneous mixture is dosed in a laminar form is a cylindrical or conveyor belt. Preferably the continuous sheet with constant desired thickness is formed using a weir, guillotine, or calendar system depending on the solution viscosity. Preferably drying step of the continuous sheet is by applying heat. Preferably the solidification is carried out in a rotary drum drying arrangement where the drying is by contact-drying method. The drum is heated internally by steam or electricity.
The heat application may be using the known heat source which includes but is not limited to infrared, forced ventilation, hot water heating, conventional oven, and combinations thereof. The heating is preferably applied to the moving support until solidification of the sheet.
Alternately the wet pre-mixture or the aerated wet pre-mixture may be casted into a mold to form a sheet, next the sheet is placed on a hot surface or a heated moving melt or a heating means with a planar heated surface with a controlled surface temperature ranging from 80°C to 170°C, more preferably from 90°C to 150°C, still preferably from 100°C to 140°C.
Preferably the drying step is carried out by applying forced ventilation, or by utilizing a combination of applied forced ventilation and heat.
Preferably any one or more of the above-mentioned process may be utilized to prepare the solid flexible laundry article according to the present invention. Preferably the process for preparing involves at least one of the following additional steps:

(i) edge-sealing at least a portion of the peripheral of said flexible solid laundry article;
(ii) perforating said flexible solid laundry article to provide one or more apertures or holes that extend through all sheets of said flexible solid laundry article; and
(iii) embossing or printing on said flexible solid laundry article.

Examples

Ex 1 to 2, in the form of flexible solid laundry article were prepared following the recipe provided in table 1:

Table 1

Material (%w/w)	Ex-1	Ex-2
Sodium linear alkyl benzene sulphonate	35.0	28.6
Cocamidopropyl betaine	2.5	2.5
Hydroxy propyl methyl cellulose	13.5	11.2
Microcrystalline cellulose	6.1	20.4
Glycerol	4.3	3.6
Tinopal CBC	1.5	1.3
Polyacrylate copolymer	9.2	7.6
Phosphonate based sequestrant	1.5	1.3
Ethoxylated polyethylene imine	6.5	5.4
Soil release polymer	3.1	2.5
Perfume	6.8	5.6
Moisture	10.0	10.0

Claims

A packaged laundry product comprising a container and a flexible solid laundry article, said flexible solid laundry article is enclosed in the container, wherein the container comprises a recyclable or biodegradable material and wherein the flexible solid laundry article comprises (i) a water-soluble polymer comprising a cellulose ether derivative; (ii) a water-insoluble disintegrant and wherein the flexible solid laundry article is free of PVOH or a copolymer of PVOH.
A packaged laundry product according to claim 1 wherein the flexible solid laundry article are stacked in a two- or three-dimensional array, preferably a three-dimensional array.
A packaged laundry product according to claim 1 or 2 wherein the container is the primary package or the secondary package.
A packaged laundry product according to claim 1 or 2 wherein the container has a compartment for containing the plurality of laundry article and a closure for the container, wherein the closure has a locking means.
A packaged laundry product according to claim any one of the preceding claims wherein the container has dividing means for dividing the container compartment into subcompartments.
A packaged laundry product according to any one of the preceding claims wherein the container has child resistant means for deterring a child from opening the container.
A packaged laundry product according to any one of the preceding claims wherein the container is shaped in the form of a tub, tray, box, or combinations thereof.
A packaged laundry product according to any one of the preceding claims wherein the container comprises:
a. a container body;

b. a top panel engaged with the container body,

c. an opening flap connected with a hinge to the top panel;

d. a locking means integral with the opening flap and detachably attachable to the container body.
A packaged laundry product according to claim 8 wherein the opening panel is separable from the top panel when the package is opened for the first time by means of a weakened portion provided on the top panel.
A packaged laundry product according to claim 9 wherein unseparated portion of the top panel after the opening panel is separated form a flush seat for the opening panel in the closed position.
A packaged laundry product according to claim 1 wherein the flexible solid laundry article has graphene or derivative thereof.
A packaged laundry product according to claim 1 wherein the flexible solid laundry article has slip additive.
A packaged laundry product according to claim 1 wherein the flexible solid laundry article has printed or embossed content thereon.
A packaged laundry product according to claim 1 wherein the flexible solid laundry article has one or more lines of frangibility or tear line or perforation line.