Patent Description:
Unit dose compositions can include a beneficial composition such as a detergent product, a color care agent, a softening agent, or a fragrance. Unit dose detergent products are often found by consumers to be preferable for use as they have several advantages, including convenience of use and dispensing, lower cost per use, and avoiding or minimizing direct skin contact with potentially irritating cleaning compositions.

Unit dose liquid detergent compositions are often contained within water-soluble or water-dispersible films, and thus are limited to low water levels to prevent the films from being dissolved or dispersed pre-maturely by the enclosed liquid detergent compositions. The typical water content of a unit dose liquid detergent composition is less than <NUM> wt% based on the total weight of the composition.

For example, <CIT> discloses unit dose liquid detergent compositions enclosed within a water-soluble polymeric film pouch, which exemplifies a liquid detergent composition with a water content of <NUM> wt%.

<CIT> discloses water-soluble packets containing concentrated liquid cleaning compositions, which contain less than <NUM> wt% of water.

<CIT> discloses water soluble pouches containing liquid detergent compositions which contain less than <NUM> wt% water, and preferably between <NUM>-<NUM> wt% water. <CIT> discloses a unit dose liquid laundry detergent composition containing <NUM>-<NUM> wt% (e.g., <NUM> wt%) of water.

Water soluble pouches containing liquid detergent composition are disclosed in patent applications <CIT>, <CIT>,<CIT> and <CIT>.

Water is an inexpensive ingredient of unit dose compositions and a ubiquitous solvent. There is a need for an aqueous composition that contains high water content, which would reduce the cost of goods while retaining the benefit of the beneficial composition. The present disclosure provides such an aqueous composition, as well as a method of producing and using such a composition in unit dose compositions.

The present invention is based on the discovery that the inclusion of a water binding agent in an aqueous composition of a unit dose pac helps to bind water, preventing pac films from being dissolved or dispersed pre-maturely by the enclosed liquid detergent compositions. As a result, the liquid composition in the unit dose pacs can have a water content much higher than that known in the conventional unit dose pacs. Despite the high water content and the high activity, the unit dose pacs of the present invention are stable. Stability of unit dose pacs are determined under stressed packaging conditions through measurement of pac height, % weight loss, dissolution rate, etc. Even if the water content is about the same as those in the art, the unit dose pacs of the present invention are much more stable and more rigid, compared to those in the art, as a result of incorporating the water binding agent and the particular formulations developed by the inventors, which in turn may cause the modification of the surfactant structure in the liquid composition. Structured surfactant system may further prevent "free" movement of water, leading to stability of the unit dose pacs.

According to one aspect of the present invention, a unit dose composition according to claim <NUM> is provided.

It has been unexpectedly discovered that the addition of the salt may facilitate the formation of a structured surfactant system. From this aspect, water unexpectedly functions more than just a water binding agent. One of the structured surfactant system is a gel form. A high content active (e.g., surfactant) formulation, for example, surfactants in an amount of or more than <NUM>%wt, requires less amount of the salt to effectuate a gel formation. In contrast, a low content active (e.g., surfactant) formulation, for example, surfactants in an amount of or less than <NUM>%wt, requires a larger amount of the salt to effectuate a gel formation, but such gel formation is more viscousmore solid like. It has further been discovered that the structured surfactant system is of lamellar structure on molecular scale. The patterns of the lamellar structures of the surfactant systems differ, depending on the surfactant and salt formulations. The physical properties of unit dose pacs prepared from the formulations are different. It was unexpected that lamellar structured surfactant composition can be compatible with water-soluble films and can survive the unit dose pacs preparation process and thus create stable unit dose pacs.

It is also unexpectedly discovered that the surfactant amount and the salt amount required to form a lamellar structure in the liquid composition are inversely related. More surfactant in the liquid composition would require less salt to form a lamellar structure. The types of lamellar structure may vary depending on the concentration of surfactant in the liquid composition. Without wishing to be bound by theory, it is believed that the lamellar-structured surfactant system provides patterns of structures that prevent "free" movement of water, and thus preventing water with high water activity from pre-maturely dissolving water soluble films of the container.

In some embodiments, the aqueous composition is substantially free of a hygroscopic chelant, a hygroscopic glycol, or an organic solvent.

In some embodiments, the aqueous composition is substantially free of a polymer that stabilizes the water-soluble container.

In some embodiments, the unit dose composition is substantially free of efflorescence.

In some embodiments, the aqueous composition comprises <NUM>% to <NUM>% by weight of water. In some embodiments, the aqueous composition has a water activity of from <NUM> to <NUM>, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM>.

The surfactant system comprises an anionic surfactant, and a non-ionic surfactant.

In some embodiments, the surfactant system further comprises a defoamer. In some embodiments, the surfactant system further comprises a zwitterionic surfactant or an amphoteric surfactant.

In some embodiments, the anionic surfactant and the non-ionic surfactant are present in a weight ratio preferably <NUM>:<NUM> to <NUM>:<NUM>, more preferably <NUM>:<NUM> to <NUM>:<NUM>.

In some embodiments, the surfactant system comprises (<NUM>) a linear alkylbenzene sulfonate (LAS) and/or an alcohol ethoxylsulfate (AES), (<NUM>) an alcohol ethoxylate (AE), and (<NUM>) a fatty acid.

In some embodiments, the LAS is present in an amount of <NUM>% to <NUM>% by weight of the surfactant system.

In some embodiments, the AES is present in an amount of <NUM>% to <NUM>% by weight of the surfactant system.

In some embodiments, the AE is present in an amount of <NUM>% to <NUM>%, preferably from <NUM>% to <NUM>%, by weight of the surfactant system.

In some embodiments, the fatty acid is present in an amount of <NUM>% to <NUM>% by weight of the surfactant system.

In some embodiments, the LAS and the AES are present in a weight ratio of from <NUM>:<NUM> to <NUM>:<NUM> (e.g., <NUM>:<NUM>).

In some embodiments, the LAS and the AE are present in a weight ratio of from <NUM>:<NUM> to <NUM>:<NUM> (e.g., <NUM>:<NUM>).

In some embodiments, the LAS and the fatty acid are present in a weight ratio of from <NUM>:<NUM> to <NUM>:<NUM> (e.g., <NUM>:<NUM>).

In some embodiments, the weight ratio of LAS : AES : AE is <NUM>-<NUM> : <NUM>-<NUM> : <NUM>-<NUM> (e.g., <NUM> : <NUM> : <NUM>).

In some embodiments, the surfactant system is a structured surfactant system or a surfactant-structured system. In some embodiments, the structured surfactant system includes lamellar structure. The lamellar structure may be present in a "Maltese Crosses" pattern or in a "Mosaic" pattern.

In some embodiments, the aqueous composition is substantially free of a sulphate surfactant.

In some embodiments, wherein the beneficial composition comprises a fragrance composition comprising a neat oil, an encapsulated fragrance, an oil-in-water emulsion, or a combination thereof. In some embodiments, the fragrance composition is present in an amount from <NUM>% to <NUM>% by weight, preferably <NUM>% to <NUM>% by weight.

However, in some embodiments, the beneficial composition does not contain any neat oil. In other embodiments, the beneficial composition does not contain any fragrance oil.

In some embodiments, the beneficial composition comprises a color care agent or a softening agent.

In some embodiments, the aqueous composition further comprises a surfactant stabilizer. Examples of the surfactant stabilizer include, but are not limited to, polysorbate, quillaja extract, octenyl succinic anhydride (OSA) modified starch, gum acacia, modified gum acacia, and a mixture thereof.

In some embodiments of the present disclosure, the aqueous composition is substantially free of a polymer that stabilizes the film. In some embodiments, the aqueous composition is substantially free of a polymer made from vinyl dicarboxylic acid monomers. In some embodiments of the present disclosure, the aqueous composition is substantially free of a polymer that stabilizes the film. In some embodiments, the aqueous composition is substantially free of a polymer made from vinyl dicarboxylic acid monomers.

In some embodiments, the water-soluble or water-dispersible film material is selected from the group consisting of polyvinyl alcohol (PVOH), polyvinyl acetate (PVA), film forming cellulosic polymer, polyacrylic acid, polyacrylamide, polyanhydride, polysaccharide, and a mixture thereof.

In some embodiments, the water-soluble or water-dispersible film material is polyvinyl alcohol (PVOH) or polyvinyl acetate (PVA).

In some embodiments, the water-soluble or water-dispersible film material is between <NUM> to <NUM> microns thick, preferably <NUM> to <NUM> microns.

The following description provides specific details, such as materials and dimensions, to provide a thorough understanding of the present invention. The skilled artisan, however, will appreciate that the present invention can be practiced without employing these specific details. Indeed, the present invention can be practiced in conjunction with processing, manufacturing or fabricating techniques conventionally used in the detergent industry. Moreover, the processes below describe only steps, rather than a complete process flow, for manufacturing the aqueous surfactant system and unit dose composition containing the aqueous surfactant system according to the present invention.

As used herein, "a," "an," or "the" means one or more unless otherwise specified.

The term "or" can be conjunctive or disjunctive.

Open terms such as "include," "including," "contain," "containing" and the like mean "comprising.

The term "solvent" used herein does not include water. It also does not include neutralization agents, such as triethanolamine, monoethanolamine, sodium hydroxide, and acids, or agents that are conventionally used as surfactants.

The phrase "substantially free of" means that a composition contains little no specified ingredient/component, such as less than <NUM> wt%, <NUM> wt%, <NUM> wt%, <NUM> wt%, <NUM> wt%, <NUM> wt%, or <NUM> wt%, or below the detectable level of the specified ingredient. For example, the phrase "substantially free of a hygroscopic chelant, a hygroscopic glycol, or an organic solvent" refers to an aqueous composition of the present disclosure that contains little or no hygroscopic chelant, hygroscopic glycol, or organic solvent. An aqueous composition of the present disclosure that is substantially free of a hygroscopic chelant, a hygroscopic glycol, or an organic solvent may contain, for example, less than <NUM> wt%, <NUM> wt%, <NUM> wt%, <NUM> wt%, <NUM> wt%, <NUM> wt%, or <NUM> wt% of a hygroscopic chelant, a hygroscopic glycol, or an organic solvent, based on the total weight of the composition.

The "%" described in the present disclosure refers to the weight percentage unless otherwise indicated.

The surfactant system can be a structured surfactant system, which is a surfactant system that has a certain set of rheological properties and exhibits viscoelastic behaviors (especially yield stress, a linear viscoelastic region) in certain strain/stress ranges. This can be achieved by including polymers, surfactants, clays, and most commonly, combinations thereof.

The surfactant system can also be a surfactant-structured system, which is a structured system that achieves its viscoelastic behaviors by including surfactants alone. A common example is a lamellar surfactant system.

While not wishing to be bound by the theory, it is believed that the structured surfactant system prevents water from migrating out of the system to weaken or dissolve a water-soluble film that encloses the system. As such, the structured surfactant system increases the overall stability of a unit dose composition. The structured surfactant system is not a solid, and does not rapidly separate, or solidify when it is diluted with water. These properties lead to its versatile applications. In some embodiments, the surfactant system further comprises a defoamer. A defoamer is a chemical additive that prevents the formation of foam and/or breaks foam already formed. Examples of commonly used defoamers include fatty acids, polydimethylsiloxanes, silicones, twin chain alcohols and some alcohols, glycols, stearates, and insoluble oils.

In some embodiments, the surfactant system further comprises a zwitterionic surfactant or an amphoteric surfactant. A zwitterionic surfactant is a net-neutrally charged molecule that has positive and negative charges. Some simple amphoteric molecules can only form a net positive or negative charge depending on the pH. Other amphoteric molecules can form a net-neutral charge, depending on the pH. Examples of zwitterionic materials include betaine.

In some embodiments, the anionic surfactant can be linear alkylbenzene sulfonic acid or a salt thereof, alkyl ethoxylated sulphate, alkyl propoxy sulphate, alkyl sulphate, or a mixture thereof. In some embodiments, the nonionic surfactant can be alcohol ethoxylate, alcohol propoxylate, or a mixture thereof.

In some embodiments, the aqueous composition can be substantially free of a sulfate surfactant. In some embodiments, the surfactant system is present in an amount of <NUM>% to <NUM>%, or <NUM>% to <NUM>% by weight. In some embodiments, the surfactant system is present in an amount of <NUM>% to <NUM>% by weight.

In some embodiments, the anionic surfactant and the non-ionic surfactant are present in a weight ratio of from <NUM>:<NUM> to <NUM>:<NUM>, more preferable from <NUM>:<NUM> to <NUM>:<NUM>. In some embodiments, the anionic surfactant and the non-ionic surfactant are present in a weight ratio of from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>. from <NUM>:<NUM> to <NUM>:<NUM>, or from <NUM>:<NUM> to <NUM>:<NUM>. In some embodiments, the anionic surfactant and the non-ionic surfactant are present in a weight ratio of from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, or from <NUM>:<NUM> to <NUM>:<NUM>. In some embodiments, the anionic surfactant and the non-ionic surfactant are present in a weight ratio of <NUM>:<NUM>.

In some embodiments, the aqueous composition comprises from <NUM>% to <NUM>% by weight of water.

In some embodiments, the aqueous composition has a water activity of from <NUM> to <NUM>, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM>.

In some embodiments, the aqueous composition of the present disclosure does not contain or is substantially free of a hygroscopic chelant, such as iron and/or manganese chelants, diethylenetriamine pentaacetate, diethylene triamine penta(methyl phosphonic acid), ethylenediamine-N,N'-disuccinic acid, ethylenediamine tetraacetate, ethylenediamine tetra(methylene phosphonic acid), hydroxyethane di(methylene phosphonic acid), <NUM>-hydroxyethanediphosphonic acid and salts thereof, N,N-dicarboxymethyl-<NUM>-aminopentane-<NUM>,<NUM>-dioic acid and salts thereof, and <NUM>-phosphonobutane-<NUM>,<NUM>,<NUM>-tricarboxylic acid and salts thereof.

In some embodiments, the aqueous surfactant system of the present disclosure does not contain or is substantially free of a hygroscopic glycol or an organic solvent, such as alcohol, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, polyethylene glycol (PEG) of molecular weight between <NUM> and <NUM>, or monoethanolamine.

The unit dose compositions of the present disclosure contain a high content of water. In some embodiments, the aqueous composition contains <NUM> to <NUM> wt%, <NUM> to <NUM> wt%, <NUM> to <NUM> wt% of water, based on the total weight of the aqueous composition. In one embodiment, the aqueous composition contains <NUM> to <NUM> wt% or <NUM> to <NUM> wt% of water, based on the total weight of the aqueous composition.

The present disclosure provides aqueous compositions containing high water content and having a water activity of from <NUM> to <NUM>. The water activity of an aqueous composition is defined as the partial pressure of water in the aqueous composition divided by the saturation pressure of water at the temperature of the aqueous composition. If no temperature is specified, the default temperature is room temperature. The water activity can be determined by placing a sample in a container which is then sealed, and after equilibrium is reached, determining the relative humidity above the sample. The water activity is calculated from the equilibrium relative humidity according to the following equation:<MAT>.

In some embodiments, the water activity of the aqueous compositions of the present disclosure is from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, from <NUM> to <NUM>, or from <NUM> to <NUM>. In some embodiments, the water activity of the aqueous compositions of the present disclosure is from <NUM> to <NUM>. In some embodiments, the water activity of the aqueous compositions of the present disclosure is <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>.

Linear alkylbenzenesulfonate (LAS) is a water soluble salt of a linear alkyl benzene sulfonate having between <NUM> and <NUM> carbon atoms of the linear alkyl group. The salt can be an alkali metal salt, or an ammonium, alkylammonium, or alkanolammonium salt. In one embodiment, the LAS comprises an alkali metal salt of C<NUM>-C<NUM> alkyl benzene sulfonic acids, such as C<NUM>-C<NUM> alkyl benzene sulfonic acids. Suitable LAS includes sodium and potassium linear, alkylbenzene sulfonates in which the average number of carbon atoms in the alkyl group is between <NUM> and <NUM>. Sodium C<NUM>-C<NUM> (e.g., C<NUM>) LAS is one suitable anionic surfactant for use herein.

In some embodiments, the amount of LAS in the surfactant system is selected so as to form a structured surfactant system. In some embodiments, the surfactant system contains <NUM> to <NUM> wt%, <NUM> to <NUM> wt%, or <NUM> to <NUM> wt% of linear alkylbenzenesulfonate, based on the total weight the surfactant system.

Alcohol ethoxysulfate (AES), also known as alkyl ether sulfates or alkyl polyethoxylate sulfates, are compounds having Formula (I):.

R<NUM>-O-(C<NUM>H<NUM>O)n-SO<NUM>M     (I),.

wherein R<NUM> is a C<NUM>-C<NUM> alkyl group, n is from <NUM> to <NUM>, and M is a salt-forming cation. Preferably, R<NUM> is a C<NUM>-C<NUM> alkyl, or a C<NUM>-C<NUM> alkyl, n is from <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM>, and M is sodium, potassium, ammonium, alkylammonium, or alkanolammonium. More preferably, R<NUM> is a C<NUM>-C<NUM> alkyl, n is from <NUM> to <NUM>, and M is sodium. In one embodiment, the alkyl ether sulfate is sodium lauryl ether sulphate (SLES). The AES will generally be used in the form of mixtures comprising varying R<NUM> chain lengths and varying degrees of ethoxylation. Frequently such mixtures will inevitably also contain some unethoxylated alkyl sulfate materials, i.e., n=<NUM> in the above Formula (I). Unethoxylated alkyl sulfates may also be added separately to the aqueous surfactant system of present disclosure and used as or in any anionic surfactant component which may be present. Suitable unalkoyxylated, e.g., unethoxylated, alkyl ether sulfate surfactants are those made by the sulfation of higher C<NUM>-C<NUM> fatty alcohols. Conventional alkyl sulfate surfactants may also be suitable herein, which have the general formula of: R<NUM>OSO<NUM>M+, wherein R<NUM> and M each has the same definition as described above.

Exemplary AES includes those sold under the tradename CALFOAM® <NUM> (Pilot Chemical Company, California).

In some embodiments, the amount of AES the aqueous surfactant system of the present disclosure is selected so as to form a structured surfactant system. In some embodiments, the surfactant system contains from <NUM> to <NUM> wt%, <NUM> to <NUM> wt%, or <NUM> to <NUM> wt% of AES, based on the total weight the surfactant system.

In some embodiments, the weight ratio of LAS to AES in the surfactant system is from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, or from <NUM>:<NUM> to <NUM>:<NUM>. In some embodiments, the weight ratio of LAS to AES is <NUM>:<NUM>.

The surfactant system of the present disclosure contains a non-ionic surfactant. A wide range of non-ionic surfactants can be used herein. For example, the non-ionic surfactants include, but are not limited to alkoxylated alcohols, polyoxyalkylene alkyl ethers (e.g., those marketed under the trade name Pluronic® (e.g., Pluronic® PE or Pluronic® RPE, available from BASF), polyoxyalkylene alkylphenyl ethers, polyoxyalkylene sorbitan fatty acid esters, polyoxyalkylene sorbitol fatty acid esters, polyalkylene glycol fatty acid esters, alkyl polyalkylene glycol fatty acid esters, polyoxyethylene polyoxypropylene alkyl ethers, polyoxyalkylene castor oils, polyoxyalkylene alkylamines, glycerol fatty acid esters, alkylglucosamides, alkylglucosides, alkylamine oxides, or a combination thereof. Preferably, the non-ionic surfactant is an alcohol ethoxylate (AE).

The AE may be primary and secondary alcohol ethoxylates, especially the C<NUM>-C<NUM> aliphatic alcohols ethoxylated with an average of from <NUM> to <NUM> moles of ethylene oxide per mole of alcohol, and more especially the C<NUM>-C<NUM> primary and secondary aliphatic alcohols ethoxylated with an average of from <NUM> to <NUM> moles, or from <NUM> to <NUM> moles of ethylene oxide per mole of alcohol.

Exemplary AEs are the condensation products of aliphatic C<NUM>-C<NUM>, preferably C<NUM>-C<NUM>, primary or secondary, linear or branched chain alcohols with ethylene oxide. In some embodiments, the alcohol ethoxylates contain <NUM> to <NUM>, or <NUM> to <NUM> ethylene oxide groups, and may optionally be end-capped by a hydroxylated alkyl group.

In one embodiment, the AE has Formula (II):.

wherein R<NUM> is a hydrocarbyl group having <NUM> to <NUM> carbon atoms, <NUM> to <NUM> carbon atoms, <NUM> to <NUM> carbon atoms, or <NUM> to <NUM> carbon atoms; and m is from <NUM> to <NUM>, or <NUM> to <NUM>.

The hydrocarbyl group may be linear or branched, and saturated or unsaturated. In some embodiments, R<NUM> is a linear or branched C<NUM>-C<NUM> alkyl or a linear group or branched C<NUM>-C<NUM> alkenyl group. Preferably, R<NUM> is a linear or branched C<NUM>-C<NUM> alkyl, C<NUM>-C<NUM> alkyl, or C<NUM>-C<NUM> alkyl group. In case (e.g., commercially available materials) where materials contain a range of carbon chain lengths, these carbon numbers represent an average. The alcohol may be derived from natural or synthetic feedstock. In one embodiment, the alcohol feedstock is coconut, containing predominantly C<NUM>-C<NUM> alcohol, and oxo C<NUM>-C<NUM> alcohols.

One suitable AE is Tomadol® <NUM>-<NUM> (available from Air Product). Other suitable AEs include Genapol® C200 (available from Clariant), which is a coco alcohol having an average degree of ethoxylation of <NUM>.

In some embodiments, the amount of non-ionic surfactant in the surfactant system is selected so as to form a structured surfactant system. In some embodiments, the aqueous surfactant system comprises <NUM> to <NUM> wt% of a non-ionic surfactant, based on the total weight the surfactant system.

In some embodiments, the surfactant system of the present disclosure comprises from <NUM> to <NUM> wt%, from <NUM> to <NUM> wt%, <NUM> to <NUM> wt%, from <NUM> to <NUM> wt%, <NUM> to <NUM> wt%, or <NUM> to <NUM> wt% of AE, based on the total weight the surfactant system.

In some embodiments, the weight ratio of LAS to non-ionic surfactant (e.g. AE) in the surfactant system is from <NUM>:<NUM> to <NUM>:<NUM>. In some embodiments, the weight ratio of LAS to AE in the surfactant system is from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>: <NUM>, or from <NUM>:<NUM> to <NUM>: <NUM>. In one embodiment, the weight ratio of LAS to AE is <NUM>:<NUM>.

The surfactant system of the present disclosure contains a fatty acid. Suitable fatty acid may be any fatty acid having formula: R<NUM>-C(O)OH, wherein R<NUM> is a C<NUM>-C<NUM> linear or branched aliphatic group. Preferably, the R<NUM> is a C<NUM>-C<NUM> linear or branched aliphatic group.

In some embodiments, the fatty acid is hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid, capric acid, undecanoic acid, dodecanoic acid (lauric acid), tridecanoic acid, myristic acid, pentadecanoic acid, palmitic acid, heptadecanoic acid, stearic acid, nonadecanoic acid, eicosanoic acid, heneicosanoic acid, docosanoic acid, myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, elaidic acid, vaccenic acid, linoleic acid, linoelaidic acid, arachidonic acid, eicosapentaenoic acid, erucic acid, docosahexaenoic acid, or a mixture thereof.

In some embodiments, the fatty acid is dodecanoic acid (also known as coconut fatty acid).

In some embodiments, the amount of the fatty acid in the surfactant system is selected so as to form a structured surfactant system. In some embodiments, the surfactant system of the present disclosure contains from <NUM> to <NUM> wt%, from <NUM> to <NUM> wt%, from <NUM> to <NUM> wt%, from <NUM> to <NUM> wt%, from <NUM> to <NUM> wt%, or from <NUM> to <NUM> wt% of fatty acid, based on the total weight the surfactant system. In some embodiments, the surfactant system of the present disclosure contains from <NUM> wt% of fatty acid based on the total weight the surfactant system.

In some embodiments, the weight ratio of LAS to fatty acid in the aqueous surfactant system is from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, from <NUM>:<NUM> to <NUM>:<NUM>, or from <NUM>:<NUM> to <NUM>:<NUM>. In one embodiment, the weight ratio of LAS to fatty acid is <NUM>:<NUM>.

In some embodiments, the weight ratio of LAS : AES : AE in the surfactant system is <NUM>-<NUM> : <NUM>-<NUM> : <NUM>-<NUM>. In one embodiment, the weight ratio of LAS : AES : AE is <NUM> : <NUM>:<NUM>.

In one embodiment, the surfactant system of the present disclosure contains <NUM> to <NUM> wt% LAS, <NUM> to <NUM> wt% AES, <NUM> to <NUM> wt% of AE, and <NUM> to <NUM> wt% fatty acid based on the total weight the surfactant system.

In one embodiment, the surfactant system of the present disclosure contains <NUM> wt% LAS, <NUM> wt% AES, <NUM> wt% of AE, and <NUM> wt% fatty acid based on the total weight the surfactant system.

The aqueous composition of the present disclosure may further contain a buffer. A wide range of buffers can be used herein. For example, the buffer may comprise a citrate or a formate, and optionally an amine (e.g., triethanolamine). In some embodiments, the aqueous composition contains from <NUM> to <NUM> wt%, preferably from <NUM> to <NUM> wt% of the buffer, based on the total weight of the aqueous composition.

A water binding agent sodium chloride is used in an aqueous composition to reduce its water activity. Further examples of the water binding agent include, but are not limited to, a salt, a saccharide, an organic solvent, and a mixture thereof.

In some embodiments, the aqueous composition of the present disclosure is substantially free of an organic solvent.

In some embodiments, the aqueous composition of the present disclosure is substantially free of a saccharide.

In some embodiments, the water binding agent is present in an amount of <NUM>% to <NUM>%.

The aqueous composition of the present disclosure may contain a surfactant stabilizer. Examples of the surfactant stabilizer include, but are not limited to, polysorbate, quillaja extract, octenyl succinic anhydride (OSA) modified starch, gum acacia, modified gum acacia, and a mixture thereof.

The aqueous composition of the present disclosure may also contain other components commonly included in a detergent composition, for example, a builder and a beneficial agent including, but not limited to an anti-redeposition agent, an enzyme, a fragrance, and a dye (colorant), a dispersing agent, a defoamer, a color component, a bleaching catalyst, a bleaching agent, a bleach activator, a whitening agent, a brightening agent, an anticorrosion agent, a deodorizing agent, a color/texture rejuvenating agent, a soil releasing polymer, a preservative, and a bittering agent, or a combination thereof.

Suitable builders include organic or inorganic detergency builders. Examples of water-soluble inorganic builders that can be used, either alone or in combination with themselves or with organic alkaline sequestrant builder salts, are glycine, alkyl and alkenyl succinates, alkali metal carbonates, alkali metal bicarbonates, phosphates, polyphosphates and silicates. Specific examples of such salts are sodium tripolyphosphate, sodium carbonate, potassium carbonate, sodium bicarbonate, potassium bicarbonate, sodium pyrophosphate and potassium pyrophosphate. Examples of organic builder salts that can be used alone, or in combination with each other, or with the preceding inorganic alkaline builder salts, are alkali metal polycarboxylates, water-soluble citrates such as sodium and potassium citrate, sodium and potassium tartrate, sodium and potassium ethylenediaminetetracetate, sodium and potassium N(<NUM>-hydroxyethyl)-nitrilo triacetates, sodium and potassium N-(<NUM>-hydroxyethyl)-nitrilo diacetates, sodium and potassium oxydisuccinates, and sodium and potassium tartrate mono- and di-succinates, such as those described in <CIT>.

Fragrance (perfume) refer to and include any fragrant substance or mixture of substances including natural (obtained by extraction of flowers, herbs, leaves, roots, barks, wood, blossoms or plants), artificial (mixture of natural oils or oil constituents) and synthetically produced odoriferous substances. The fragrance can comprise an ester, an ether, an aldehyde, a ketone, an alcohol, a hydrocarbon, or a mixture thereof.

Typically, perfumes are complex mixtures of blends of various organic compounds such as alcohols, aldehydes, ethers, aromatic compounds and varying amounts of essential oils (e.g., terpenes). The essential oils themselves are volatile odoriferous compounds and also serve to dissolve the other components of the perfume.

In some embodiments, the fragrance component is in the form of free fragrance. In some embodiments, at least some of the fragrance can be encapsulated in, for example, water-insoluble shell, microcapsule, nanocapsule or any combination thereof. The microcapsules can be water-soluble or water-insoluble.

Examples of encapsulated fragrances are described in, for example, <CIT>, <CIT>, <CIT>, <CIT> and <CIT>, and <CIT>.

The fragrance (perfume) can have, for example, a musky scent, a putrid scent, a pungent scent, a camphoraceous scent, an ethereal scent, a floral scent, a peppermint scent, or any combination thereof. The fragrance comprises methyl formate, methyl acetate, methyl butyrate, ethyl butyrate, isoamyl acetate, pentyl butyrate, pentyl pentanoate, octyl acetate, myrcene, geraniol, nerol, citral, citronellol, linalool, nerolidol, limonene, camphor, terpineol, alpha-ionone, thujone, benzaldehyde, eugenol, cinnamaldehyde, ethyl maltol, vanillin, anisole, anethole, estragole, thymol, indole, pyridine, furaneol, <NUM>-hexanol, cis-<NUM>-hexenal, furfural, hexyl cinnamaldehyde, fructone, hexyl acetate, ethyl methyl phenyl glycidate, dihydrojasmone, oct-<NUM>-en-<NUM>-one, <NUM>-acetyl-<NUM>-pyrroline, <NUM>-acetyl-<NUM>,<NUM>,<NUM>,<NUM>-tetrahydropyridine, gamma-decalactone, gamma-nonalactone, delta-octalone, jasmine lactone, massoia lactone, wine lactone, sotolon, grapefruit mercaptan, methanthiol, methyl phosphine, dimethyl phosphine, nerolin, <NUM>,<NUM>,<NUM>-trichloroanisole, or any combination thereof.

Suitable enzymes include those known in the art, such as amylolytic, proteolytic, cellulolytic or lipolytic type, and those listed in <CIT>. One preferred protease, sold under the trade name SAVINASE® by Novo Nordisk Industries A/S, is a subtillase from Bacillus lentus. Other suitable enzymes include proteases, amylases, lipases and cellulases, such as ALCALASE® (bacterial protease), EVERLASE® (protein-engineered variant of SAVINASE®), ESPERASE® (bacterial protease), LIPOLASE® (fungal lipase), LIPOLASE ULTRA (Protein-engineered variant of LIPOLASE), LIPOPRIME® (protein-engineered variant of LIPOLASE), TERMAMYL® (bacterial amylase), BAN (Bacterial Amylase Novo), CELLUZYME® (fungal enzyme), and CAREZYME® (monocomponent cellulase), sold by Novo Nordisk Industries A/S. Also suitable for use in the present disclosure are blends of two or more of these enzymes, for example a protease/lipase blend, a protease/amylase blend, a protease/amylase/lipase blend, and the like.

All dyes (colorants) suitable for use in detergent composition can be used in herein. A variety of dye colors can be used, such as blue, yellow, green, orange, purple, clear, etc. Suitable dyes include, but are not limited to chromophore types, e.g., azo, anthraquinone, triarylmethane, methine quinophthalone, azine, oxazine thiazine, which may be of any desired color, hue or shade. Suitable dyes can be obtained from any major supplier such as Clariant, Ciba Speciality Chemicals, Dystar, Avecia or Bayer. In some embodiments, the colorant is Liquitint® Blue HP (available from Milliken Chemical), which can be added in the form of a <NUM>% aqueous dye solution, i.e., <NUM>% active dye+<NUM>% water.

Suitable biocidal agents include an anti-microbial, a germicide, or a fungicide. For example, a biocidal agent includes triclosan (<NUM>-chloro-<NUM>-(<NUM>,<NUM>-dichloro-phenoxy) phenol)), and the like.

Suitable optical brighteners include stilbenes such as TINOPAL® AMS; distyrylbiphenyl derivatives such as TINOPAL® CBS-X, stilbene/naphthotriazole blends (e.g., TINOPAL® RA-<NUM>, available from Ciba Geigy); oxazole derivatives, or coumarin brighteners.

Suitable foam stabilizing agents include a polyalkoxylated alkanolamide, amide, amine oxide, betaine, sultaine, C<NUM>-C<NUM> fatty alcohols, and those disclosed in <CIT>. An auxiliary foam stabilizing surfactant, such as a fatty acid amide surfactant, may also be included in the aqueous composition disclosed herein. Suitable fatty acid amides include C<NUM>-C<NUM> alkanol amides, monoethanolamides, diethanolamides, or isopropanolamides.

Suitable anti-redeposition agents are typically polycarboxylate materials. Polycarboxylate materials, which can be prepared by polymerizing or copolymerizing suitable unsaturated monomers, are admixed in their acid form. Unsaturated monomeric acids that can be polymerized to form suitable polycarboxylates include acrylic acid, maleic acid (or maleic anhydride), fumaric acid, itaconic acid, aconitic acid, mesaconic acid, citraconic acid and methylenemalonic acid. The presence in the polycarboxylates herein of monomeric segments, containing no carboxylate radicals such as vinylmethyl ether, styrene, ethylene, etc. is suitable provided that such segments do not constitute more than <NUM> wt% of the polymer.

Particularly suitable polycarboxylates can be derived from acrylic acid. Such acrylic acid-based polymers which are useful herein are the water-soluble salts of polymerised acrylic acid. The average molecular weight of such polymers in the acid form ranges from <NUM>,<NUM> to <NUM>,<NUM>, from <NUM>,<NUM> to <NUM>,<NUM>, or from <NUM>,<NUM> to <NUM>,<NUM>. Water-soluble salts of such acrylic acid polymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble polymers of this type are known materials (e.g., those described in <CIT>). In one embodiment, the polycarboxylate is sodium polyacrylate.

Acrylic/maleic-based copolymers may also be used as a component of the anti-redeposition agent. Such materials include the water-soluble salts of copolymers of acrylic acid and maleic acid. The average molecular weight of such copolymers in the acid form ranges from <NUM>,<NUM> to <NUM>,<NUM>, from <NUM>,<NUM> to <NUM>,<NUM>, or from <NUM>,<NUM> to <NUM>,<NUM>. The ratio of acrylate to maleate segments in such copolymers will generally range from <NUM>:<NUM> to <NUM>:<NUM>, or from <NUM>:<NUM> to <NUM>:<NUM>. Water-soluble salts of such acrylic acid/maleic acid copolymers can include, for example, the alkali metal, ammonium and substituted ammonium salts. Soluble acrylate/maleate copolymers are known materials (e.g., those described in <CIT>). Other useful polymers include maleic/acrylic/vinyl alcohol terpolymers (e.g., a terpolymer containing <NUM>/<NUM>/<NUM> of acrylic/maleic/vinyl alcohol as described in <CIT>).

Polyethylene glycol can act as a clay soil removal-anti-redeposition agent. Molecular weight of suitable polyethylene glycol can range from <NUM>,<NUM> to <NUM>,<NUM>, or <NUM>,<NUM> to <NUM>,<NUM>. Polyaspartate and polyglutamate dispersing agents may also be used herein.

Any polymeric soil release agent known to those skilled in the art can optionally be employed herein as well. Polymeric soil release agents are characterized by having both hydrophilic segments, to hydrophilize the surface of hydrophobic fibers, such as polyester and nylon, and hydrophobic segments, to deposit upon hydrophobic fibers and remain adhered thereto through completion of washing and rinsing cycles and, thus, serve as an anchor for the hydrophilic segments. This can enable stains occurring subsequent to treatment with the soil release agent to be more easily cleaned in later washing procedures.

Exemplary anti-redeposition agents include an acrylic polymer selected from SOKALAN PA <NUM>, SOKALAN PA <NUM>, SOKALAN PA <NUM>, and SOKALAN CP <NUM> (BASF GmbH, Germany) and ACUSOL <NUM> and ACUSOL 445N (The Dow Chemical Company, Midland, Michigan); an acrylic acid/maleic acid copolymer selected from ACUSOL 460N and ACUSOL 505N (The Dow Chemical Company) and SOKALAN CP <NUM>, SOKALAN CP <NUM>, and SOKALAN CP <NUM> (BASF GmbH, Germany); and an anionic polymer selected from ALCOSPERSE <NUM> and ALCOSPERSE <NUM> (Alco Chemical, Chattanooga, TN) and ACUSOL 480N (The Dow Chemical Company, Midland, Michigan); and DEQLTEST SPE <NUM> (Italmatch Chemicals, Genova, Italy); and an ethoxylated polyethylene imine SOKALAN HP <NUM> (BASF, Germany).

Suitable soil-releasing polymers include, but are not limited to, TEXCARE SRN - a nonionic polyester of polypropylene terephthalate (Clariant); REPEL-O-TEX SRP - a polyethylene glycol polyester (Solvay); end-capped and non-end-capped sulfonated and unsulfonated PET/POET polymers of the type as disclosed in <CIT> and <CIT>; polyethylene glycol/polyvinyl alcohol graft copolymers such as SOKALAN HP <NUM> (BASF, Germany); and anionic hydrophobic polysaccharides of the type as disclosed in <CIT>.

Any suitable process can be used to make the aqueous compositions of the present disclosure.

In one aspect, the present disclosure provides a unit dose composition comprising, a water-soluble container and an aqueous composition of the present disclosure. The unit dose may be a pouch that comprises a water-soluble or water-dispersible film which fully encloses the aqueous composition in at least one compartment. The water-soluble container (e.g., pouch) of the present disclosure may be in any desirable shape and size, e.g., square, rectangular, oval, elliptoid, superelliptical, or circular shape.

The water-soluble container of the present disclosure is made from a water-soluble or water-dispersible material which dissolves, ruptures, disperses, or disintegrates upon contact with water, releasing thereby the composition or cleaning system contained within the container. In preferred embodiments, the water soluble single-compartment container, which may be in the form of a pouch, is formed from a water soluble polymer. Non-limiting examples of suitable water soluble polymers include polyvinyl alcohol, cellulose ethers, polyethylene oxide, starch, polyvinylpyrrolidone, polyacrylamide, polyacrylonitrile, polyvinyl methyl ether-maleic anhydride, polymaleic anhydride, styrene maleic anhydride, hydroxyethylcellulose, methylcellulose, polyethylene glycols, carboxymethylcellulose, polyacrylic acid salts, alginates, acrylamide copolymers, guar gum, casein, ethylene-maleic anhydride resins, polyethyleneimine, ethyl hydroxyethylcellulose, ethyl methylcellulose, hydroxyethyl methylcellulose, and mixtures thereof.

In some embodiments, the water-soluble or water-dispersible film material can be polyvinyl alcohol (PVOH), polyvinyl acetate (PVA), film forming cellulosic polymer, polyacrylic acid, polyacrylamide, polyanhydride, polysaccharide, or a mixture thereof. In some embodiments, the water-soluble or water-dispersible film material is polyvinyl alcohol (PVOH) or polyvinyl acetate (PVA).

In one embodiment, the water soluble container is made from a lower molecular weight water-soluble polyvinyl alcohol (PVOH) film-forming resin.

Suitable PVOH resins are sold under trade name MONOSOL® (e.g., Monosol film M8630, available from MonoSol LLC, Merrillville, Indiana). The preferred grade is MONOSOL® film having a weight average molecular weight range of <NUM>,<NUM> to <NUM>,<NUM> and a number average molecular weight range of <NUM>,<NUM> to <NUM>,<NUM>. In some embodiments, the film material will have a thickness of approximately <NUM> mil or <NUM> micrometers. Other suitable PVOH film forming resins include those sold under trade name Solublon®, available from Aicello Corporation (e.g., Solublon® PT75, Aiichi, Japan; North American subsidiary in North Vancouver, BC, Canada).

In some embodiments, the water-soluble container may further contain a cross-linking agent, e.g., a cross-linking agent selected from the group consisting of formaldehyde, polyesters, epoxides, isocyanates, vinyl esters, urethanes, polyimides, acrylics with hydroxyl, carboxylic, isocyanate or activated ester groups, bis(methacryloxypropyl)tetramethylsiloxane (styrenes, methylmetacrylates), n-diazopyruvates, phenylboronic acids, cis-platin, divinylbenzene (styrenes, double bonds), polyamides, dialdehydes, triallyl cyanurates, N-(<NUM>-ethanesulfonylethyl)pyridinium halides, tetraalkyltitanates, titanates, borates, zireonates, or mixtures thereof. In one embodiment, the cross-linking agent is boric acid or sodium borate.

In some embodiments, the water soluble container can have a protective layer between the film polymer and the composition in the container. In some embodiments, the protective layer may comprise polytetrafluoroethylene (PTFE).

In some embodiments, the water-soluble or water-dispersible film material is between <NUM> to <NUM> microns thick, preferably <NUM> to <NUM> microns. In some embodiments, the water-soluble or water-dispersible film material has a thickness of from <NUM> to <NUM> microns, from <NUM> to <NUM> microns, from <NUM> to <NUM> microns, from <NUM> to <NUM> microns, from <NUM> to <NUM> microns, from <NUM> to <NUM> microns, from <NUM> to <NUM> microns, or from <NUM> to <NUM> microns.

The unit dose may optionally comprise additional compartments, which may comprise an additional composition. The additional composition may be liquid, solid, or mixtures thereof. Alternatively, any additional solid components may be suspended in a liquid-filled compartment. Each compartment may have the same or different compositions.

The water-soluble container (e.g., pouch) of the present disclosure may be prepared in any suitable way, such as via molding, casting, extruding or blowing, and is then filled using an automated filling process. Examples of processes for producing and filling water-soluble containers, suitable for use in accordance with the present disclosure, are described in <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and Z <CIT>.

The aqueous composition or unit dose composition of the present disclosure can be added to a wash liquor to which laundry is present, or to which laundry is added. It may be used in combination with other laundry detergent compositions such as fabric softeners or stain removers. It may also be used in an automatic washing machine operation and added directly to the drum or to the dispenser drawer.

In some embodiments, the unit dose composition of the present disclosure is substantially free of efflorescence. Efflorescence is a phenomenon when solvated salts precipitate out on or in the film.

In some embodiments, the aqueous composition of the present disclosure comprises a beneficial composition comprising a color care agent or a softening agent.

By utilizing water binding agents such as salts (i.e. sodium citrate or sodium chloride), the water activity of a high water product can be reduced to <NUM> or below to create stable unit doses (e.g. pacs). For example, the following solutions were made and their water activity were measured at <NUM> using an Aqua Lab 4TEV DUO (a water activity meter) on the capacitance setting.

When creating single dose pacs with a PVOH water-soluble film, the <NUM>% sodium chloride solution ruptured immediately due to its high water activity. However, the <NUM>% and <NUM>% sodium chloride solutions can be incorporated into pacs and properly sealed. Additionally, the <NUM>% sodium chloride solution created a much more rigid, stable pac and was not as elongated (i.e. <NUM> inches long for <NUM>% versus <NUM> inches long for <NUM>%). Pacs containing the <NUM>% and <NUM>% sodium chloride solutions were stable at room temperature for at least <NUM> hours.

Solutions of <NUM>% and <NUM>% sodium chloride solutions were created with and without surfactant (TOMADOL <NUM>-<NUM> nonionic and/or Alcohol Ethoxysulfate (AES)) to mimic a detergent product. Total water level of pacs with surfactants was <NUM> to <NUM>%. All pacs showed stability during the pac making process, with the pacs containing the <NUM>% NaCl solution having superior rigidity as compared to the <NUM>% NaCl solution. Visually, it showed that incorporating surfactants improved the pac stability by enhancing rigidity.

Initial work focused on surfactant systems to study the role that total surfactant and total added salt (for example, sodium chloride, sodium sulfate, trisodium citrate) played in pac compatibility.

The lamellar surfactant system prepared according to Table <NUM> was placed into a pac. The formula contained and <NUM>% total surfactant and almost <NUM>% total water. The total surfactant is composed of LAS, cocofatty acid, alcohol ethoxylate, and TOMODOL <NUM>-<NUM>. The total water amount includes added DI water and water present in other materials, such as <NUM>% citric acid and <NUM>% NaOH. Despite the high water amount, the pac survived the pac making process. There was no evidence of elongation.

It is unexpectedly discovered that the formulation (i.e., the components and ratios thereof) of the above composition, even with only a very small amount of a salt, allows the compostion to reach a critical interchangeable biphase (gel-liquid transition) stage by slightly adjusting the concentration of the active. For example, the composition of Table <NUM> might be presented in a gel form. Upon dilution to arround <NUM>% active, the gel form was transitioned to a liquid form.

Further, when the active was adjusted back slightly, even to <NUM>%, the composition re-formed to the gel phase. At this point, additional pacs were prepared from the re-formed gel phase, which contained a water level of approximately <NUM>% (versus the earlier prepared pacs having a water level of <NUM>%).

Because of the structured nature of the gel, it can serve to suspend particles, specifically encapsulated fragrances. For example, <NUM>% encapsulated fragrance slurry and <NUM>% fragrance oil were added in the composition in Table <NUM>, and placed into a pac. The pac was stable, and the encapsulates showed no signs of settling or creaming out.

Water activity was measured, ranging from <NUM> to <NUM>, which is higher than that of commercial unit dose formulations, which range from <NUM> to <NUM>.

Lamellar laundry detergent formulations were prepared by incorporating polymers, enzymes, chelators, fragrances, and other functional materials commonly used in a finished product into a base similar to that in Table <NUM>. The formula is shown in Table <NUM>.

Pacs were made with the formula from Table <NUM>. They survived the pac-making process, and were stable, indicating that lamellar systems can incorporate common performance-enhancing laundry material.

Claim 1:
A unit dose composition comprising:
a water-soluble container formed from a water-soluble or water-dispersible film material;
an aqueous composition comprising:
water present in an amount of <NUM>% to <NUM>% by weight;
a surfactant system present in an amount of <NUM>% to <NUM>% by weight, wherein the anionic surfactant and the non-ionic surfactant are present in a weight ratio of from <NUM>:<NUM> to <NUM>:<NUM>; and
a water binding agent selected from the group consisting of a salt, the salt being sodium chloride, wherein the water binding agent is present in an amount of from <NUM>% to <NUM>% by weight;
wherein the aqueous composition has a water activity of from <NUM> to <NUM>, and wherein the surfactant system comprises:
(<NUM>) a linear alkylbenzene sulfonate (LAS) and/or an alcohol ethoxylsulfate (AES),
(<NUM>) an alcohol ethoxylate (AE), and
(<NUM>) a fatty acid
and wherein the surfactant system contains from <NUM> to <NUM> wt% of fatty acid.