Patent ID: 8466099

Claim:
A process for preparing a flexible porous dissolvable solid structure article, comprising the steps of: a. preparing a pre-mixture comprising a surfactant, a water soluble polymer, and optionally a plasticizer, wherein said pre-mixture comprises: i. from about 15% to 50% solids; and ii. a viscosity of from about 2,500 cps to 150,000 cps; b. aerating said pre-mixture by introducing a gas into the pre-mixture to form a wet aerated pre-mixture; c. forming the wet aerated pre-mixture into one or more shapes to provide a shaped wet aerated pre-mixture; and d. drying the shaped wet aerated pre-mixture in a drying environment, wherein the drying environment is heated, such that the shaped wet aerated pre-mixture is dried within about 3 minutes to about 90 minutes to a final moisture content from about 0.1% to about 25% moisture, to a dry density of from about 0.10 g/cm 3 to about 0.40 g/cm 3 , and a percent open cell content of from about 80% to about 100%, to form the flexible porous dissolvable solid structure article comprising the surfactant in an amount from 23% to about 75% by weight of the article.