Water-soluble unit dose article including water-soluble core construction

1 . A method for making a single unit dose article containing a carrier solvent with an active cleaning formulation, the method comprising:

forming a water-soluble core substrate comprising a plurality of fibers including a water-soluble resin, the water-soluble core substrate containing a carrier solvent with an active cleaning formulation, wherein the carrier solvent comprises water, wherein the water-soluble resin comprises a polyvinyl alcohol polymer and wherein upon contact of the carrier solvent with at least one fiber of the plurality of fibers at a temperature in a range from 10° C. to 20° C. for five minutes or longer, the water-soluble core substrate exhibits a degree of shrinkage of 0.5% to 65% and the water-soluble core substrate, when contacted with water having a temperature as low as 5° C. to 10° C., disintegrates in a time period of not more than 300 seconds to release the active cleaning formulation;

forming an outer water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite material thereof, into an open pouch defining an interior volume configured to contain the water-soluble core substrate and the carrier solvent with the active cleaning formulation;

introducing the water-soluble core substrate and the carrier solvent with the active cleaning formulation into the interior volume; and

sealing the outer water-soluble material to enclose the interior volume.

2 . The method according to claim 1 , wherein forming a water-soluble core substrate comprising a plurality of fibers including a water-soluble resin comprises forming one of a water-soluble nonwoven substrate, a water-soluble foam substrate, or a water-soluble film substrate.

3 . The method according to claim 1 , wherein forming a water-soluble core substrate comprising a plurality of fibers including a water-soluble resin comprises at least one of saturating the water-soluble core substrate with the active cleaning formulation, disposing the active cleaning formulation on a surface of the water-soluble core substrate, coating a surface of the water-soluble core substrate with the active cleaning formulation, embedding the active cleaning formulation in the water-soluble core substrate, or impregnating the water-soluble core substrate with the active cleaning formulation.

4 . The method according to claim 1 , wherein sealing the outer water-soluble material comprises forming a seal at a bonding interface to enclose the water-soluble core substrate and the carrier solvent with the active cleaning formulation in the interior volume.

5 . The method according to claim 1 , wherein forming a water-soluble core substrate comprising a plurality of fibers including a water-soluble resin comprises forming a water-soluble nonwoven substrate into a plurality of layers, with the carrier solvent and the active cleaning formulation disposed between adjacent layers of the plurality of layers.

6 . The method according to claim 5 , wherein forming a water-soluble nonwoven-substrate into a plurality of layers comprises folding a continuous sheet of a water-soluble nonwoven web in a serpentine construction to form the plurality of layers.

7 . The method according to claim 5 , wherein forming a water-soluble nonwoven substrate into a plurality of layers comprises stacking a plurality of separate substrate sheets in a plied construction.

8 . The method according to claim 5 , further comprising applying the carrier solvent comprising glycerol with the active cleaning formulation to a surface of the water-soluble nonwoven substrate to a maximum coat weight of 120 gsm for the carrier solvent with the active cleaning formulation.

9 . The method according to claim 8 , wherein the carrier solvent comprising glycerol with the active cleaning formulation is applied to the surface of the water-soluble nonwoven substrate until the single unit dose article comprises 55% by weight of the active cleaning formulation.

10 . The method according to claim 9 , further comprising forming the water-soluble nonwoven substrate into 25 layers to 110 layers.

11 . The method according to claim 1 , wherein the water-soluble resin is a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a combination thereof.

12 . A method for making a single unit dose article containing a carrier solvent with an active cleaning formulation, the method comprising:

forming a water-soluble core substrate comprising a plurality of fibers including a water-soluble resin, the water-soluble core substrate containing a carrier solvent with an active cleaning formulation, wherein the carrier solvent comprises water and wherein upon contact of the carrier solvent with at least one fiber of the plurality of fibers at a temperature in a range from 10° C. to 20° C. for five minutes or longer, the water-soluble core substrate exhibits a degree of shrinkage of 0.5% to 65%, and the water-soluble core substrate, when contacted with water having a temperature as low as 5° C. to 10° C., disintegrates in a time period of not more than 300 seconds to release the active cleaning formulation;

forming an outer water-soluble material comprising at least one of a water-soluble nonwoven material, a water-soluble foam material, a water-soluble film material, or a composite material thereof, into an open pouch defining an interior volume configured to contain the water-soluble core substrate and the carrier solvent with the active cleaning formulation;

introducing the water-soluble core substrate and the carrier solvent with the active cleaning formulation into the interior volume; and

sealing the outer water-soluble material to enclose the interior volume,

wherein the outer water-soluble material comprises a water-soluble film laminated to a water-soluble nonwoven material.