A fabric care article made of solid or semi-solid matrix of materials for repetitive or multiple use in a machine drying apparatus such as a tumble dryer. The matrix includes a structuring agent comprising a filler structuring agent and a polymeric structuring agent. The filler structuring agent comprises about 0.2 % to about 10% and the polymeric structuring agent comprises about 0.5 to about 20% by weight of the composition. The matrix further includes up to about 25% of an anionic soap surfactant, about 10% to about 60% of free fatty acid, and about 1% to about 50% of a non-ionic, but is substantially free from cationic surfactant. When the fabric care article is used up, it simply disappears, indicating to a user that the article needs to be replenished.
1. A process of making a cast matrix solid or semi-solid multiple use fabric care article for a tumble dryer, the process comprising
(a) mixing up to about 25% of an anionic surfactant comprising soap, from about 10% to about 60% of free fatty acid, from about 1% to about 50% of a nonionic material, and from about 0.5% to about 10% polymeric structuring agent, to obtain a mixture;
(b) pouring the mixture into a mold where from about 0.2% to about 10% of a filler non-woven structuring agent in the form of a sheet or fiber form is also placed, to obtain the fabric care article.
2. The process of claim 1 , wherein said anionic surfactant and said non-ionic material are water soluble.
3. The process of claim 1 , wherein said fatty acid comprises a C 8 to C 24 saturated or unsaturated fatty acid and mixtures thereof.
4. The process of claim 1 , wherein said fatty acid has Melting Point of about 10 deg. C. to about 65 deg. C.
5. The process of claim 1 , wherein said non-woven comprises polyester, polyethylene, polypropylene, cellulose, and mixtures thereof.
6. The process of claim 1 , wherein said polymeric structuring agent comprises polyamides, block copolymers of ethylene oxide and propylene oxide having hydrophilic and lypophilic end groups, alkyl phenol polylower alkylene oxide lower alkanols, polymers of lower alkylene glycols, polyalkylene glycol ethers of higher fatty alcohols and poly alkylene glycol esters of higher fatty acids, polyoxyalkylenated fatty alcohols, polyurethanes, polylactide, polyacrylamide, polyacrylates, polyethylene, polyvinyl alcohol, and mixtures thereof.
7. The process of claim 1 , wherein said matrix is substantially free from cationic surfactarit.
8. The process of claim 1 , wherein the ratio of said anionic surfactant to said fatty acid to said non-ionic material is about 1/1.5/1 to about 1/2.5/2 by the weight.
9. The process of claim 1 , wherein said solid or semi-solid matrix composition is cast into a bar of about 10 to about 30 grams.
10. The process of claim 1 , further comprising providing a package for the fabric care article.
11. The process of claim 10 , wherein said package retains said matrix therein and permits delivery of said matrix materials onto fabrics in a tumble dryer.
12. The process of claim 11 , wherein said package controls the amount of said materials delivered onto said fabrics per cycle of said tumble dryer.
13. The process of claim 10 , wherein said package is provided with a delivery window.
14. The process of claim 13 , wherein said delivery window comprises a material that adsobs and/or absorbs said matrix materials during the operation of said tumble dryer.
15. The process of claim 14 , wherein said sorptive material controls delivery of said matrix materials onto said fabrics.
16. The process of claim 14 , wherein said sorptive material comprises non-woven material comprising polyester, polypropylene, cellulose, and mixtures thereof.
17. A method of fabric care comprising:
(a) preparing a fabric care article by the process of claim 1 ;
(b) placing the article in a machine tumble dryer;
(c) loading said dryer with damp laundered fabric; and
(d) operating said dryer to achieve an elevated temperature of up to about 90 deg. C.; and
repeating steps (c) and (d) multiple times.