Disposable cleaning product
The invention is directed at a disposable dry cleansing article that is formed from a melt extruded fibrous web that has incorporated into the fibers forming the web from 0.5 to 20 percent by weight of a melt extruded lathering surfactant. The invention, dry article generally comprises a melt extruded fibrous web of a thermoplastic polymer having a basis weight of from about 10 to 200 g/m 2 , preferably 10 to 150 g/m 2 wherein the fibers have a lathering surfactant incorporated into the fiber at a level that allows the article to be used two (2) or more times with a rinse foam volume of 15 or more, with an initial foam volume of at least 50 ml. The novel melt extruded web can be made by the following sequential steps: (a) providing to an extruder a thermoplastic resin, such as polypropylene; (b) blending into the resin a lathering surfactant at a temperature at which the surfactant is not significantly degraded; (c) forming the blend into melt extruded fibers, (d) collecting the fibers, (e) forming the fibers into a web and optionally, further treating the web by coating additional components, laminating to further layers or consolidating for strength or the like.
1. A disposable personal care cleansing article comprising a fibrous web containing melt extruded fibers, the melt extruded fibers comprising a blend of fiber-forming polymer with a melt extruded lathering surfactant, wherein the article has a foam volume for two or more rinsings, where the initial foam value is at least 30 ml and said article is substantially dry prior to use.
2. The cleansing article as defined in claim 1 wherein the foam volume is at least 5 ml for three or more rinsings.
3. The cleansing article as defined in claim 1 wherein the initial foam volume is 40 ml or more.
4. The cleansing article as defined in claim 1 wherein the initial foam volume is 50 ml or more.
5. The cleansing article as defined in claim 4 wherein the foam volume is at least 5 ml for three or more rinsings.
6. The cleansing article as defined in claim 1 wherein the melt extruded lathering surfactant is present in an amount of from 0.5 to 20 percent by weight of the melt extruded fibers containing lathering surfactant and the fibers further include a melt extruded hydrophilic surfactant.
7. The cleansing article as defined in claim 1 wherein the melt extruded lathering surfactant is present in an amount of from 5.0 to 20 percent by weight of the melt extruded fibers containing lathering surfactant.
8. The cleansing article as defined in claim 1 wherein the fiber-forming polymer consists of a polyolefin.
9. The cleansing article defined in claim 1 wherein an additional lathering surfactant is present in an amount of from 0.5 to 20% by weight of the cleansing article.
10. The cleansing article defined in claim 1 wherein the melt extruded lathering surfactant is present in an amount of from 5 to 20% by weight of the fiber forming polymer blend and the cleansing article has a foam volume of greater than 10 ml for three or more rinsings.
11. The cleansing article defined in claim 10 wherein at least one additional lathering surfactant is further added onto or impregnated into said cleansing article.
12. The cleansing article defined in claim 11 wherein said at least one additional lathering surfactant comprises from about 0.5% to about 20 percent by weight of the cleansing article.
13. The cleansing article defined in claim 12 wherein said lathering surfactant is selected from the group consisting of anionic lathering surfactants, nonionic lathering surfactants, amphoteric lathering surfactants, and mixtures thereof.
14. The cleansing article defined in claim 13 wherein said anionic lathering surfactant is selected from the group consisting of sarcosinates, sulfates, isethionates, phosphates, taurates, lactylates, glutamates and mixtures thereof; wherein said nonionic lathering surfactant is selected from the group consisting of amine oxides, alkyl glucosides, alkyl polyglucosides, polyhydroxy fatty acid amides, alkoxylated fatty acid esters, sucrose esters, and mixtures thereof; and wherein said amphoteric lathering surfactant is selected from the group consisting of betaines, sultaines, hydroxysultaines, alkyhminoacetates, iminodialkanoates, aminoalkanoates, and mixtures thereof.
15. The cleansing article defined in claim 1 wherein the melt extruded surfactant is sodium cocoyl isethionate.
16. The cleansing article defined in claim 13 further comprising a conditioning component.
17. The cleansing article defined in claim 13 wherein said article further comprises a safe and effective amount of one or more active ingredients selected from the group consisting of anti-acne actives, anti-wrinkle and anti-skin atrophy actives skin barrier repair actives, non-steroidal cosmetic soothing actives, non-stearoidal anti-inflammatory actives, topical anesthetics, artificial tanning agents and accelerators, skin lightening actives, sebum stimulators, sebum inhibitors, anti-microbial and anti-fungal agents, sunscreen actives, anti-oxidants, and mixtures thereof.
18. The cleansing article defined in claim 1 wherein said the fibrous web comprises a meltblown fiber web.
19. The cleansing article defined in claim 18 wherein the melt extruded fibers are polyolefin fibers.
20. The cleansing article defined in claim 19 wherein the melt extruded fibers contain from 0.5 to 20% by weight a melt extruded lathering surfactant.
21. The cleansing article defined in claim 19 wherein the melt extruded lathering surfactant comprises sodium cocoyl isethionate.
22. The cleansing article defined in claim 19 wherein the melt extruded fiber webs further has incorporated within its structure additional discrete fibers or particles.
23. The cleansing article defined in claim 1 wherein the cleansing article has a basis weight of from 10 to 200 g/m 2 .
24. The cleansing article defined in claim 19 wherein the melt extruded fibers are multicomponent fibers.
25. The cleansing article defined in claim 1 wherein the melt extruded fibers are multicomponent fibers.
26. The cleansing article defined in claim 1 wherein an additional layer is joined to the melt extruded fiber containing layer.
27. The cleansing article defined in claim 26 wherein the additional layer is a functionally different layer.
28. The cleansing article defined in claim 1 wherein the melt extruded fibers are a continuous fiber.
29. The cleansing article defined in claim 1 wherein the melt extruded fibers are a discontinuous fiber.
30. The cleansing article defined in claim 18 wherein the melt extruded fibers are a multicomponent fiber.
31. The cleansing article defined in claim 19 wherein the cleansing article nonwoven fibrous web has a basis weight of from 10 to 100 g/m 2 .
32. The cleansing article defined in claim 1 wherein the cleansing article is from 10 to 100 cm 2 and is provided in a package containing more than 2 cleansing articles.
33. The cleansing article defined in claim 32 wherein the package contains at least 10 cleansing articles.
34. The cleansing article defined in claim 16 wherein said conditioning component is melt extruded.
35. The cleansing article defined in claim 1 wherein the cleansing article is embossed with a pattern.
36. The cleansing article defined in claim 1 wherein the melt extruded fibers further include a hydrophilic surfactant.