Porous, dissolvable solid substrate and surface resident coating comprising matrix microspheres

1. A personal care article comprising:

(a) a porous dissolvable solid substrate comprising:

i. from about 30% to about 70% of a surfactant by weight of the porous dissolvable solid substrate;

wherein the surfactant comprises an anionic surfactant selected from the group consisting of alkyl and alkyl ether sulfates, sulfated monoglycerides, sulfonated olefins, alkyl aryl sulfonates, primary or secondary alkane sulfonates, alkyl sulfosuccinates, acid taurates, acid isethionates, alkyl glycerylether sulfonate, sulfonated methyl esters, sulfonated fatty acids, alkyl phosphates, acyl glutamates, acyl sarcosinates, alkyl lactylates, anionic fluorosurfactants, sodium lauroyl glutamate, and combinations thereof;

ii. from about 5% to about 50% water-soluble polymer by weight of the porous dissolvable solid substrate;

iii. from about 0.5% to about 30% plasticizer by weight of the porous dissolvable solid substrate; and

(b) a surface resident coating comprising from about 10% to about 100% of matrix microspheres wherein the matrix microspheres comprise from about 25% to about 70% of a starch derived material, from about 5% to about 60% of a cationic surfactant conditioner, and from about 5% to about 60% of a perfume, all by weight relative to the total weight of the porous dissolvable solid substrate and wherein the weight ratio of the porous dissolvable solid substrate to the surface resident coating is from 110:1 to about 0.5:1, wherein the starch-derived materials is selected from the group consisting of hydrolyzed starches, acid modified starches, enzymatic hydrolyzed starches, octenyl succinic acid anhydride modified starches (OSAN starches), dextrinized OSAN starches, dextrins, maltodextrins, pregelatinized waxy maize starches, and mixtures thereof;

wherein the porous dissolvable solid substrate comprises a percent open cell content from about 80% to about 100.0%; and wherein the cationic surfactant conditioner is selected from the group consisting of cetyltrimethylammonium chloride, behenyltrimethylammonium chloride (BTAC), stearyltrimethylammonium chloride, cetylpyridinium chloride, octadecyltrimethylammonium chloride, hexadecyltrimethylammonium chloride, octyldimethylbenzylammonium chloride, decyldimethylbenzylammonium chloride, stearyldimethylbenzylammonium chloride, didodecyldimethylammonium chloride, dioctadecyldimethylammonium chloride, distearyldimethylammonium chloride, tallowtrimethylammonium chloride, cocotrimethylammonium chloride, dipalmitoylethyldimethylammonium chloride, PEG-2oleylammonium chloride, and salts of these, where the chloride is replaced by halogen, acetate, citrate, lactate, glycolate, phosphate, nitrate, sulphate, alkylsulphate and mixtures thereof;

and wherein the personal care articles have a hand dissolution value of from about 1 to about 30 strokes.

2. The personal care article of claim 1 , wherein the matrix microspheres comprise from about 30% to about 60% starch derived material by weight relative to the total weight of the porous dissolvable solid substrate.

3. The personal care article of claim 1 , wherein the matrix microspheres comprise from about 35% to about 50% starch derived material by weight relative to the total weight of the porous dissolvable solid substrate.

4. The personal care article of claim 1 , wherein the matrix micropheres comprise from about 15% to about 50% cationic surfactant conditioner by weight relative to the total weight of the porous dissolvable solid substrate.

5. The personal care article of claim 1 , wherein the matrix micropheres comprise from about 20% to about 40% cationic surfactant conditioner by weight relative to the total weight of the porous dissolvable solid substrate.

6. The personal care article of claim 1 , wherein the matrix micropheres comprise from about 15% to about 50% perfume by weight relative to the total weight of the porous dissolvable solid substrate.

7. The personal care article of claim 1 , wherein the matrix micropheres comprise from about 20% to about 40% perfume by weight relative to the total weight of the porous dissolvable solid substrate.

8. The personal care article of claim 2 , wherein the surfactant further comprises a Group II surfactant, wherein the Group II surfactant is selected from the group consisting of amphoteric, zwitterionic, and combinations thereof.

9. The personal care article of claim 1 , wherein the weight ratio of the porous dissolvable solid substrate to the surface resident coating is from about 20:1 to about 1:1.

10. The personal care article of claim 1 , wherein the weight ratio of the porous dissolvable solid substrate to the surface resident coating is from about 10:1 to about 1.5:1.

11. The personal care article of claim 1 , wherein the weight ratio of the porous dissolvable solid substrate to the surface resident coating is from about 7:1 to about 3:1.

12. The personal care article of claim 1 , wherein the surface resident coating is a powder.

13. The personal care article of claim 1 , wherein the surface resident coating is in the form of a layer, a coating, and combinations thereof.

14. The personal care article of claim 1 , wherein the surface resident coating is attached to at least a portion of the solid/air interface of the porous dissolvable solid substrate.

15. The personal care article of claim 1 , wherein the surface resident coating covers the outer surface of the porous dissolvable solid substrate.

16. The personal care article of claim 1 , wherein the dissolvable personal care article comprises two porous dissolvable solid substrates, and wherein the surface resident coating is a layer situated between the two porous dissolvable solid substrates.

17. The personal care article of claim 1 , the porous dissolvable solid substrate having a basis weight of from about 125 grams/m 2 to about 3,000 grams/m 2 and a thickness of from about 0.5 mm to about 10 mm.

18. The personal care article of claim 1 , wherein the porous dissolvable solid substrate comprises a specific surface area from about 0.03 m 2 /gram to about 0.25 m 2 /gram.

19. The personal care article of claim 1 , wherein the porous dissolvable solid substrate comprises a cell wall thickness of from about 0.02 mm to about 0.15 mm.

20. A method for making a personal care article, the method comprising:

(a) preparing a processing mixture comprising from about 30% to about 70% of a surfactant, wherein the surfactant comprises an anionic surfactant selected from the group consisting of alkyl and alkyl ether sulfates, sulfated monoglycerides, sulfonated olefins, alkyl aryl sulfonates, primary or secondary alkane sulfonates, alkyl sulfosuccinates, acid taurates, acid isethionates, alkyl glycerylether sulfonate, sulfonated methyl esters, sulfonated fatty acids, alkyl phosphates, acyl glutamates, acyl sarcosinates, alkyl lactylates, anionic fluorosurfactants, sodium lauroyl glutamate, and combinations thereof, from about 5% to about 50% water-soluble polymer, and from about 0.5% to about 30% plasticizer;

(b) aerating the processing mixture by introducing a gas into the processing mixture to form an aerated wet mixture;

(c) forming the aerated wet mixture into one or more desired shapes;

(d) drying the aerated wet mixture to form a porous dissolvable solid substrate; and

(e) applying a surface resident coating comprising from about 10% to about 100% of matrix microspheres wherein the matrix microspheres comprise from about 25% to about 70% of a starch derived material, from about 5% to about 60% of a cationic surfactant conditioner, and from about 5% to about 60% of a perfume in powdered form to the porous dissolvable solid substrate; wherein the starch-derived materials is selected from the group consisting of hydrolyzed starches, acid modified starches, enzymatic hydrolyzed starches, octenyl succinic acid anhydride modified starches (OSAN starches), dextrinized OSAN starches, dextrins, maltodextrins, pregelatinized waxy maize starches, and mixtures thereof; wherein the porous dissolvable solid substrate comprises a percent open cell content from about 80% to about 100.0%; and wherein the cationic surfactant conditioner is selected from the group consisting of cetyltrimethylammonium chloride, behenyltrimethylammonium chloride (BTAC), stearyltrimethylammonium chloride, cetylpyridinium chloride, octadecyltrimethylammonium chloride, hexadecyltrimethylammonium chloride, octyldimethylbenzylammonium chloride, decyldimethylbenzylammonium chloride, stearyldimethylbenzylammonium chloride, didodecyldimethylammonium chloride, dioctadecyldimethylammonium chloride, distearyldimethylammonium chloride, tallowtrimethylammonium chloride, cocotrimethylammonium chloride, dipalmitoylethyldimethylammonium chloride, PEG-2oleylammonium chloride, and salts of these, where the chloride is replaced by halogen, acetate, citrate, lactate, glycolate, phosphate, nitrate, sulphate, alkylsulphate and mixtures thereof;

and wherein the resulting personal care articles have a hand dissolution value of from about 1 to about 30 strokes.

21. The method of making a personal care article according to claim 20 , wherein the surface resident coating is applied to the porous dissolvable solid substrate at a humidity of about 20% to about 70%.

22. The method of making a personal care article according to claim 20 , wherein the surface resident coating is applied to the porous dissolvable solid substrate at a humidity of about 30% to about 60%.

23. The method of making a personal care article according to claim 20 , wherein the surface resident coating is applied to the porous dissolvable solid substrate having a moisture content of about 5% to about 20%.