Films including a water-soluble layer and a vapor-deposited organic coating

1. A method of forming a soluble unit dose article comprising:

forming a film by providing a first layer of water-soluble polymeric material and vapor depositing an organic coating to at least one surface of the first layer of water-soluble polymeric material to form a second layer, wherein the organic coating comprises a poly(p-xylylene) polymer;

vapor depositing a third layer comprising an inorganic coating to at least one surface of the first layer of water-soluble polymeric material; wherein the inorganic coating comprises a plurality of microfractures;

forming an open pouch from the film;

filling the open pouch with a composition; and

closing the open pouch.

2. The method of claim 1 , wherein vapor depositing uses chemical vapor deposition.

3. The method of claim 1 , wherein vapor depositing uses plasma-assisted chemical vapor deposition.

4. The method of claim 1 , further comprising partially ablating the at least one surface of the first layer of water-soluble polymeric material.

5. The method of claim 4 , wherein the at least one surface of the first layer of water-soluble polymeric material is partially ablated with one or more of a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment.

6. The method of claim 4 , wherein the at least one surface of the first layer of water-soluble polymeric material is partially ablated with helium-oxygen plasma or an argon-oxygen plasma.

7. The method of claim 1 , further comprising substantially fully ablating the at least one surface of the first layer of water-soluble polymeric material.

8. The method of claim 7 , wherein the at least one surface of the first layer of water-soluble polymeric material is substantially fully ablated with one or more of a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment.

9. The method of claim 7 , wherein the at least one surface of the first layer of water-soluble polymeric material is substantially fully ablated with helium-oxygen plasma or an argon-oxygen plasma.

10. The method of claim 1 , wherein the water-soluble polymeric material comprises polyvinyl alcohol.

11. The method of claim 1 , wherein the poly(p-xylylene) polymer comprises one or more of poly(p-xylylene) polymer, poly(dichloro-p-xylylene) polymer, α-perfluorodi-p-xylene polymer, and poly(tetrafluoro-p-xylylene) polymer.

12. The method of claim 1 , wherein the organic coating consists of the poly(p-xylylene) polymer.

13. The method of claim 1 , wherein the organic coating is directly attached to the surface of the first layer comprising the water-soluble polymeric material.

14. The method of claim 1 , wherein the organic coating has a thickness of from about 10 to about 500 nanometers.

15. The method of claim 1 , wherein the inorganic coating comprises a metal oxide.

16. The method of claim 1 , wherein the second layer is substantially free from microfractures and covers a portion of the plurality of microfractures in the third layer.

17. The method of claim 1 , wherein the third layer is directly attached to a surface of the first layer.

18. The method of claim 17 , wherein the second layer is directly attached to a surface of the third layer.