Process for making a water-soluble foam component

Abstract

The present invention relates to a process for preparing a water-soluble foam matrix which is capable of delivering an active ingredient and articles of manufacture comprising said foam matrix, said article comprising: i) a water-soluble polymeric component in the form of a foam matrix; and ii) an active ingredient component dispersed throughout said matrix; said process comprising the steps of: a) admixing a water-soluble polymer and an active ingredient to form a homogeneous admixture, said admixture having a viscosity of at least 150 Pa-sec; b) introducing a gas or a compound capable of releasing a gas into said admixture to form a foam matrix; and c) optionally, shaping said matrix to provide a matrix having a shape or a form.

What is claimed is:  
     
         1 . A process for preparing an article of manufacture capable of controllably releasing one or more active ingredients, said article comprising: 
 i) a water-soluble polymeric component in the form of a foam matrix; and    ii) an active ingredient component dispersed throughout said matrix;    said process comprising the steps of: 
 a) admixing a water-soluble polymer and an active ingredient to form a homogeneous admixture, said admixture having a viscosity of at least 150 Pa-sec;  
 b) introducing a gas or a compound capable of releasing a gas into said admixture to form a foam matrix; and  
 c) optionally, shaping said matrix to provide a matrix having a shape or a form.  
   
     
     
         2 . A process according to  claim 1  wherein said homogenous admixture has a viscosity of at least 200 Pa-sec.  
     
     
         3 . A process according to  claim 2  wherein said homogenous admixture has a viscosity of at least 250 Pa-sec.  
     
     
         4 . A process according to  claim 3  wherein said homogenous admixture has a viscosity of at least 300 Pa-sec.  
     
     
         5 . A process according to  claim 4  wherein said homogenous admixture has a viscosity of at least 350 Pa-sec.  
     
     
         6 . A process according to  claim 1  wherein said water-soluble polymer is selected from the group consisting of polyvinyl alcohol, polyvinyl pyrrolidone, polyalkylene oxides, cellulose ethers, polycarboxylic acids, polyamino acids, polyacrylamide, and mixtures thereof.  
     
     
         7 . A process according to  claim 6  wherein said polymer is polyvinyl alcohol, hydroxypropyl methylcellulose, maleic/acrylic acid copolymers, and mixtures thereof.  
     
     
         8 . A process according to  claim 1  wherein said active ingredient is a detersive surfactant selected from the group consisting of anionic, cationic, nonionic, zwitterionic, ampholytic surfactants and mixtures thereof.  
     
     
         9 . A process according to  claim 1  wherein said active ingredient is a cosmetic component selected from the group consisting of astringents, emollients, vitamins, moisturizers, abrasives, anti-acne agents, surfactants, aloe, and mixtures thereof.  
     
     
         10 . A process according to  claim 1  wherein said active ingredient is a laundry adjunct selected from the group consisting of enzymes, bleaching systems, fabric softener actives, soil release agents, builders, optical brighteners, aesthetic agents, and mixtures thereof.  
     
     
         11 . A process according to  claim 1  wherein said active ingredient is a fabric modifying agent selected from the group consisting of dyes, cellulosic crosslinking agents, surface modifying agents, anti-static agents, and mixtures thereof.  
     
     
         12 . A process according to  claim 1  wherein said active ingredient is a pharmaceutically active agent.  
     
     
         13 . A process according to  claim 1  wherein step (a) further comprises admixing one or more dissolution aids.  
     
     
         14 . A process according to  claim 1  wherein step (a) further comprises admixing one or more pH adjusting agents.  
     
     
         15 . A process according to  claim 1  wherein step (a) further comprises admixing one or more stabilizing agents.  
     
     
         16 . A process according to  claim 1  wherein said foam matrix has a relative density of from 0.01 g/cm 3  to about 0.95 g/cm 3 .  
     
     
         17 . A process according to  claim 16  wherein said foam matrix has a relative density of from 0.05 g/cm 3  to about 0.9 g/cm 3 .  
     
     
         18 . A process according to  claim 17  wherein said foam matrix has a relative density of from 0.1 g/cm 3  to about 0.5 g/cm 3 .  
     
     
         19 . A process according to  claim 1  wherein said foam matrix has an elastic modulus of less than 10 GPa.  
     
     
         20 . A process according to  claim 19  wherein said foam matrix has an elastic modulus of less than 1 GPa.  
     
     
         21 . A process according to  claim 1  wherein said gas is selected from the group consisting of nitrogen, carbon dioxide, anhydrous air, and mixtures thereof.  
     
     
         22 . A process according to  claim 1  wherein said foam matrix is shaped by extruding said foam matrix formed in step (b).  
     
     
         23 . A process according to  claim 1  wherein said foam matrix is formed into a granule.  
     
     
         24 . A process according to  claim 23  wherein said granule has an average size of from 10 to 2000 microns.  
     
     
         25 . A process according to  claim 24  wherein said granule has an average size of from 50 to 2000 microns.  
     
     
         26 . A process according to  claim 25  wherein said granule has an average size of from 100 to 1500 microns.  
     
     
         27 . A process according to  claim 26  wherein said granule has an average size of from 200 to 1000 microns.  
     
     
         28 . A process according to  claim 1  wherein said foam matrix is formed into a sheet said sheet having a mean thickness of from about 0.01 microns to about 100,000 microns.  
     
     
         29 . A process according to  claim 28  wherein said foam matrix is formed into a sheet said sheet having a mean thickness of from about 0.05 microns to about 50,000 microns.  
     
     
         30 . A process according to  claim 29  wherein said foam matrix if formed into a sheet said sheet having a mean thickness of from about 0.1 microns to about 30,000 microns.  
     
     
         31 . An article of manufacture comprising: 
 i) a water-soluble polymeric component in the form of a foam matrix; and    ii) an active ingredient component dispersed throughout said matrix;    said article of manufacture formed from a process comprising the steps of: 
 a) admixing a water-soluble polymer and an active ingredient to form a homogeneous admixture, said admixture having a viscosity of at least 150 Pa-sec;  
 b) introducing a gas or a compound capable of releasing a gas into said admixture to form a foam matrix;  
 c) shaping said matrix into an article of manufacture;  
 d) optionally, coating said article of manufacture with a coating to formed a coated article of manufacture.  
   
     
     
         32 . An article according to  claim 31  wherein said homogenous admixture has a viscosity of at least 350 Pa-sec.  
     
     
         33 . An article according to  claim 31  wherein said water-soluble polymer is selected from the group consisting of polyvinyl alcohol, polyvinyl pyrrolidone, polyalkylene oxides, cellulose ethers, polycarboxylic acids, polyamino acids, polyacrylamide, and mixtures thereof.  
     
     
         34 . An article according to  claim 31  wherein said active ingredient is a detersive surfactant selected from the group consisting of anionic, cation ic, nonionic, zwitterionic, ampholytic surfactants and mixtures thereof.  
     
     
         35 . An article according to  claim 31  wherein said active ingredient is a cosmetic component selected from the group consisting of astringents, emollients, vitamins, moisturizers, abrasives, anti-acne agents, surfactants, aloe, and mixtures thereof.  
     
     
         36 . An article according to  claim 31  wherein said active ingredient is a laundry adjunct selected from the group consisting of enzymes, bleaching systems, fabric softener actives, soil release agents, builders, optical brighteners, aesthetic agents, and mixtures thereof.  
     
     
         37 . An article according to  claim 31  wherein said active ingredient is a fabric modifying agent selected from the group consisting of dyes, cellulosic crosslinking agents, surface modifying agents, anti-static agents, and mixtures thereof.  
     
     
         38  An article according to  claim 31  wherein said active ingredient is a pharmaceutically active agent.  
     
     
         39 . An article according to  claim 31  wherein step (a) further comprises admixing one or more dissolution aids.  
     
     
         40 . An article according to  claim 31  wherein step (a) further comprises admixing one or more pH adjusting agents.  
     
     
         41 . An article according to  claim 31  wherein step (a) further comprises admixing one or more stabilizing agents.  
     
     
         42 . An article according to  claim 31  wherein said article comprises a foam matrix having a relative density of from 0.1 g/cm 3  to about 0.5 g/cm 3 .  
     
     
         43 . An article according to  claim 31  wherein said article comprises a foam having an elastic modulus of less than 1 GPa.  
     
     
         44 . An article according to  claim 31  wherein said article is shaped by extruding said foam matrix formed in step (b).  
     
     
         45 . An article according to  claim 31  wherein said article is formed into a granule having an average size of from 200 to 1000 microns.  
     
     
         46 . An article according to  claim 31  wherein said article is in the form of a sheet having a mean thickness of from about 0.1 microns to about 30,000 microns.