Active containing fibrous structures with multiple regions having differing characteristics

Abstract

A fibrous structure including filaments wherein the filaments comprise one or more filament-forming materials and one or more active agents that are releasable from the filament when exposed to conditions of intended use, the fibrous structure further having at least two regions with different properties, in particular wherein each region has different average densities. Methods of treating fabrics with a fibrous structure are also provided herein.

What is claimed is: 
     
         1 . A fibrous structure comprising filaments wherein the filaments comprise one or more filament-forming materials and one or more active agents that are releasable from the filament when exposed to conditions of intended use, the fibrous structure further comprising:
 (a) a continuous network region, wherein the network region comprises a first average density; and   (b) a plurality of discrete zones comprising a second average density, wherein the discrete zones being dispersed throughout the network region, and wherein the first average density and the second average density are different.   
     
     
         2 . The fibrous structure of  claim 1 , wherein the first average density is from about 0.05 g/cc to about 0.80 g/cc. 
     
     
         3 . The fibrous structure of  claim 1 , wherein the second average density is from about 0.05 g/cc to about 0.80 g/cc. 
     
     
         4 . The fibrous structure of  claim 1 , wherein the continuous network region is a macroscopically monoplanar, patterned, continuous network region. 
     
     
         5 . The fibrous structure of  claim 1 , wherein the total level of the one or more filament-forming materials present in the filaments is less than 80% by weight on a dry filament basis and the total level of the one or more active agents present in the filaments is greater than 20% by weight on a dry filament basis. 
     
     
         6 . The fibrous structure of  claim 1 , wherein the one or more filament-forming materials and the one or more active agents are present in the filament at a weight ratio of filament-forming materials to active agents of less than 4.0. 
     
     
         7 . The fibrous structure of  claim 1 , wherein the one or more filament-forming materials comprises a polymer. 
     
     
         8 . The fibrous structure of  claim 7 , wherein the polymer is selected from the group consisting of: pullulan, hydroxypropylmethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, polyvinyl pyrrolidone, carboxymethyl cellulose, sodium alginate, xanthan gum, tragacanth gum, guar gum, acacia gum, Arabic gum, polyacrylic acid, methylmethacrylate copolymer, carboxyvinyl polymer, dextrin, pectin, chitin, levan, elsinan, collagen, gelatin, zein, gluten, soy protein, casein, polyvinyl alcohol, carboxylated polyvinylalcohol, sulfonated polyvinyl alcohol, starch, starch derivatives, hemicellulose, hemicellulose derivatives, proteins, chitosan, chitosan derivatives, polyethylene glycol, tetramethylene ether glycol, hydroxymethyl cellulose, and mixtures thereof. 
     
     
         9 . The fibrous structure of  claim 1  exhibits a basis weight of about 1500 gsm or less as measured according to the Basis Weight Test Method described herein. 
     
     
         10 . The fibrous structure of  claim 1 , wherein the one or more active agents comprises a surfactant. 
     
     
         11 . The fibrous structure of  claim 1 , wherein at least one of the one or more active agents is selected from the group consisting of: skin benefit agents, medicinal agents, lotions, fabric care agents, dishwashing agents, carpet care agents, surface care agents, hair care agents, air care agents, and mixtures thereof. 
     
     
         12 . The fibrous structure of  claim 1 , wherein the fibrous structure comprises two or more different active agents. 
     
     
         13 . The fibrous structure of  claim 1 , wherein the fibrous structure further comprises a dissolution aid. 
     
     
         14 . The fibrous structure of  claim 1  exhibits a water content of from 0% to about 20% as measured according to the Water Content Test Method described herein. 
     
     
         15 . The fibrous structure of  claim 1  exhibits an average disintegration time of about 60 s or less as measured according to the Dissolution Test Method described herein. 
     
     
         16 . The fibrous structure of  claim 1  exhibits an average dissolution time of about 600 s or less as measured according to the Dissolution Test Method described herein. 
     
     
         17 . The fibrous structure of  claim 1  exhibits an average basis weight normalized disintegration time of about 1.0 s/gsm or less as measured according to the Dissolution Test Method described herein. 
     
     
         18 . The fibrous structure of  claim 1  exhibits an average basis weight normalized dissolution time of about 10 s/gsm or less as measured according to the Dissolution Test Method described herein. 
     
     
         19 . The fibrous structure of  claim 1 , wherein at least some of the filaments exhibit a diameter of less than 50 μm as measured according to the Diameter Test Method described herein. 
     
     
         20 . A fibrous structure comprising filaments wherein the filaments comprise one or more filament-forming materials and one or more active agents that are releasable from the filament when exposed to conditions of intended use, the fibrous structure further comprising at least a first region and a second region, each of the first and second regions having at least one common intensive property, wherein the at least one common intensive property of the first region differs in value from the at least one common intensive property of the second region. 
     
     
         21 . The fibrous structure of  claim 20 , wherein the common intensive property is selected from the group consisting of density, basis weight, elevation, opacity, and any combination thereof. 
     
     
         22 . The fibrous structure of  claim 20 , wherein the at least one common intensive property comprises density such that the network region has a relatively high density relative to a relatively low density of the plurality of discrete zones. 
     
     
         23 . The fibrous structure of  claim 22 , wherein the average density of the network region is from about 0.15 g/cc to about 0.80 g/cc and the average density of the discrete zones is from about 0.05 g/cc to about 0.15 g/cc. 
     
     
         24 . The fibrous structure of  claim 20 , wherein the at least one common intensive property comprises density such that the network region has a relatively low density relative to a relatively high density of the plurality of discrete zones. 
     
     
         25 . The fibrous structure of  claim 24 , wherein the average density of the network region is from about 0.05 g/cc to about 0.15 g/cc and the average density of the discrete zones is from about 0.15 g/cc to about 0.80 g/cc. 
     
     
         26 . The fibrous structure of  claim 20 , wherein the first region comprises from about 5% to about 95% of the total area of the fibrous structure. 
     
     
         27 . The fibrous structure of  claim 20 , wherein the second region comprises from about 5% to about 95% of the total area of the fibrous structure. 
     
     
         28 . A process for making a fibrous structure, the process comprising the step of depositing a plurality of filaments on to a three-dimensional molding member comprising a non-random repeating pattern such that a fibrous structure comprising one or more filament-forming materials and one or more active agents that are releasable from the filaments when exposed to conditions of intended use is produced, the fibrous structure further comprising at least a first region and a second region, each of the first and second regions having at least one common intensive property, wherein the at least one common intensive property of the first region differs in value from the at least one common intensive property of the second region. 
     
     
         29 . The process of  claim 28 , wherein the at least one common intensive property comprises density such that the substantially continuous network region has a relatively high density relative to a relatively low density of the plurality of discrete zones. 
     
     
         30 . The process of  claim 28 , wherein the at least one common intensive property comprises density such that the substantially continuous network region has a relatively low density relative to a relatively high density of the plurality of discrete zones. 
     
     
         31 . A method for treating a fabric article in need of treatment, the method comprising the step of treating the fabric article with a fibrous structure according to  claim 1 . 
     
     
         32 . The method according to  claim 31 , wherein the step of treating comprises one or more steps selected from the group consisting of:
 (a) pre-treating the fabric article before washing the fabric article;   (b) contacting the fabric article with a wash liquor formed by nonwoven web with water;   (c) contacting the fabric article with the nonwoven web in a dryer;   (d) drying the fabric article in the presence of the nonwoven web in a dryer; and   (e) combinations thereof.