Pouches having water-soluble films made from polyvinyl alcohol polymer blends, and related methods

Abstract

Pouches that include a water-soluble film and a composition at least partially enclosed by the water-soluble film in at least one compartment, where the water-soluble film includes a polyvinyl alcohol (PVOH) resin blend. Methods of making and using such pouches and films.

What is claimed is: 
     
         1 . A pouch comprising a water-soluble film and a household care composition at least partially enclosed by the water-soluble film in at least one compartment,
 the water-soluble film comprising a polyvinyl alcohol (PVOH) resin blend comprising:
 a first PVOH polymer comprising carboxylated anionic monomer units, vinyl alcohol monomer units and optionally vinyl acetate monomer units,
 wherein the carboxylated anionic monomer unit is present in the first PVOH polymer in an amount of from about 3 mol. % to about 6 mol. %, and 
 wherein the carboxylated anionic monomer unit is derived from a member selected from the group consisting of maleic acid, monoalkyl maleate, dialkyl maleate, maleic anyhydride, and combinations thereof; 
 
 a second PVOH polymer consisting essentially of vinyl alcohol monomer units and optionally vinyl acetate monomer units, 
   wherein the first PVOH polymer is present in an amount in a range from about 10 wt. % to about 50 wt. % of total PVOH polymers in the film.   
     
     
         2 . A pouch according to  claim 1 , wherein the PVOH resin blend is present in the water-soluble film in an amount in a range of about 50 wt. % to about 95 wt. %, or from about 50% to about 80%, more preferably from about 60% to about 75%, by weight of the film. 
     
     
         3 . A pouch according to  claim 1 , wherein the carboxylated anionic monomer unit is derived from a monoalkyl maleate unit selected from the group consisting of monomethyl maleate, salts, preferably alkali metal salts, thereof, and combinations thereof. 
     
     
         4 . A pouch according to  claim 1 , wherein the carboxylated anionic monomer unit is present in the first PVOH polymer in an amount of from about 3 mol. % to about 5 mol. %, or from about 3.5 mol. % to about 4.5 mol. %, or from about 4 mol. % to about 4.5 mol. %. 
     
     
         5 . A pouch according to  claim 1 , wherein the carboxylated anionic monomer is present in an amount in a range of from about 0.5 mol % to about 3 mol % of total PVOH polymer in the film. 
     
     
         6 . A pouch according to  claim 1 , wherein the first PVOH polymer is present in an amount in a range from about 20 wt. % to about 50 wt. %, more preferably from about 30 wt. % to about 40 wt. %, of total PVOH polymers in the film. 
     
     
         7 . A pouch according to  claim 1 , wherein the first PVOH polymer is characterized by a 4% solution viscosity at 20° C. (μ 1 ) of from about 10 cP to about 40 cP, or from about 10 cP to about 30 cP, or from about 12 cP to about 25 cP, or from about 14 cP to about 20 cP. 
     
     
         8 . A pouch according to  claim 1 , wherein the first PVOH polymer is characterized by a degree of hydrolysis of 60% to about 99%, preferably from about 80% to about 98%, preferably from about 83% to about 95%, preferably from about 85% to about 92%. 
     
     
         9 . A pouch according to  claim 1 , wherein the second PVOH polymer is characterized by a degree of hydrolysis of from about 60% to about 99%, preferably from about 80% to about 98%, preferably from about 85% to about 95%, preferably from about 87% to about 92%. 
     
     
         10 . A pouch according to  claim 1 , wherein the second PVOH polymer is characterized by a 4% solution viscosity at 20° C. (μ 2 ) from about 3.0 cP to about 30 cP, or from about 7 cP to about 30 cP, or from about 10 cP to about 30 cP, or from about 12 cP to about 25 cP. 
     
     
         11 . A pouch according to  claim 12 , wherein the first PVOH polymer is characterized by a 4% solution viscosity at 20° C. (μ 1 ), and wherein an absolute viscosity difference |μ 2 −μ 1 | for the first PVOH polymer and the second PVOH polymer is in a range of 0 cP to about 10 cP. 
     
     
         12 . A pouch according to  claim 1 , wherein the second PVOH polymer is present in an amount in a range from about 50 wt. % to about 90 wt. % of total PVOH polymers in the film, or from about 50 wt % to about 80 wt. %, or from about 60 wt. % to about 70 wt. %. 
     
     
         13 . A pouch according to  claim 1 , wherein the PVOH resin blend comprises a third PVOH polymer. 
     
     
         14 . A pouch according to  claim 1 , wherein the water-soluble film further comprises at least a third water-soluble polymer which is other than a PVOH polymer. 
     
     
         15 . A pouch according to  claim 14 , wherein third water-soluble polymer is selected from the group consisting of polyethyleneimines, polyvinyl pyrrolidones, polyalkylene oxides, polyacrylamides, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polyamides, gelatines, methylcelluloses, carboxymethylcelluloses and salts thereof, dextrins, ethylcelluloses, hydroxyethyl celluloses, hydroxypropyl methylcelluloses, maltodextrins, starches, modified starches, guar gum, gum Acacia, xanthan gum, carrageenan, polyacrylates and salts thereof, copolymers thereof, blends thereof, and combinations thereof. 
     
     
         16 . A pouch according to  claim 1 , wherein the water-soluble film further comprises one or more components selected from the group consisting of plasticizers, plasticizer compatibilizers, lubricants, release agents, fillers, extenders, cross-linking agents, antiblocking agents, antioxidants, detackifying agents, antifoams, nanoparticles, bleaching agents, surfactants, and combinations thereof. 
     
     
         17 . A pouch according to  claim 1 , wherein the water-soluble film further comprises one or more plasticizers in an amount in a range of about 1 wt. % to about 40 wt. % of the film. 
     
     
         18 . A pouch according to  claim 1 , wherein the film comprises an aversive agent, preferably a bittering agent, more preferably denatonium benzoate and/or a derivative thereof. 
     
     
         19 . A pouch according to  claim 1 , wherein the film has an undeformed thickness of from about 5 to about 200 μm, or from about 20 to about 100 μm, or from about 40 to about 85 μm, or about 76 μm. 
     
     
         20 . A pouch according to  claim 1 , wherein the pouch further comprises at least two compartments, or at least three compartments. 
     
     
         21 . A pouch according to  claim 20 , wherein a second compartment is superposed on a first compartment. 
     
     
         22 . A pouch according to  claim 1 , wherein the household care composition is selected from the group consisting of light duty liquid detergents compositions, heavy duty liquid detergent compositions, hard surface cleaning compositions, laundry detergent gels, bleaching compositions, laundry additives, fabric enhancer compositions, shampoos, body washes, other personal care compositions, and mixtures thereof. 
     
     
         23 . A pouch according to  claim 1 , wherein the composition is in the form of a liquid. 
     
     
         24 . A pouch comprising a water-soluble film and a household care composition at least partially enclosed by the water-soluble film in at least one compartment,
 the water-soluble film comprising a polyvinyl alcohol (PVOH) resin blend comprising:
 a first PVOH polymer comprising carboxylated anionic monomer units, vinyl alcohol monomer units and optionally vinyl acetate monomer units,
 wherein the carboxylated anionic monomer unit is derived from a member selected from the group consisting of maleic acid, monoalkyl maleate, dialkyl maleate, maleic anyhydride, and combinations thereof, 
 wherein the first PVOH polymer is present in an amount in a range from about 10 wt. % to about 50 wt. % of total PVOH polymers in the film, 
 wherein the carboxylated anionic monomer unit is present in the film in an amount in a range of from about 0.5 mol % to about 3 mol % of total PVOH polymer in the film, and 
 
 a second PVOH polymer consisting essentially of vinyl alcohol monomer units and optionally vinyl acetate monomer units. 
   
     
     
         25 . A pouch according to  claim 24 , wherein the composition is a liquid. 
     
     
         26 . A pouch according to  claim 24 , wherein the household care composition is selected from the group consisting of light duty liquid detergents compositions, heavy duty liquid detergent compositions, hard surface cleaning compositions, laundry detergent gels commonly used for laundry, bleaching compositions, laundry additives, fabric enhancer compositions, shampoos, body washes, other personal care compositions, and mixtures thereof. 
     
     
         27 . A method of forming a pouch according to  claim 1 , the method comprising the steps of:
 providing the water-soluble film;   shaping the film to form an open compartment;   providing the composition to the open compartment;   sealing the open compartment to form a pouch having a sealed compartment having the composition enclosed therein.   
     
     
         28 . A method according to  claim 27 , wherein the open compartment is sealed with at least a second sealed compartment, so that the pouch formed by the method is a multi-compartment pouch having superposed compartments. 
     
     
         29 . A method of treating a substrate, where the method includes the step of contacting the substrate with the composition of the pouch of  claim 1  in the presence of water.