Dissolvable sheet containing a cleaning active and method of making same

Abstract

A dissolvable sheet having a water-soluble substrate, and one or more cleaning actives disposed uniformly throughout the water-soluble substrate. The water-soluble substrate is formed from a first substrate builder comprising polyvinyl alcohol, a second substrate builder, such as starch, and sodium laurylglucosides hydroxypropylsulfonate, and is sized and shaped to form a sheet, and hold a premeasured amount of the cleaning active. The substrate dissolves when contacted with a sufficient amount of water, thereby releasing the cleaning active into the water, which also dissolves in the water. A method of making the dissolvable sheet is also disclosed.

Claims

1. A laundry or dishwashing non-fibrous dissolvable sheet formed on a heated surface, comprising: from about 12 wt-% to about 28 wt-% of polyvinyl alcohol (PVA); from about 10 wt-% to about 30 wt-% of starch; from about 10 wt-% to about 25 wt-% of potassium cocoate or alpha olefin sulfonate; from about 5 wt-% to about 20 wt-% of glycerin; from about 5 wt-% to about 40 wt-% of sodium laurylglucosides hydroxypropylsulfonate; and from 0 wt-% to about 5 wt-% of one or more enzymes; wherein said dissolvable sheet is free of sulfate and ethoxylate surfactants.

2. The dissolvable sheet as claimed in claim 1, further comprising a food grade preservative.

3. The dissolvable sheet as claimed in claim 2, wherein said preservative comprises potassium sorbate.

4. The dissolvable sheet as claimed in claim 1, a wherein said one or more enzymes comprise amylase enzymes, pectinase enzymes, lipase enzymes, cellulase enzymes, mannanase enzymes, or a combination thereof.

5. The dissolvable sheet as claimed in claim 1, further comprising a release agent.

6. The dissolvable sheet as claimed in claim 5, wherein said release agent comprises an oil, a plant oil, a glyceride, a triglyceride, a glycol, a glycerol, a paraffin, a wax, or a mineral oil.

7. The dissolvable sheet as claimed in claim 1, further comprising a water softener and chelating agent.

8. The dissolvable sheet as claimed in claim 7, wherein said water softener and chelating agent comprises aminopolycarboxylate, glutamate diacetate, ethylenediaminetetraacetic acid, nitrilotriacetic acid, gluconate, aminopolycarboxylic acid, sodium gluconate, tetrasodium glutamate diacetate or carboxymethyl inulin.

9. The dissolvable sheet as claimed in claim 1, further comprising a fragrance.

10. The dissolvable sheet as claimed in claim 9, wherein said fragrance comprises an essential oil, a botanical extract, or a natural aromachemical.

11. The dissolvable sheet as claimed in claim 1, further comprising a scale inhibitor, wherein said scale inhibitor is a carboxymethyl inulin, or a polyacrylate polymer.

12. The dissolvable sheet as claimed in claim 1, further comprising: from about 1 wt-% to about 10 wt-% of cocoamidopropyl betaine; a from about 1 wt-% to about 5 wt-% of a 50% liquid glutamate diacetate; from about 5 wt-% to about 20 wt-% an alkyl polyglucoside having 10-16 carbons; and from about 1 wt-% to about 10 wt-% of lauramine oxide.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Reference will now be made to the preferred embodiments of the present invention with reference, by way of example only, to the following drawings in which:

(2) FIG. 1 is a top view of a dissolvable sheet containing a cleaning active, according to an embodiment of the present invention;

(3) FIG. 2 is a side view of the dissolvable sheet of FIG. 1;

(4) FIG. 3 is a top view of a dissolvable sheet that is easily severable into two smaller portions, according to another embodiment of the present invention; and

(5) FIG. 4 is a side view of the dissolvable sheet of FIG. 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(6) The present invention is described in more detail with reference to exemplary embodiments thereof as shown in the appended drawings. While the present invention is described below including preferred embodiments, it should be understood that the present invention is not limited thereto. Those of ordinary skill in the art having access to the teachings herein will recognize additional implementations, modifications, and embodiments which are within the scope of the present invention as disclosed and claimed herein.

(7) A dissolvable sheet 10 according to an embodiment of the present invention is shown in FIGS. 1 and 2. Preferably, the dissolvable sheet 10 has a water-soluble substrate 12, and a cleaning active 14 disposed uniformly throughout the water-soluble substrate 12. The water-soluble substrate 12 is preferably sized and shaped to form a sheet, and hold a premeasured amount of the cleaning active 14. The water-soluble substrate 12 is configured to dissolve when contacted with a sufficient amount of water, thereby releasing the cleaning active 14 into the water. According to the example shown in FIG. 1, the dissolvable sheet 10 may be sized and shaped to form a square sheet, which is, for example, about 102 mm long by about 102 mm wide, about 0.8 mm thick, and has a weight of about 4 grams. It will of course be appreciated that the dissolvable sheet may be formed with other dimensions and weights depending on the application, or the amount of cleaning active 14 required or desired to be stored in and delivered by the dissolvable sheet 10, when dissolved in water. Accordingly, it is contemplated that the dissolvable sheet 10 may be shaped as a rectangle, or any other polygon, including triangle, trapezoid, diamond, rhombus, parallelogram, and the like, as well as arcuate shapes, such as circles, ovals and the like, and combinations thereof. Furthermore, the lengths and widths may be larger or smaller than 102 mm, the thickness may be larger or smaller than 0.8 mm, and the weight may be larger or smaller than 4 grams. All such embodiments are comprehended by the present invention.

(8) Referring now to FIGS. 3 and 4, the dissolvable sheet 10 may preferably be configured to allow the user to easily select a combination of premeasured unit doses for a particular application. Most preferably, the dissolvable sheet 10 may be provided with a frangible member, or line of weakness 16, to make it easier for the user to separate and remove one or more smaller portions 18 from the dissolvable sheet 10, so they may be used. Preferably, the frangible member/line of weakness 16 may be in the form of a line of perforations, cuts, partial cuts, or thinner material.

(9) By way of example, the dissolvable sheet 10 shown in FIGS. 3 and 4 is in the shape of a square containing two smaller portions 18, that may be separated along the lines of weakness 16 by a user. It will be appreciated that the dissolvable sheet may contain more or fewer such portions 18. In this example, the portions 18 have the same dimensions. For example, the portions 18 may each be good for a partial application, such as for example delivering cleaning active to wash water in a washing machine suitable for a half load of laundry. Accordingly, a user would be able to use the full dissolvable sheet with a full load of laundry, or sever one portion 18 from the dissolvable sheet 10 to use with a half load of laundry.

(10) Preferably, the dissolvable sheet 10 may have an aesthetic visual and tactile structure, including a uniformly coloured and/or pattern, a spongy texture, which feels silky smooth, and dry to the touch, and has characteristics resembling those of fabric, such as being pliable, without breaking or cracking when being handled.

(11) Having described an embodiment of the dissolvable sheet 10 of the present invention, a method of making a dissolvable sheet containing a cleaning active in the form of a water-soluble laundry detergent sheet 10, which is free of sulfates and ethoxylates, is described next. Good results have been obtained with this method for making 102 mm by 102 mm square sheets, which can be deposited in the tub of a washing machine with clothes at the start of the wash cycle, or placed in the washing machine's detergent dispenser.

(12) According to a preferred embodiment of the present invention, the ingredients used to make the dissolvable sheets 10 are mixed in three separate batches. A First Solution and a Second Solution may be made separately in two large batches because they are preferably made to be shelf-stable, in that they are storable for a relatively long period of time (i.e. from two days to two months or longer) after the ingredients are thoroughly mixed together. A Final Solution, which includes portions of the First Solution and the Second Solution, may be made in a smaller batch for immediate use. The Final Solution is typically non-shelf-stable, in that it is usable only for a relatively short period of time (i.e. four to eight hours) after the ingredients are thoroughly mixed together, because it tends to deteriorate.

(13) Although it may be advantageous to make the dissolvable sheets 10 using the above three batch system (i.e. First Solution, Second Solution, and Final Solution), in a large scale manufacturing operation, it will be appreciated that the Final Solution may be made directly, without needing to first prepare the First and Second Solutions. All such embodiments are comprehended by the present invention.

(14) Preferably, the Final Solution may be applied to a heated surface to dry, thereby forming the dissolvable sheet. Provided that the drying step is undertaken in a timely manner the deterioration problem identified above is avoided.

(15) The drying step may be performed using a method known in the art, such as for example, drying on a hot plate, a non-stick (Teflon) pan, or one of the methods disclosed in U.S. Pat. No. 9,464,264, the disclosure of which is incorporated herein in its entirety by reference, whereby the Final Solution is dried to form the dissolvable sheet 10.

(16) Preferably, the drying step may be performed using a heated cylinder of the type disclosed in U.S. Pat. No. 9,464,264, whereby a rising portion of an outer surface of the heated cylinder is brought into contact with the Final Solution as the heated cylinder is being rotated, to coat the outer surface with the Final Solution. The heated cylinder is sized and shaped to allow excess Second Solution to drain off the rising portion of the outer surface in a direction opposite to the direction of rotation. Preferably, an application reservoir for holding a liquid volume of the Final Solution is positioned against the rising portion of the outer surface, to allow an even coating to be drawn up onto the rising outer surface of the heated cylinder, and dried to form the dissolvable sheet 10.

Example 1

(17) For preparing a dissolvable sheet 10 that is sulfate and ethoxylate free, the First Solution may preferably comprise at least: a) from about 2 wt-% to about 30 wt-% of one or more Polyvinyl alcohols (PVA); b) from about 2 wt-% to about 80 wt-% of a first cleaning active 14; c) from about 1 wt-% to about 50 wt-% a Glycerol or a Glycol; and d) from about 20 wt-% to 80 wt-% of Water.

(18) Most preferably, the First Solution may comprise at least: a) from about 7 wt-% to about 15 wt-% of one or more Polyvinyl alcohols (PVA); b) from about 12 wt-% to about 30 wt-% of a first cleaning active 14; c) from about 4 wt-% to about 10 wt-% a Glycerol or a Glycol; and d) from about 31 wt-% to 50 wt-% of Water; and e) from about 0.1 wt % to 5 wt-% of Preservative.

(19) Examples of suitable Polyvinyl alcohols (PVA) include Polyvinyl alcohol (PVA) B-05, and Polyvinyl alcohol (PVA) B-17.

(20) Examples of a suitable first cleaning active 14 include nonionic or anionic surfactants, such as, natural saponified soaps, Glucosides, Sulfonic acid salts, Sulfonates, Phosphoric acid esters, Carboxylic acid salts, Potassium cocoate, other saponified fatty acid soap products, Alkyl polyglucoside (C10-16) (i.e. manufactured by BASF Corporation under the trade name Glucopon® 425 N), Sodium lauryl glucose carboxylate, short/medium/long chain Glucoside surfactant, Alpha olefin sulfonate, and combinations thereof.

(21) Preferably, the first cleaning active 14 may be an anionic surfactant, particularly, Potassium cocoate (i.e. manufactured by Derrek Soap Company under the trade name Ecoblend™ KCO).

(22) More preferably, the first cleaning active 14 may be a combination of an anionic surfactant, particularly, Potassium cocoate, with a non-ionic surfactant, particularly, Alkyl polyglucoside (C10-16) (i.e. manufactured by BASF Corporation under the trade name Glucopon® 425 N).

(23) An example of a suitable Preservative is Potassium sorbate, which is a food-grade preservative. The purpose of the preservative is to increase the shelf life of the First and Second Solutions by inhibiting bacteria growth. Accordingly, if a prolonged shelf life is not required, then the Preservative may be omitted.

(24) Good results have been obtained using a First Solution, being made by mixing the following ingredients in the indicated amounts, which is enough to make about 5000 102 mm×102 mm×0.8 mm square water-soluble laundry sheets:

(25) TABLE-US-00001 Ingredients Function Weight (kg) Wt-% Polyvinyl alcohol biodegradable supporting 1.60 2.9 (PVA) B-05 matrix Polyvinyl alcohol biodegradable supporting 5.10 9.4 (PVA) B-17 matrix Potassium sorbate food-grade preservative 0.02 0.1 Alkyl polyglucoside plant-based, 1.00 1.8 (C10-16) biodegradable surfactant (non-ionic) Potassium cocoate plant-based, 12.00 22.1 biodegradable surfactant (anionic) Glycerin improve texture of sheets 3.60 6.6 and stability of sheet Water natural solvent, used 31.00 57.1 temporarily during manufacturing as a process aid Total 54.32 kg 100.0%

(26) The above First Solution, including Potassium cocoate, may be used up to 48 hours after being prepared, with proper storage.

(27) The Second Solution may preferably comprise at least: a) optionally, from about 0.5 wt-% to about 20 wt-% of one or more enzymes; b) from about 1 wt-% to about 60 wt-% of a second cleaning active 14; c) from about 4 wt-% to about 80 wt-% of a third cleaning active 14; d) from about 5 wt-% to about 30 wt-% of one or more water softeners and chelating agents; and e) from about 5 wt-% to about 40 wt-% of Water.

(28) Most preferably, the Second Solution may comprise at least: a) optionally, from about 5 wt-% to about 20 wt-% of one or more enzymes; b) from about 10 wt-% to about 30 wt-% of a second cleaning active 14; c) from about 50 wt-% to about 80 wt-% of a third cleaning active 14; d) from about 15 wt-% to about 30 wt-% of one or more water softeners and chelating agents; e) from about 10 wt-% to about 30 wt-% of Water; and f) from about 0.1 wt-% to about 5 wt-% of Preservative.

(29) Examples of suitable enzymes include Protease, Amylase, Pectinase, Lipase, Cellulase, and Mannanase enzymes. However, inclusion of enzymes in the Second Solution (and/or Final Solution) is optional, and as mentioned above, care needs to be taken when incorporating enzymes into the Second Solution (and/or the Final solution), as their activity can be stopped when subjected to high heat, such as for example, during the drying step. Thus, if the temperatures in any of the processing steps are expected to be higher than what the enzymes will tolerate (i.e. about 60° C.), it is preferable to omit the enzymes, as it is unlikely that they will remain functional in the resulting dissolvable sheet 10.

(30) Examples of a suitable second cleaning active 14 include cationic, zwitterionic, or anionic surfactants, such as, natural saponified soaps, Glucosides, Sulfonic acid salts, Sulfonates, Phosphoric acid esters, Carboxylic acid salts, Amphoacetates, Sultaines, Betaines, Cocoamidaproply betaine (also known as CocoBetaine), Potassium cocoate, Cocamidopropyl hydroxysultaine, Sodium lauroamphoacetate, and combinations thereof.

(31) Preferably, the second cleaning active 14 may be an amphoteric and zwitterionic surfactant, particularly, Cocamidopropyl betaine (i.e. manufactured by Walsh & Associates, Inc., St. Louis, Missouri, under the trade name Walwet™ CAPB).

(32) Examples of a suitable third cleaning active 14 include amphoteric or nonionic surfactants, such as, Amine oxides, Glucosides, Sulfonic acid salts, Sulfonates, Phosphoric acid esters, Carboxylic acid salts, Cetyl betaine, Lauramine oxide, Sodium lauriminodipropionate, Alkyl polyglucoside (C10-16) (i.e. manufactured by BASF Corporation under the trade name Glucopon® 425 N), Sodium lauryl glucose carboxylate, short/medium/long chain Glucoside surfactant, specialty glucosides, such as, Disodium alkylpolyglucose citrate, and combinations thereof.

(33) Preferably, the third cleaning active 14 may be an amphoteric and non-ionic surfactant, such as, Lauramine oxide, Alkyl polyglucoside (C10-16) (i.e. manufactured by BASF Corporation under the trade name Glucopon® 425 N), Sodium laurylglucosides hydroxypropylsulfonate, and combinations thereof. Most preferably, the third cleaning active 14 may be Alkyl polyglucoside (C10-16) in combination with Lauramine oxide.

(34) Examples of suitable release agents and additives include Oils, Silicones, Plant oils, Triglycerides, Glycols, Glycerols, Paraffins, Waxes, and Mineral oil.

(35) Examples of a suitable water softener and chelating agent include Aminopolycarboxylates, Glutamate diacetate, Ethylenediaminetetraacetic acid, Nitrilotriacetic acid, Gluconates, Aminopolycarboxylic acids, Sodium gluconate, Tetrasodium GLDA, and Carboxymethyl inulin (i.e. manufactured by Cosun Biobased Products B.V., Dinteloord, The Netherlands, under the trade name Carboxyline® 25 D Powder).

(36) Preferably, the water softener and chelating agent may be a plant based biodegradable water solubilizer such as, for example, Sodium gluconate, Tetrasodium GLDA, or Carboxymethyl inulin.

(37) Good results have been obtained using a Second Solution being made by mixing the following ingredients in the indicated amounts, which is enough to make 5000 102 mm×102 mm×0.8 mm square water-soluble laundry sheets:

(38) TABLE-US-00002 Weight Ingredients Function (kg) Wt-% Medley ® Brilliant liquid enzyme blend 0.5 4.5 100 L Cocamidopropyl coconut oil based, 1.0 9.0 betaine biodegradable surfactant and foam booster (amphoteric and zwitterionic) Tetrasodium GLDA plant-derived and food grade, 2.0 18.0 (Liquid 50%) biodegradable water softener Alkyl polyglucoside plant based, biodegradable 5.0 45.1 (C10-16) surfactant (non-ionic) Sodium gluconate plant-derived and food 0.1 0.9 grade, biodegradable water softener that prevents soil from resettling on fabric after it has been removed during washing Lauramine oxide plant-derived, 1.0 9.0 biodegradable, surfactant and foam stabilizer (non-ionic) Water natural solvent, used 1.5 13.5 temporarily during manufacturing as a process aid Total 11.1 kg 100.0%

(39) The above Second Solution, may be used up to about two months after being prepared, with proper storage.

(40) The Final Solution may preferably comprise at least: a) from about 10 wt-% to about 80 wt-% of the above First Solution; b) from about 10 wt-% to about 80 wt-% of the above Second Solution; c) from about 5 wt-% to about 50 wt-% of a starch powder; d) from about 5 wt-% to about 50 wt-% of a fourth cleaning active 14; e) from about 0.1 wt-% to about 10 wt-% of a release agent or additive; f) optionally, from about 0.1 wt-% to about 6 wt-% of a fragrance; g) from about 0.1 wt-% to about 10 wt-% of a stabilizer, water treatment, scale inhibitor, soil anti-redeposition agent; and h) from about 0.1 wt-% to about 20 wt-% of Water.

(41) Examples of a suitable fourth cleaning active 14 include ionic, anionic, zwitterionic, cationic, or amphoteric surfactants, such as, Amine oxides, Glucosides, Sulfonic acid salts, Sulfonates, Phosphoric acid esters, Carboxylic acid salts, Cetyl betaine, Lauramine oxide, Sodium lauriminodipropionate, Alkyl polyglucoside (C10-16) (i.e. manufactured by BASF Corporation under the trade name Glucopon® 425 N), Sodium lauryl glucose carboxylate, short/medium/long chain Glucoside surfactant, Sodium laurylglucosides hydroxypropylsulfonate, and combinations thereof.

(42) Preferably, the fourth cleaning active 14 may be an amphoteric and non-ionic surfactant, particularly, Sodium laurylglucosides hydroxypropylsulfonate.

(43) Sodium laurylglucosides hydroxypropylsulfonate (i.e. manufactured by Colonial Chemical, South Pittsburgh, TN, under the trade name Suga®Nate 160 Dry) is a 100% biobased sulfate-free surfactant in anhydrous form. Unexpectedly, the applicant has discovered that Sodium laurylglucosides hydroxypropylsulfonate may be used both as a water-soluble substrate builder as well as a cleaning active. Without being bound to a particular theory, it is believed that the matrix formed by the Starch and PVA is capable of accommodating the Sodium laurylglucosides hydroxypropylsulfonate molecules within its structure, and holds together as a unitary physical structure when dried, unlike any of the other cleaning actives mentioned above.

(44) Examples of suitable release agents or additives include Oils, Silicones, Plant oils, Triglycerides, Glycols, Glycerols, Paraffins, Waxes, and Mineral oil.

(45) Examples of suitable fragrances include natural fragrances such as essential oils, botanical extracts and natural aromachemicals to impart pleasant odor.

(46) Examples of suitable stabilizer, water treatment, scale inhibitor, soil anti-redeposition agents, include Carboxymethyl inulin, water soluble polymers, partially neutralized Itaconic acid, Polyacrylate polymers, and Cellulose.

(47) Good results have been obtained using a Final Solution being made by mixing the following ingredients in the indicated amounts, which is enough to make 5000 102 mm×102 mm×0.8 mm square water-soluble laundry sheets:

(48) TABLE-US-00003 Ingredients Function Weight (kg) Wt-% First Solution concentrated stock 54.32 67.4 solution Second Solution concentrated stock 11.10 13.8 solution Sodium plant-derived, 4.00 5.0 laurylglucosides biodegradable builder hydroxypropyl- and surfactant sulfonate (i.e. Suga ® Nate 160 Dry) Starch powder plant-derived, 8.00 9.9 biodegradable texture/structure builder Cellulose plant-based, used as soil 1.00 1.2 anti-redeposition agent Glycerin improve texture of sheets 0.90 1.1 and slip, and boost cleaning performance of surfactants Mineral oil non-hazardous softener 0.20 0.2 and processing aid (mold release agent for manufacturing process) Essential oil blend natural essential oils, as 0.60 0.7 (i.e. Lavender & replacement for synthetic Grapefruit) fragrance Carboxyline ® threshold crystal growth 0.50 0.6 25 D Powder (scale inhibitor) Total 80.62 kg 100.0%

(49) The above Final Solution, is intended for immediate use, and should be discard after about 8 hours of being prepared.

(50) When preparing the Final Solution, the First Solution is preferably mixed first with the starch powder for 1 minute. Then the Second Solution is added to the mixture, followed by the remaining ingredients. The mixture is mixed for 29 minutes. Preferably the final mixture will have a viscosity 75,500 cp at 20° C.

(51) Next the Final Solution may be applied to a surface, dried into a sheet, and cut to produce 102 mm×102 mm square sheets, having an average thickness of 0.8 mm and an average weight of 4 grams, which represent one dose of laundry detergent for a large load of laundry. In this regard, an apparatus such as the apparatus for making a laundry detergent sheet disclosed in U.S. Pat. No. 9,464,264 may be used to dry the final mixture in the form of a sheet, and cut it to size the desired dimensions.

(52) It is contemplated that some or all of the Starch powder in the Final Solution may be substituted with another suitable builder such as, for example, Sodium bicarbonate, Sodium carbonate, Cellulose, Stearates, and the like.

(53) Similarly, it is contemplated that some or all of the Glycerin in the Final Solution may be substituted with Zemea® Propanediol (manufactured by DuPont Tate & Lyle Bio Products, LLC, Loudoni, TN), Augeo™ Clean (manufactured by Solvay, Houston, TX), or other plant based solvents.

(54) Similarly, it is contemplated that some or all of the Mineral oil in the Final Solution may be substituted with another suitable oil, including a plant oil, a silicone, a glyceride, and the like.

(55) Each 102 mm×102 mm square dissolvable sheet made according to the above example ended up having the following ingredients, in substantially the following amounts:

(56) TABLE-US-00004 Ingredients Weight (g) Wt-% Polyvinyl alcohol (PVA) B-05 0.160 4.0% Polyvinyl alcohol (PVA) B-17 0.524 13.1% Potassium sorbate 0.004 0.1% Potassium cocoate 0.636 15.9% Glycerin 0.372 9.3% Medley ® Brilliant 100 L 0.048 1.2% Cocamidopropyl betaine 0.044 1.1% Tetrasodium GLDA - Liquid 50% 0.096 2.4% Alkyl polyglucoside (C10-16) 0.280 7.0% Sodium gluconate 0.020 0.5% Lauramine oxide 0.052 1.3% Sodium laurylglucosides 0.424 10.6% hydroxypropylsulfonate (i.e. Suga ® Nate 160 Dry) Starch powder 0.920 23.0% Cellulose 0.024 0.6% Glycerin 0.096 2.4% Mineral oil 0.020 0.5% Essential oil blend (i.e. Lavender & 0.052 1.3% Grapefruit) Carboxyline ® 25 D Powder 0.052 1.3% Water 0.176 4.4% Total 4.000 g 100.0%

(57) However, dissolvable sheets 10 according to other embodiments of the present invention, may be made to have the following ingredients, in substantially the following amounts:

(58) TABLE-US-00005 Ingredients Wt-% Polyvinyl alcohol (PVA) B-05 about 2% to about 8% Polyvinyl alcohol (PVA) B-17 about 10% to about 20% Potassium Sorbate 0% to about 1% Potassium cocoate about 10% to about 25% Glycerin about 5% to about 20% Medley ® Brilliant 100 L 0% to about 5% Cocamidopropyl betaine about 1% to about 10% Tetrasodium GLDA - Liquid 50% about 1% to about 5% Alkyl polyglucoside (C10-16) about 5% to about 20% Sodium gluconate 0% to about 5% Lauramine oxide about 1% to about 10% Sodium laurylglucosides about 5% to about 40% hydroxypropylsulfonate (i.e. Suga ® Nate 160 Dry) Starch powder 10% to about 25% Cellulose 0% to about 5% Mineral oil 0% to about 5% Essential oil blend (i.e. Lavender & 0% to about 5% Grapefruit) Carboxyline ® 25 D Powder 0% to about 5% Water 0% to about 10% Total 100.0%

Example 2

(59) The shelf-life of the First Solution may be extended significantly, from about 48 hours to two months or more, primarily by replacing the Potassium cocoate with Alpha olefin sulfonate (AOS).

(60) Most preferably, the First Solution may comprise at least: a) from about 7 wt-% to about 15 wt-% of one or more Polyvinyl alcohols (PVA); b) from about 7 wt-% to about 30 wt-% of a first cleaning active 14; c) from about 4 wt-% to about 15 wt-% a Glycerol or a Glycol; d) from about 50 wt-% to 70 wt-% of Water; and e) from about 0.5 wt-% to 2 wt-% of Preservative

(61) Preferably, the first cleaning active 14 may be the anionic surfactant, Alpha olefin sulfonate (i.e manufactured by Stephan Company and sold under the trade name Bio-Terge® AS-40 HP).

(62) Good results have been obtained using a First Solution, being made by mixing the following ingredients in the indicated amounts, which is enough to make about 5000 102 mm×102 mm×0.8 mm square water-soluble laundry sheets:

(63) TABLE-US-00006 Ingredients Function Weight (kg) Wt-% Polyvinyl alcohol biodegradable supporting 1.674 3.00 (PVA) B-05 matrix Polyvinyl alcohol biodegradable supporting 5.580 10.00 (PVA) B-17 matrix Potassium sorbate food-grade preservative 0.022 0.04 Alpha olefin plant-based, 11.160 20.00 sulfonate biodegradable surfactant (non-ionic) Glycerin improve texture of sheets 3.906 7.00 and stability of sheet Water natural solvent, used 33.458 59.96 temporarily during manufacturing as a process aid Total 55.8 kg 100.0%

(64) The above First Solution, including Alpha olefin sulfonate, may be used up to two months after being prepared, with proper storage.

(65) Most preferably, the Second Solution may comprise at least: a) from about 5 wt-% to about 20 wt-% of one or more enzymes; b) from about 10 wt-% to about 30 wt-% of a second cleaning active 14; c) from about 50 wt-% to about 80 wt-% of a third cleaning active 14; d) from about 15 wt-% to about 30 wt-% of one or more water softeners and chelating agents; and e) from about 10 wt-% to about 30 wt-% of Water.

(66) Examples of a suitable enzyme, second cleaning active 14, release agents, additives, water softeners, and chelating agents, include the same ones previously mentioned above.

(67) Preferably, the second cleaning active 14 may be Alkyl polyglucoside (C10-16) (i.e. manufactured by BASF Corporation under the trade name Glucopon® 425 N).

(68) Examples of a suitable third cleaning active 14 include amphoteric or nonionic surfactants, such as, Amine oxides, Glucosides, Sulfonic acid salts, Sulfonates, Phosphoric acid esters, Carboxylic acid salts, Cetyl betaine, Lauramine oxide, Sodium lauriminodipropionate, an amphoteric and zwitterionic surfactant, particularly, Cocamidopropyl betaine (i.e. manufactured by Walsh & Associates, Inc., St. Louis, Missouri, under the trade name Walwet™ CAPB), Sodium lauryl glucose carboxylate, short/medium/long chain Glucoside, specialty glucosides, such as, Disodium alkylpolyglucose citrate, and combinations thereof.

(69) Preferably, the third cleaning active 14 may be an amphoteric and non-ionic surfactant, such as, Lauramine oxide, Alkyl polyglucoside (C10-16) (i.e. manufactured by BASF Corporation under the trade name Glucopon® 425 N), Sodium laurylglucosides hydroxypropylsulfonate, and combinations thereof. Most preferably, the third cleaning active 14 may be Alkyl polyglucoside (C10-16) in combination with Lauramine oxide.

(70) Good results have been obtained using a Second Solution being made by mixing the following ingredients in the indicated amounts, which is enough to make 5000 102 mm×102 mm×0.8 mm square water-soluble laundry sheets:

(71) TABLE-US-00007 Ingredients Function Weight (kg) Wt-% Medley ® Brilliant liquid enzyme blend 4.23 34.10 100 L Cocamidopropyl coconut oil based, 0.74 5.93 betaine biodegradable surfactant and foam booster (amphoteric and zwitterionic) Tetrasodium GLDA plant-derived and food 1.31 10.54 (Liquid 50%) grade, biodegradable water softener Alkyl polyglucoside plant based, biodegradable 3.68 29.66 (C10-16) surfactant (non-ionic) Sodium gluconate plant-derived and food 0.08 0.66 grade, biodegradable water softener that prevents soil from resettling on fabric after it has been removed during washing Lauramine oxide plant-derived, 0.74 5.93 biodegradable, surfactant and foam stabilizer (non-ionic) Water natural solvent, used 1.64 13.18 temporarily during manufacturing as a process aid Total 12.42 kg 100.0%

(72) The above Second Solution, may be used up to about two months after being prepared, with proper storage.

(73) The Final Solution may preferably comprise at least: a) from about 10 wt-% to about 80 wt-% of the above First Solution; b) from about 10 wt-% to about 80 wt-% of the above Second Solution; c) from about 5 wt-% to about 50 wt-% of a starch powder; d) from about 5 wt-% to about 50 wt-% of a fourth cleaning active 14; e) from about 0.1 wt-% to about 10 wt-% of a release agent or additive; f) optionally, from about 0.1 wt-% to about 6 wt-% of a fragrance; g) from about 0.1 wt-% to about 10 wt-% of a stabilizer, water treatment, scale inhibitor, soil anti-redeposition agent; and h) from about 0.1 wt-% to about 20 wt-% of Water.

(74) Examples of a suitable fourth cleaning active 14, release agents, additives, fragrances, stabilizer, water treatment, scale inhibitor, and soil anti-redeposition agents, include the same ones previously mentioned above.

(75) Good results have been obtained using a Final Solution being made by mixing the following ingredients in the indicated amounts, which is enough to make 5000 102 mm×102 mm×0.8 mm square water-soluble laundry sheets:

(76) TABLE-US-00008 Weight Ingredients Function (kg) Wt-% First Solution concentrated stock 55.800 66.90 solution Second Solution concentrated stock 12.405 14.87 solution Sodium plant-derived, 4.000 4.80 laurylglucosides biodegradable builder hydroxypropylsulfonate and surfactant (i.e. Suga ® Nate 160 Dry) Starch powder plant-derived, 9.000 10.79 biodegradable texture/structure builder Glycerin improve texture of 0.900 1.08 sheets and slip, and boost cleaning performance of surfactants Mineral oil non-hazardous softener 0.200 0.24 and processing aid (mold release agent for manufacturing process) Essential oil blend natural essential oils, as 0.600 0.72 (i.e. Lavender & replacement for Grapefruit) synthetic fragrance Carboxyline ® 25 D threshold crystal growth 0.500 0.60 Powder (scale inhibitor) Total 83.41 kg 100.0%

(77) The above Final Solution, is intended for immediate use, and should be discarded after about 8 hours of being prepared.

(78) When preparing the Final Solution, the First Solution is preferably mixed first with the starch powder for 1 minute. Then the Second Solution is added to the mixture, followed by the remaining ingredients. The mixture is mixed for 45 minutes. Preferably the final mixture will have a viscosity 35,000 cp at 20° C.

(79) Next the Final Solution may be applied to a surface, dried into a sheet, and cut to produce 102 mm×102 mm square sheets, having an average thickness of 0.8 mm and an average weight of 4 grams, which represent one dose of laundry detergent for a large load of laundry. In this regard, an apparatus such as the apparatus for making a laundry detergent sheet disclosed in U.S. Pat. No. 9,464,264 may be used to dry the final mixture in the form of a sheet, and cut it to size the desired dimensions.

(80) Each 102 mm×102 mm square dissolvable sheet made according to the above example ended up having the following ingredients, in substantially the following amounts:

(81) TABLE-US-00009 Ingredients Weight (g) Wt-% Polyvinyl alcohol (PVA) B-05 0.177  4.42% Polyvinyl alcohol (PVA) B-17 0.590 14.74% Potassium sorbate 0.002  0.06% Alpha olefin sulfonate (AOS) 0.467 11.68% Glycerin 0.430 10.75% Medley ® Brilliant 100 L 0.013  0.32% Cocamidopropyl betaine 0.031  0.78% Tetrasodium GLDA - Liquid 50% 0.063  1.56% Alkyl polyglucoside (C10-16) 0.205  5.12% Sodium gluconate 0.009  0.23% Lauramine oxide 0.025  0.61% Sodium laurylglucosides 0.423 10.57% hydroxypropylsulfonate (i.e. Suga ® Nate 160 Dry) Starch powder 0.971 24.28% Copolymer of 1-vynilimidazole and 0.035  0.88% 1-vynil-2-pyrrolidone (i.e. Sokalan ® PA 25 CL Granular) Glycerin 0.099  2.48% Mineral oil 0.022  0.55% Essential oil blend (i.e. Lavender & 0.067  1.67% Grapefruit) Carboxyline ® 25 D Powder 0.052  1.31% Water 0.320  8.00% Total 4.00 g 100.0%

(82) However, dissolvable sheets 10 according to other embodiments of the present invention, may be made to have the following ingredients, in substantially the following amounts:

(83) TABLE-US-00010 Ingredients Wt-% Polyvinyl alcohol (PVA) B-05 about 2% to about 8% Polyvinyl alcohol (PVA) B-17 about 10% to about 20% Potassium Sorbate 0% to about 1% Alpha olefin Sulfonate (AOS) about 10% to about 25% Glycerin about 5% to about 20% Medley ® Brilliant 100 L 0% to about 5% Cocamidopropyl betaine about 1% to about 10% Tetrasodium GLDA - Liquid 50% about 1% to about 5% Alkyl polyglucoside (C10-16) about 5% to about 20% Sodium gluconate 0% to about 5% Lauramine oxide about 1% to about 10% Sodium laurylglucosides about 5% to about 40% hydroxypropylsulfonate (i.e. Suga ® Nate 160 Dry) Starch powder 10% to about 30% Copolymer of 1-vynilimidazole and 0% to about 5% 1-vynil-2-pyrrolidone (i.e. Sokalan ® PA 25 CL Granular) Mineral oil 0% to about 5% Essential oil blend (i.e. Lavender & 0% to about 5% Grapefruit) Carboxyline ® 25 D Powder 0% to about 5% Water 0% to about 10% Total 100.0%

(84) As can now be appreciated, the present invention allows a dissolvable sheet containing a cleaning active to be made, that is free of sulfates and ethoxylates. For example, at least some prior art dissolvable laundry detergent sheets are made with Alpha olefin sulfonate (an example of a petroleum derived sulfonate), Sodium lauryl sulfate (an example of a petroleum derived sulfate surfactant), and Peg-7 glyceryl cocoate (an example of a petroleum derived ethoxylated surfactant). These three ingredients were previously thought to be necessary for making dissolvable laundry detergent sheets having a useful laundry detergent payload for satisfactory cleaning performance, an aesthetic appearance and texture, and a desirable form factor.

(85) Surprisingly, however, the applicant has found a selection and combination of chemical compounds as substitutes for the above sulfate and ethoxylated surfactants, while retaining substantially the same performance and aesthetic attributes of the prior art dissolvable laundry detergent sheets.

(86) Additionally, the applicant has found that sulfate free and ethoxylate free surfactants that were previously not considered to be compatible with other ingredients used to make prior art dissolvable laundry sheets, could be made to work by balancing multiple sulfate and ethoxylate free surfactants with differing ionic charges and characters to create a synergistic effect of cleaning and the creation of micelles.

(87) Similarly, sulfate free and ethoxylate free surfactants that were not previously considered to be compatible with other ingredients used to make prior art dissolvable laundry sheets, may be made to work by increasing the total amount of sulfate and ethoxylate free surfactants (for example, in the Second Solution) and reducing the total amount of Water being added as a temporary solvent, to form a critical micelle concentration (CMC). The CMC has been found to significantly improve the cleaning performance of the resulting dissolvable sheets 10. The CMC also allows the shelf-stable solutions (for example, the Second Solution) to emulsify otherwise insoluble or unstable ingredients. Thus, combining surfactants in the Second Solution to form a CMC, as described above, may be a useful step in a method for making dissolvable sheets 10 with improved cleaning performance, and for incorporating otherwise unstable or insoluble chemical compounds into the dissolvable sheets 10. Advantageously, this effect may be controlled by adjusting the ionic charge of the surfactant cleaning actives in the First and Second Solutions.

(88) Additionally, the applicant has found that by reducing the amount of Water being added as a temporary solvent in the First and/or Second Solutions, and/or using the Water content present in certain ionic and nonionic surfactants when formulating the First and/or Second Solutions, is it possible to increase the overall concentration of the cleaning active(s) in the dissolvable sheets 10.

(89) While reference has been made to various preferred embodiments of the invention other variations, implementations, modifications, alterations and embodiments are comprehended by the broad scope of the appended claims. Some of these have been discussed in detail in this specification and others will be apparent to those skilled in the art. Those of ordinary skill in the art having access to the teachings herein will recognize these additional variations, implementations, modifications, alterations and embodiments, all of which are within the scope of the present invention, which invention is limited only by the appended claims.