TECHNICAL FIELD
The present invention is related to process of making dissolvable polymeric film of Poly ethylene
oxide (PEO) by use of high shear. The invention also relates to articles formed from such films
and apparatus for making the same
BACKGROUND AND PRIOR ART
Dissolvable films are generally understood to be thin material sections that dissolve under a
stream of solvent. Thin sections of a soap (or surfactant) are consequently usable in cleaning and
personal hygiene applications.
However, in the absence of a mechanical (or chemical) matrix, the soap tends to rapidly dissolve
or disintegrate under a stream of water. Sometimes, under storage or during use, a dissolvable
soap film may tear, break or disintegrate making it inconvenient, often undesirable to use. It is
hence desirable that the dissolvable soap film be cast on a film-forming polymer (or substrate) so
as to have substantive mechanical strength and to facilitate rigorous or frequent outdoor use.
It is known in the art to impregnate paper, silk, linen or any other known woven, fibrous or
textile material with soap, soap solution or surfactant and to use the composite in place of an
ordinary hard cake or liquid soap. However, the difficulty with such design format is that a
fibrous, wet and adherent mass, may choke and clog water outlets and conduits and prove
impractical in many situations due to substrate erosion. It is hence desirable to have a
dissolvable substrate.
US 5,062,986 teaches a film shaped soap and provides a portable film based soap. It discloses
the usage of water-soluble polymers such as polyester of polyether polyol and a poly carboxylic
acid.

US Patent publication 20050003991 relates to rapidly water-soluble strip of film carrying
surfactants. This publication discloses the use of plasticizer to provide a desired flexibility to the
soap film.
Japanese patent application KOKAI 53-91912 discloses a film-shape detergent using a synthetic
detergent and methylcellulose. However, certain design shortcomings appear inherent in the
protocol, arising particularly from the harshness of the synthetic detergent. These include hand
chapping, poor solubility of film in water, a hard tactile feel to hand during use and so on.
US 2,356,168 discloses a method of making soap leaves or soap sheets using methylcellulose as
a film-forming polymer. US 4,108,800 relates to cleaning compositions based on polyethylene
oxide. This patent is silent on the usage of polyethylene oxide as a film-forming material. US
1,573,529 relates to soap bars and particularly toilet soap bars and teaches the use of
polyethylene oxide to provide a tactile feel accompanied with a creamy and silky lather that may
be pleasant to a user. The use of poly ethylene oxide appears confined to enhancing tactile and
sensorial characteristics of a soap and rather teaches away from its use as a film forming or
substrate providing material.
The use of film forming materials has been generally known in the art, however, there has been
no motivation to provide for a dissolvable film. Though, polyethylene oxide film forming
precursors have been available, manufacturers generally teach and recommend their use under
low shear.
As such, little of the known art teaches polyethylene oxide as a film-forming polymer.
US5302308 refer to polyethylene oxide compounds employed which are commercially available
from Union Carbide. These compounds are water-soluble resins that possess high wet tack and
adhesion properties. They cure to form a tough, flexible film. These films can be heat-sealed, and
form stable agglomerates when a hot particle contacts a polyethylene oxide film.

The polyethylene oxide derivatives, polyethylene glycol and methoxy polyethylene glycol, are
relatively nonvolatile and thermally stable. Their physical form ranges from thick liquids to
waxy solids. Their primary advantage as dust inhibitors over petroleum oils and waxes is that
they possess low toxicity and water solubility.
US3999358 teaches seed tape made commercially from polyethylene oxide film. This film, though
essentially polyethylene oxide, may contain some additional materials (plasticizer, stabilizer, antioxidant,
dye, etc.). The film, in order to be operative, is readily water soluble. The tape itself is sensitive to the
applied moisture, though generally insensitive to atmospheric humidity. The tape is water soluble; so
obviously the applied moisture used for sealing must be kept below an amount that would simply dissolve
the tape.
But no known art exists that provides a dissolvable film using polyethylene oxide which upon
subjecting the precursor to high shear degradation or processing under a high rate of mixing may
homogenize and smoothen the film texture and yet provide the mechanical strength without the
use of plasticizer.
The present inventors have now found a process for making a dissolvable film in the absence of
additional plasticizing media, by applying high shear to the dispersion of dissolvable film
forming polymer unlike the prior art. The film formed by the said process is suitable as article in
combination with hair and body care components with or without fillers.
BRIEF DESCRIPTION OF THE INVENTION
According to one aspect the present invention provides a dissolvable film making apparatus
comprising at least one reservoir of a film forming polymer, at least one chamber for dispersing
the film forming polymer with a fluid media to provide a film forming solution, at least one
device for applying shear to the film forming solution, and at least one casting platform for
casting the film forming solution to provide a dissolvable film

According to one aspect the present invention provides a process for making a dissolvable film.
The process comprises the steps of providing a film forming polymer, mixing the film forming
polymer with fluid media to form a dispersion, applying high shear to the dispersion to provide a
film forming solution, and applying the film forming solution on a casting platform to provide a
dissolvable film made in the absence of additional plasticizing media.
According to another aspect the present invention provides an article comprising the dissolvable
film and surfactant
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages and features of the invention will become apparent upon
reading the following detailed description and upon reference to the drawings in which:
Figure 1 illustrates an apparatus of the present invention that provides the dissolvable film of the
present invention.
Figure 2 illustrates the process of the present invention that provides the dissolvable film of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, like reference characters designate like or corresponding parts
throughout the several illustrations shown in the figures. It is also understood that terms such as
"top", "bottom", "outward", "inward", and the like are words of convenience and are not to be
construed as limiting terms. Moreover, it will be understood that the illustrations are for the
purpose of describing a particular exemplary embodiment of the invention and are not intended
to limit the invention thereto.
Referring generally to Figures 1 and 2, embodiments of the invention address the needs
described above by providing a dissolvable film making apparatus (100) and a process of making
a dissolvable film (200).

In one embodiment, the present invention provides a dissolvable film making apparatus (100).
The dissolvable film making apparatus (100) of the present invention comprises at least one
reservoir (110) of a film forming polymer (120), at least one chamber (130) for dispersing the
film forming polymer (120) with a fluid media (140) to provide a film forming solution (150), at
least one device (160) for applying shear to the film forming solution (150) and at least one
casting platform (170) for casting the film forming solution (150) to provide a dissolvable film
(180) of the present invention. An exemplary representation of one embodiment of the apparatus
of the present invention (100) is illustrated in Figure 1 of this specification. In another
embodiment, the present invention provides a process (200) for making a dissolvable film (180).
The process (200) for making dissolvable film (180) comprises the steps of providing (210) a
film forming polymer (120), mixing (220) the film forming polymer (120) with fluid media
(140) to form a dispersion (145), applying shear (230) to the dispersion (145) to provide a film
forming solution (150) and applying (240) the film forming solution (150) on a casting platform
(170) to provide a dissolvable film (180) of the present invention. An exemplary representation
of one embodiment of the process of the present invention (200) is illustrated in Figure 2 of this
specification.
In the process of the present invention high shear mechanism is used to provide the dissolvable
film which provides mechanical strength. Accordingly there is no requirement for a plasticizing
agent or similar chemical moiety, or other physical matrix to provide the mechanical strength
and integrity to the dissolvable film. Film processing under high shear rates, as defined in the
present invention, also obviates the necessity for film preservatives and provides films of a
superior mechanical texture as compared to dissolvable films made conventionally.
The dissolvable films of the present invention may be used in home and personal care
applications and in industrial applications such as automobiles, aerospace, biotechnology,
Pharmaceuticals, nutraceuticals, agriculture, medicinal, surgical, foods petroleum, and so on. It
is generally understood that a dissolvable film typically defines materials that are water soluble
or water dispersible or both water soluble and water dispersible. A dissolvable film typically
disintegrates upon contact with fluid media and film dissolution (or disintegration) generally
occurs through film dissolution or film dispersion into the fluid media.

The film-forming polymer (120) of the present invention is a substantive component of the
dissolvable film (180) and provides the chemical backbone and mechanical strength to the film,
generally without requiring plasticizing or binding materials. Typically, the film-forming
polymer (120) provides a relatively thick polymeric film upon drying and demonstrates a
sufficient mechanical strength for hand washing and also facilitates its disintegration upon
application of water. Typically, the film forming polymer is present in an amount from about
0.01-10% by weight in the initial formulation and preferably from about 0.01-5% by weight, and
more preferably, from about 0.01-3% by weight of the dissolvable film (180). Preferably, the
molecular weight of the film-forming polymer is substantially above 10,000. A non-limiting
example of the composition of the present invention is provided in Table 1.

Referring generally to Table 1, it may be observed that polyethylene oxide is present in an
amount from about 0.01% to about 5% by weight of the formulation. The surface active agent is
present in an amount from about 0.1 % to about 70% by weight of the formulation and optional
ingredients, that are usually added as per need are generally present in an amount from about
0.1% to about 70% by weight of the formulation.
Suitable film forming polymers (120) of the present invention include, but are not limited to, at
least one of poly(ethylene oxide), poly ethylene glycol, cellulosic derivatives, poly vinyl alcohol,
polypropylene oxide, vinyl alcohol/vinyl acetate copolymer, vinyl
alcohol/poly(alkyleneoxy)acrylate copolymer, vinyl alcohol/vinyl acetate/poly-
(alkyleneoxy)acrylate copolymer, methylcellulose, ethylcellulose, hydroxyethylcellulose,
carboxymethylcellulose, quaternised hydroxyethylcellulose, hydroxypropylmethylcellulose,
starch, modified starches, natural starches, aluminum starch octenyl succinate, algin, guar, agar,

shellac polymer, polyvinyl pyrrolidone-based polymers, polyethylene glycol, xantham gum,
polyquaternium polymers, pullulan, hydroxypropyl cellulose gelatin, polyvinyl alcohol, sodium
alginate, tragacanth gum, acacia gum, arabic gum, polyacrylic acid, methylmethacrylate
copolymer, carboxyvinyl polymer, amylase, hydroxy propyl starch phosphates, high amylase
starch, hydroxypropylated high amylose starch, dextrin, pectin, chitan, chitosan, levan, elsinan,
collagen, zein, glutan, soy protein isolate, whey protein isolate, casein, locust bean gum, karaya
gum, carrageenan, gellan, furcellaran, polyhydroxy acid polymers, and a combination thereof.
Particularly suitable film forming polymers of the present invention are water-soluble films
forming polymers such as polyethylene oxide, methylcellulose, starches, modified starches,
natural starches, aluminum starch octenyl succinate, hydroxy propyl starch phosphates, and a
combination thereof.
Within the scope of the present invention, the term "poly(ethylene oxide)" generally includes
polymeric ethylene glycols such as poly ethylene oxide, poly ethylene glycol, and star poly
ethylene oxide. Star polyethylene oxide is generally understood by a person of ordinary skill in
the art to refer to a multi-armed dendron-like molecule having a compact central core and
multiple poly ethylene oxide chains extending from the central core. Typically, a star poly
ethylene oxide molecule may be synthesized with more than about 150 polyethylene arms.
Poly ethylene glycol or poly (ethylene oxide) has the following structure:
HO-(CH2-CH2-O)n-H
Poly(ethylene oxide) molecules (referred to hereinafter as "PEO") are nonionic. high molecular
weight polymers. They exhibit many properties that are typical of other classes of water-soluble
polymers, such as but not limited to, lubricity, binding, water retention, thickening, and film
formation. PEO is one of the most extensively studied of all water-soluble synthetic polymers,
both for its wide range of applications and from the fundamental standpoint of understanding the
behavior of polymer solutions. Generally, any variety of PEO polymers available to a
practitioner of the art can be used in the present invention. In a preferred embodiment of the
present invention, the disposable film is made using low shear conditions for mixing and
homogenizing the polymer solution.

The reservoir of the present invention generally refers to a storage tank within the dissolvable
film forming apparatus that holds the film-forming polymer. Fluid media of the present
invention generally refers to any solvent that may be used to uniformly disperse the film-forming
polymer. Suitable solvents may be selected from the group consisting of alcohol solvents,
ketone solvents, amide solvents, ether solvents, ester solvents, aliphatic hydrocarbon solvents,
aromatic solvents, and halogen-containing solvents, polar solvents such as but not limited to
water, non-polar solvents, and a combination thereof.
The chamber of the present invention generally refers to a processing space where the film
forming polymer is dispersed along with fluid media to form at least one of a dispersion or a film
forming solution of the present invention.
Within the scope of the present invention, the device for applying shear, generally refers to any
known device, that operates upon the principle of stirring, shaking, paddle mixing, shear mixing,
heating, homogenizing, pressurizing, sonicating, agitating or the like, so as to provide a
substantially dispersed phase. Frequently, depending upon the choice of film forming polymer
precursor and attendant fluid media, a solution may be obtained. Typically, the shear rate
applied within the present invention is in excess of about 70 revolutions per minute (referred to
hereinafter as 'rpm'). Generally, the solution is ready for casting within about 30 minutes of
shearing or agitation under the aforementioned conditions. The casting platform is generally
maintained at a temperature of about 30°C to about 250°C. The drying time of the film typically
depends upon the choice of precursor, the choice of solvent, the thickness of the cast layer and
the desired porosity of the final product. Porous films are generally produced by a rapid rate of
heating while dense films may be obtained by a slow heating.
The casting platform of the present invention generally refers to a solid, substantially planar
surface for disposing or casting the film forming solution prior to drying. Drying may be
achieved by conduction, convection, radiation heat transfer processes or a combination thereof.
The casting platform of the present invention may be made of any suitable material such as
Teflon, wood, metal, concrete, plastic, or the like and is generally, non-sticky in nature. As per
need, the casting platform of the present invention may also be a modified vacuum drying table,
a microwave platform or a similar such device.

In one embodiment of the present invention, a suitable foaming surfactant may be added to the
film forming solution to provide a cleansing media. The cleansing agent provides foaming,
lathering, and cleansing properties to the dissolvable film during use or upon contact with water.
The surface active agent is typically present an amount of from about 0.1% to about 70% by
weight, and more preferably from about 0.1% to about 60% by weight of the formulation.
Suitable surfactants include at least one of, anionic surfactants, nonionic surfactants, betaines,
sultaines, amphoterics, zwitterionic surfactants, imidazolines, sulfosuccinates, amineoxides,
alkanolamides, sugar surfactants, metal soaps, lactates, gluconates, galacturonic acid,
glucarolactone, gallic acid, glucoheptanoic acid, amino acids, 12-hydroxystearic acid,
laurylamidobetaine, stearyl amphoacetate, lauryl amphopropionate, and stearyl
amphopropionate, and a combination thereof.
In another embodiment of the present invention, the dissolvable film comprises abrasive agents
to improve the cleansing ability of the dissolvable film. Abrasive agents mildly scour the skin
surface and optionally, in combination with surfactant they aid the cleansing agent in removal of
embedded soils, such as but not limited to oils, grease and similar skin, fabric or environmental
emissions. Abrasive agents may be present in an amount of from about 0.1% to about 70% by
weight of dissolvable film. Suitable abrasive agents include, without limitation, pumice,
polyethylene beads, silica, diatomaceous earth, nylon 12 beads, polymethacrylate polymers,
nutshells, clays, jojoba wax, chemicals like calcium carbonate and a combination thereof.
In one embodiment of the present invention, the dissolvable film comprises optional ingredients
that may provide additional benefits to a user. Specific examples of optional benefit ingredients
include, for example, surface active agents, tyrosine inhibitors, cosmetic agents, fragrances,
toner, insect repellants, mosquito repellants, room fresheners, perfume, seeds, pollens, grains,
fertilizers, nematicide, germicide, weedicide, biocide, pesticide antimicrobial, humectants,
moisturizers, fragrances, skin conditioning agents, lipids, botanicals, vitamin E, tocopherols and
other vitamins, enzymes, wound healing agents and a combination thereof. Optional ingredients
are typically present in an amount of from about 0.1% to about 70% by weight of dissolvable
film and more preferably, in an amount of from about 0.1% to about 60% by weight of
dissolvable film.

One embodiment of the present invention provides a water disintegrable cleansing wipe having
increased strength and durability that disintegrates only after a prolonged rinse under water.
Such format is desirable if the dissolvable film is to be used on exceptionally dirty hands, or
hands containing grease or other hard-to-remove contaminants. The dissolvable film hence
provides an increased mechanical strength and durability. A film with such characteristics
includes one or more natural or synthetic fibers used as filler materials. Natural or synthetic
fibers typically increase the mechanical strength and durability of the film, and cause the film to
require an increased amount of time for disintegration into water. Filler fibers may also increase
the cleansing ability of the film, as they may tend to be slightly abrasive on the skin when used.
Depending on the desired increase in mechanical strength and durability, a fiber filler may be
provided in the water disintegratable wipe in an amount of from about 1% to about 20% by
weight of the dissolvable film. Suitable fiber fillers include, without limitation, soft wood fibers,
hard wood fibers, non-wood vegetable fibers, nanometer sized woven fibers of cellulosic
materials and a combination thereof.
In one embodiment, the dissolvable film of the present invention may be manufactured by
introducing the film-forming polymer and cleansing agent into a fluid media and cast into a gel
at a temperature of from about 25°C to about 60°C. Sometimes, the gel may also include
optional components, such as foam stabilizers, abrasives, fiber fillers and a combination thereof.
Frequently, a dissolvable gel comprises other optional ingredients to provide additional specific
benefits to the user. Specific examples of optional skin health components include, for example,
surface active agents, tyrosine inhibitors, cosmetic agents, fragrances, toner, insect repellants,
mosquito repellants, room fresheners, perfume, seeds, pollens, grains, fertilizers, nematicide,
germicide, weedicide, biocide, pesticide antimicrobial, humectants, moisturizers, fragrances, skin
conditioning agents, lipids, botanicals, vitamin E, tocopherols and other vitamins, enzymes, and
a combination thereof.
Generally, the dissolvable films of the present invention disintegrate upon contact with water and
scrubbing in less than about 120 seconds, more preferably in less than about 90 seconds, and
most preferably in less than about 60 seconds. The disintegration rate may be controlled, using
various means, to ensure that the cleansing agent and additives have a sufficient time to lather

and effectively clean the surface. The film dissolution (or disintegration rate) usually depends
upon the temperature of water for rinsing as also the amount of water inherently present in the
film and the scrubbing rate.
The dissolvable films of the present invention are generally rectangular in shape and may have
any suitable thickness depending upon specification and need. For instance, the dissolvable film
may have a thickness ranges from about 10 nanometers to about 100 millimeters. Optionally, the
film may assume a variety of shapes, including but not limited to, generally rectangular, circular,
oval, square, or irregularly shaped depending upon numerous factors. Dissolvable films of a fine
thickness, that is typically in the sub-micron to nanometer size regime, are typically cast using
additional, optional apparatuses such as high-speed spin coaters, Langmuir-Blodgett troughs, and
the like.
Typically, films may be packaged singly or as a multi-layered stack of dry films. The stack of
dissolvable films may be placed in a container, such as a cardboard tub, plastic tub, to provide a
package of films for eventual sale to a consumer. Alternatively, the films may be rolled and
provided with tear-off perforations to facilitate dispensing at the time of use, particularly when
one hand may be wet.
While the invention may be susceptible to various modifications and alternative forms, specific
embodiments have been shown by way of example in the drawings and have been described in
detail herein. However, it should be understood that the invention is not intended to be limited to
the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents,
and alternatives falling within the spirit and scope of the invention.

ELEMENT LIST
100 dissolvable film making apparatus
110 reservoir
120 film forming polymer
130 chamber
140 fluid media
145 dispersion
150 film forming solution
160 device for applying shear
170 casting platform
180 dissolvable film
200 process for making dissolvable film
210 providing a film forming polymer
220 mixing a film forming polymer with fluid media
230 applying shear to dispersion
240 applying film forming solution on a casting platform.