FABRIC SHEET ASSEMBLIES FOR DELIVERING MALODOR CONTROL IN WASH LIQUOR AND METHODS FOR FORMING THE SAME

Abstract

Fabric sheet assemblies for delivering malodor control in wash liquor during a laundering process and methods for forming such fabric sheet assemblies are provided. In one example, a fabric sheet assembly includes one or more substrate layers including a first substrate layer. The first substrate layer is configured to absorb and/or adsorb malodor compounds from the wash liquor. An odor controlling composition is carried by the one or more substrate layers and is configured to be released into the wash liquor.

Description

TECHNICAL FIELD

The technical field relates generally to fabric sheet assemblies for laundering, and more particularly, relates to fabric sheet assemblies for delivering malodor control in wash liquor during a laundering process and methods for making such fabric sheet assemblies.

BACKGROUND

Odor issues often occur in the laundering process for a variety of reasons. One source of malodor is the rancidification of oils. These oils can be naturally produced by living organisms, such as the oily secretion from sebaceous glands, e.g. sebum, of humans, pets, and/or the like. Additionally, these oils can also come from foreign oily substances in the form of stains or residue from a foreign object.

The rancidification of oil can occur, for example, via any one of the following mechanisms: hydrolytic, oxidative, or microbial. In both the hydrolytic and oxidative mechanisms, oily compounds, which may initially have a pleasant odor or substantially no odor at all, are broken into smaller molecules (e.g., short-chain fatty acids or the like) that are recognized as nefarious odors by human olfactory receptors. Odors may also be produced by bacterial or fungi growth in the presence of moisture and heat. A combination of rancidification and biological growth mechanisms can also occur, producing molecules with nefarious odors.

Odors are also commonly caused by the decomposition and/or digesting of solid molecules, forming gases. Additionally, with the advancement of certain technologies, unintended consequence of creating conditions that are more susceptible to biological growth and entrapment of malodorous gases can occur. For example, newer models of washing machines (e.g. high efficiency washing machines) may leave dead spots for standing water and/or certain types of washable materials such as spandex clothing (or other clothing made from synthetic materials) may have increased oleophilic characters that can entrap oils, bacteria, and fungi.

Removing such malodor compounds from clothing and other washable materials via a laundering process can be challenging. For example, during a washing cycle, clothing is agitated in or otherwise in contact with wash liquor (e.g., combination of water, detergent, and optionally other fabric washing ingredients), causing the malodor compounds on the clothing to be transferred into the wash liquor. Unfortunately, at the end of the washing cycle while the wash liquor is being drained from the washing reservoir, at least a portion of the malodor compounds in the wash liquor can redeposit or otherwise transfer back onto the clothing, thereby leaving the just washed clothing with an undesirable odor.

Accordingly, it is desirable to provide improvements for reducing and/or removing malodor from clothing and/or other washable materials during a laundering process. Furthermore, other desirable features and characteristics of the various embodiments described herein will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background.

SUMMARY

Fabric sheet assemblies and methods for forming fabric sheet assemblies are provided herein. In accordance with an exemplary embodiment, a fabric sheet assembly for delivering malodor control in wash liquor during a laundering process includes one or more substrate layers including a first substrate layer. The first substrate layer is configured to absorb and/or adsorb malodor compounds from the wash liquor. An odor controlling composition is carried by the one or more substrate layers and is configured to be released into the wash liquor.

In another exemplary embodiment, a fabric sheet assembly for delivering malodor control in wash liquor during a laundering process includes a backing substrate layer, a permeable substrate layer, and a core substrate layer that is disposed between the backing substrate layer and the permeable substrate layer. The core substrate layer includes nonwoven, micro-porous polypropylene fibers. One or more odor controlling compositions are disposed on the backing substrate layer and include one or more encapsulated fragrances.

In accordance with an exemplary embodiment, a method for forming a fabric sheet assembly for delivering malodor control in wash liquor during a laundering process is provided. The method includes arranging a core substrate layer between a backing substrate layer and a permeable substrate layer. The core substrate layer is configured to absorb and/or adsorb malodor compounds from the wash liquor. The backing substrate layer, the core substrate layer, and the permeable substrate layer are coupled together. One or more odor controlling compositions are deposited on the backing substrate layer. The one or more odor controlling compositions are configured to be released into the wash liquor.

BRIEF DESCRIPTION OF THE DRAWINGS

The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:

FIG. 1 illustrates a perspective view of a fabric sheet assembly in a laundry washing apparatus in accordance with an exemplary embodiment;

FIG. 2 illustrates a perspective view of a portion of a fabric sheet assembly in accordance with an exemplary embodiment;

FIG. 3 illustrates a sectional view of a fabric sheet assembly in accordance with an exemplary embodiment;

FIG. 4 illustrates a sectional view of a fabric sheet assembly in accordance with an exemplary embodiment;

FIG. 5 illustrates an exploded perspective view of a fabric sheet assembly in accordance with an exemplary embodiment;

FIGS. 6A-6D illustrate various plan views of one or more odor controlling compositions of a fabric sheet assembly arranged in various patterns in accordance with various exemplary embodiments; and

FIG. 7 illustrates a method for forming a fabric sheet assembly in accordance with an exemplary embodiment.

DETAILED DESCRIPTION

The following Detailed Description is merely exemplary in nature and is not intended to limit the various embodiments or the application and uses thereof. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

Various embodiments contemplated herein relate to fabric sheet assemblies and methods for forming fabric sheet assemblies. The exemplary embodiments taught herein provide a fabric sheet assembly that is configured to be combined with clothing and/or other washable fabric materials in wash liquor during a laundering process for controlling malodor. During the laundering process, malodor compounds such as short-chain fatty acids, oils, bacteria, fungi, or other hydrophobic-like malodor compounds are transferred from clothing or other washable fabric materials into the wash liquor.

The fabric sheet assembly includes one or more substrate layers including a first substrate layer. In an exemplary embodiment, the first substrate layer is a hydrophobic (e.g., water hating), oleophilic (e.g., oil loving) substrate layer that has a relatively high affinity for short-chain fatty acids, oils, bacteria, fungi, and other malodor compounds. As such, the malodor compounds present in the wash liquor are absorbed, adsorbed, and/or otherwise transferred to and entrapped in the first substrate layer.

Additionally, the fabric sheet assembly includes an odor controlling composition carried on the one or more substrate layers. In an exemplary embodiment, the odor controlling composition dissolves or is otherwise released into the wash liquor during the laundering process. In one example, the odor controlling composition includes one or more fragrances (e.g., a blooming or fast releasing fragrance and/or a longer-lasting fragrance) that are released into the wash liquor and transferred to the clothing and/or other washable fabric materials in the wash liquor.

In an exemplary embodiment, it has been found that by absorbing and/or adsorbing the malodor compounds onto the first substrate layer of the fabric sheet assembly, when the wash liquor is drained from the washing reservoir, the malodor compounds remain intact with the fabric sheet assembly and are not redeposited or otherwise transferred back onto the clothing. As such, the just washed clothing will be relatively free of malodor. Further, by transferring the odor controlling composition to the clothing during the laundering process, the just washed clothing will have an enhanced fresh and clean desirable odor (e.g., a blooming fragrance effect and/or a longer-lasting fragrance).

FIG. 1 illustrates a perspective view of a fabric sheet assembly 10 in accordance with an exemplary embodiment. As illustrated, the fabric sheet assembly 10 is disposed in wash liquor 12 that is contained in a washing reservoir 14 of a laundry washing apparatus 16 in accordance with an exemplary embodiment. Clothing and/or other washable fabric materials (not shown) are likewise disposed in the wash liquor 12 with the fabric sheet assembly 10 during a washing stage of a laundering process.

Referring also to FIG. 2, the fabric sheet assembly 10 includes one or more substrate layers 18 including a substrate layer 20. The substrate layer 20 is configured to absorb and/or adsorb malodor compounds 22 from the wash liquor 12. In one example, the malodor compounds 22 are short-chain fatty acids, oils, bacteria, fungi, and/or other hydrophobic-like malodor compounds that have transferred from the clothing or other washable fabric materials into the wash liquor 12 during the washing stage of the laundering process. In an exemplary embodiment, the substrate layer 20 is hydrophobic and oleophilic, and has a relatively high affinity for short-chain fatty acids, oils, bacteria, fungi, and other hydrophobic-like malodor compounds. As such, the malodor compounds 22 are entrapped or preferentially remain intact to the substrate layer 20 even when the wash liquor 12 is drained from the washing reservoir 14 at the end of the washing stage of the laundering process.

In an exemplary embodiment, the substrate layer 20 is formed of fibers 24 that may be woven or non-woven. In one example, the fibers 24 are non-woven fibers. The fibers 24 are formed of a hydrophobic, oleophilic material(s), such as an olefinic material, for example polypropylene. In an exemplary embodiment, the fibers 24 are micro-porous fibers that have micropores 26 formed therein to facilitate absorption and/or adsorption of the malodor compounds 22. Various substrate layers 20 formed of a non-woven polypropylene are commercially available under the product name Fiberweb Nonwoven Products' from Avintiv Technical Nonwoven, located at 70 Old Hickory Boulevard, Old Hickory, Tenn. 37138.

Referring back to FIG. 1, the fabric sheet assembly 10 includes an odor controlling composition 28 that is disposed on and carried by the one or more substrate layers 18. When the fabric sheet assembly 10 is arranged in the laundry washing apparatus 16 and comes into contact with the wash liquor 12 during the laundering process, the odor controlling composition 28 dissolves or is otherwise released into the wash liquor 12.

The odor controlling composition 28 may include various active ingredients for enhancing or improving odor, such as, for example, bleach, a bleach activator, metal, a metal oxide, a fragrance, bacteria, an enzyme, and/or zeolites. In an exemplary embodiment, the odor controlling composition 28 includes a fragrance (e.g., encapsulated fragrances), such as a blooming fragrance (e.g., fast releasing fragrance) that is released into the wash liquor 12 and transfers to the clothing and/or other washable fabric materials for a pleasurable laundering odor experience. Alternatively, the fragrance may be a longer-lasting fragrance that is released into the wash liquor 12 and transfers to the clothing and/or other washable fabric materials for a pleasurable odor experience when the clothing or other washable fabric material is worn. In addition to the active ingredient(s), the odor controlling composition 28 may include other ingredients such as binders, e.g., polyethylene glycol polymers (PEG), polyvinyl alcohol (PVOH), cornstarch, and/or the like, water, processing aids, flow additives, and the like.

Referring also to FIGS. 6A-6D, the odor controlling composition 28 may be arranged in a pattern on the one or more substrate layers 18. For example, and as illustrated in FIGS. 1 and 6B, the odor controlling composition 28 may be arranged in a parallel lines pattern 30 on the one or more substrate layers 18. Other non-limiting examples of patterns for the odor controlling composition 28 include an in-phase juxtaposed squiggly lines pattern 32, a dots pattern 34, and an alternating-phase juxtaposed squiggly lines pattern 36, as illustrated in FIGS. 6A, 6C, and 6D, respectively.

The fabric sheet assembly 10 may include an additional odor controlling composition 38 that has a different composition than the odor controlling composition 28. As illustrated, the additional odor controlling composition 38 is disposed on and carried by the one or more substrate layers 18 and may be incorporated as part of a pattern together with the odor controlling composition 28 either as a separate pattern feature(s), or alternatively, as forming part of the same pattern feature(s). Additionally, and as will be discussed in further detail below, the odor controlling composition(s) 28 and/or 38 may have a different color, e.g., white (for example the order controlling composition(s) 28 and/or 38 may be naturally white or can be opacified with the addition of a whitening additive(s) such as titanium dioxide or the like), than the underlying top substrate layer of the one or more substrate layers 18 such that when the odor controlling composition(s) 28 and/or 30 dissolves in the wash liquor 12, it will be visibly apparent that the odor controlling composition(s) 28 and/or 30 has transferred from the fabric sheet assembly 10 to the wash liquor 12.

Referring to FIGS. 1 and 3, the one or more substrate layers 18 may be configured as a single layer construction that includes only the substrate layer 20. Alternatively, and as illustrated in FIGS. 4 and 5, the one or more substrate layers 18 may be configured as a multilayer construction that includes the substrate layer 20 and one or more additional substrate layers. For example, and as illustrated in FIG. 4, the fabric sheet assembly 10 may include four substrate layers including the substrate layer 20 as a first core substrate layer, an additional core substrate layer 40, a backing substrate layer 42 overlying the two core substrate layers 20 and 40, and a permeable substrate layer 44 disposed adjacent to the two core substrate layers 20 and 40 on a side opposite the backing substrate layer 42. In this example, the additional core substrate layer 40 may include nonwoven polypropylene fibers that are hydrophobic and the substrate layer 20 may include nonwoven, microporous polypropylene fibers that are hydrophobic and relatively more oleophilic than the polypropylene fibers in the additional core substrate layer 40. In an alternative example, and as illustrated in FIG. 5, the fabric sheet assembly 10 may include three substrate layers including the substrate layer 20 as a core substrate layer that is disposed between the backing substrate layer 42 and the permeable substrate layer 44.

With continuing reference to FIGS. 4-5, the backing substrate layer 42 is an exterior substrate layer that directly interfaces with and carries the odor controlling compositions 28 and 38. In an exemplary embodiment, the backing substrate layer 42 is formed of polypropylene fibers, such as non-woven polypropylene fibers, for example, spunbond non-woven polypropylene fibers. Various backing substrate layers 42 formed of spunbond non-woven polypropylene fibers are commercially available under the product name Typar® from Avintiv Technical Nonwoven, located at 70 Old Hickory Boulevard, Old Hickory, Tenn. 37138. In an exemplary embodiment, the odor controlling composition(s) 28 and/or 38 is applied to the backing substrate layer 42 by extrusion while the odor controlling composition(s) 28 and/or 38 is hot, followed by cooling of the odor controlling composition(s) 28 and/or 38 to couple the odor controlling composition(s) 28 and/or 38 to the backing substrate layer 42.

In an exemplary embodiment, the permeable substrate layer 44 is an exterior substrate layer that together with the backing substrate layer 42 helps keep the core substrate layer(s), specifically the substrate layer 20 and if present, the additional core substrate layer 40, together. For example, the core layer(s) 20 and 40 may be susceptible to fraying or partially unraveling while being agitated in the wash liquor 12 during the laundering process. As such, the permeable substrate layer 44 and the backing substrate layer 42 help support the core layer(s) 20 and 40 to prevent fraying and/or to hold the core layer(s) 20 and 40 together. In an exemplary embodiment, the permeable substrate layer 44 is formed of polyester fibers, such as non-woven polyester fibers or spunbond polyester fibers, for example, a polyester mesh formed of non-woven or spunbond polyester fibers. In an exemplary embodiment, the permeable substrate layer 44 is configured as a mesh substrate layer, for example, formed of a polyester mesh or other material in the form of a mesh. Various permeable substrate layers 44 formed of non-woven or spunbond polyester fibers are commercially available under the product names Reemay® and/or DiamondWeb™ from Avintiv Technical Nonwoven, located at 70 Old Hickory Boulevard, Old Hickory, Tenn. 37138.

As will be discussed in further detail below, the backing substrate layer 42, the core substrate layer(s) 20 and 40, and the permeable substrate layer 44 are coupled together by welding to define a weld 46 (e.g., welded zone or region). In one example, the weld 46 is formed by applying heat and pressure to various regions of the multilayer construction to fuse the backing substrate layer 42, the core substrate layer(s) 20 and 40, and the permeable substrate layer 44 together. In an exemplary embodiment, the fabric sheet assembly 10 has a perimeter edge section 48 that surrounds an interior portion 50 of the fabric sheet assembly 10 and the sheet assembly 10 is welded along the perimeter edge section 48. Advantageously, this helps prevent the various substrate layers 20, 40, 42, and 44 from delaminating along the perimeter edge section 48. Alternatively, welding may be applied continuously or discontinuously (e.g., spot welds, pattern welds, or the like) along one or more region(s) of the fabric sheet assembly 10 such that the backing substrate layer 42, the core substrate layer(s) 20 and 40, and the permeable substrate layer 44 are held together by one or more weld zones that are adjacent to one or more non-weld zones so as to not completely fuse or flatten out the non-woven fibers of the various substrate layers 20, 40, 42, and 44.

In an exemplary embodiment, the fabric sheet assembly 10 has one or more relatively bright, conspicuous colors so that the fabric sheet assembly 10 is conspicuous to a product user when being removed together with other just washed clothing from the laundry washing apparatus 16, for example, prior to being transferred to a dryer. In one embodiment, the core substrate layer(s) 20 and 40 has a white color and the backing substrate layer 42 has a relatively bright, conspicuous non-white color, such as a relatively bright yellow or orange color, for example a relatively bright yellow. In another embodiment, the core substrate layer(s) 20 and 40 has a white color and the permeable substrate layer 44 has a relatively bright, conspicuous non-white color, such as a relatively bright yellow or orange color, for example a relatively bright orange. Further, and as discussed above, the odor controlling composition(s) 28 and/or 38 may have a different color, such as white, than the backing substrate layer 42 for high contrast. In an exemplary embodiment, advantageously when the odor controlling composition(s) 28 and/or 30 dissolves in the wash liquor 12, the relatively bright, conspicuous non-white color of the backing substrate layer 42 will become fully exposed, visibly indicating to the product user the high-tech efficacy of the odor controlling composition(s) 28 and/or 38 being released into the wash liquor 12 without the negative impacts of potentially staining any of the clothing.

As illustrated in FIG. 1, the fabric sheet assembly 10 has a polygonal shape, such as a rectangular or square shape, or the like. Alternatively, the fabric sheet assembly 10 may have a curved shape, oval shape, splined shape, circular shape, or any other shape to facilitate handling by the product user. Further, the fabric sheet assembly 10 is sized for convenient handling by a product user for use in the laundry washing apparatus 16. In an exemplary embodiment, the fabric sheet assembly 10 has a maximum dimension (e.g., diagonal dimension of a square shape) of from about 100 to about 500 mm, such as from about 200 to about 400 mm, for example about 250 to about 350 mm.

Referring to FIG. 7, a method 200 for forming a fabric sheet assembly for delivering malodor control in wash liquor during a laundering process in accordance with an exemplary embodiment is provided. The method 200 includes arranging (STEP 202) a core substrate layer between a backing substrate layer and a permeable substrate layer. The core substrate layer is configured to absorb and/or adsorb malodor compounds from the wash liquor. The backing substrate layer, the core substrate layer, and the permeable substrate layer are coupled together (STEP 204) by applying heat and pressure to fuse the substrate layers together and form a weld. One or more odor controlling compositions are deposited (STEP 206) on the backing substrate layer. The one or more odor controlling compositions are configured to be released into the wash liquor. In an exemplary embodiment, the backing substrate layer with the one or more odor controlling compositions, the core substrate layer, and the permeable substrate layer are die cut (STEP 208) along the weld to form the fabric sheet assembly that is sized for convenient handling by a product user for use during the laundering process.

In an exemplary embodiment, a method for using a fabric sheet assembly for delivering malodor control in wash liquor during a laundering process is provided. The method includes combining soiled laundry, the fabric sheet assembly, and wash liquor. Malodor compounds are released from the soiled laundry into the wash liquor. The fabric sheet assembly includes one or more substrate layers as described herein including a first substrate layer that absorbs and/or absorbs malodor compounds from the wash liquor. An odor controlling composition as described herein is carried by the one or more substrate layers. The odor controlling composition is released into the wash liquor to help further control the odor of the soiled laundry.

EXAMPLES AND TRIAL RUNS SECTION

The following are examples and trial runs conducted in accordance with various exemplary embodiments. The examples and trial runs are provided for illustration purposes only and are not meant to limit the various embodiments of the fabric sheet assembly in any way.

Examples—Odor Controlling Compositions

The odor controlling composition can have a variety of different formulas. Two formulas, in combination, that were tested in both manufacturing and consumer settings as well as a third formula using a more flexible carrier for increased flexibility and decreased brittleness are provided below. In these examples, the primary function of the odor controlling composition(s) is as follows: (1) to carry a fragrance(s) or active ingredient(s) to the wash liquor as a pattern of the composition(s) is applied to the backing substrate layer and then upon dissolution delivering these formulas to the wash liquor; and (2) secondarily acting as an indicator as the white formula(s) dissolves revealing only the brightly colored backing substrate layer. In this instance, the carrier in Examples 1 and 2 is polyethylene glycol (PEG) delivering Popscent™* and Fircaps™**, respectively, for blooming (e.g., laundering experience) and longer-lasting fragrance (e.g. experience in wear). In the test runs, Examples 1 and 2 are dosed at equal amounts. Each formula can be dosed at 1 to 5 g, such as 1 to 3 g, for example 1.5 g, in which the dosing level refers to the amount of product (e.g., odor controlling composition(s)) that is released into the wash liquor 12 during the washing stage.

* Popscent™ is core shell polymeric capsule(s) containing perfume that gets deposited onto clothing or other washable fabric material and upon drying, the capsules become brittle and break due to naturally occurring physical forces such as movement, rubbing, or the like, thus releasing the perfume for a longer-lasting pleasurable fragrance odor experience when the clothing or other washable fabric material is worn. Popscent™ is commercially available from Firmenich Inc., which is headquartered in 250 Plainsboro Road, Plainsboro N.J. 08536.
**Fircaps™ is a starch capsule(s) delivery system containing fragrance that dissolves in the wash liquor, thus releasing the fragrance to the clothing or other washable fabric material to demonstrate a blooming effect (e.g., fast releasing fragrance) for a pleasurable laundering odor experience. Fircaps™ is commercially available from Firmenich Inc., which is headquartered in 250 Plainsboro Road, Plainsboro N.J. 08536.

Example 1: Formula AL-2-OG-32

Ingredient  Wt. %
PEG 3350    40 to 99 (e.g., about 86 to about 87)
Popscent ™* 1 to 60 (e.g., about 13 to about 14)

Example 2: Formula AL-2-OG-33

Ingredient  Wt. %
PEG 3350    70 to 99 (e.g., about 93 to about 94)
Fircaps ™** 1 to 30 (e.g., about 6 to about 7)

Example 3: Formula EB-02-OG34***

***The use of polyvinyl alcohol in the Formula EB-02-OG34 was found to provide improved flexibility of the odor controlling composition 28 for handling relative to the polyethylene glycol (PEG) formulations (e.g., Formula AL-2-OG-33 and Formula AL-2-OG-33).

Ingredient               Wt. %
Polyvinyl alcohol        1 to 20 (e.g., about 22 to about 23)
Water                    1 to 40 (e.g., about 38 to about 39)
Cornstarch               0 to about 8.3 (about 5 to about 6)
Encapsulated fragrance - 1 to 60 (e.g., about 33 to about 34)
(e.g., Popscent ™*or Fircaps ™**)

Note—the odor controlling composition(s) can alternatively or also comprise odor-control material(s) such as, for example, a combination of sodium percarbonate and bleach activator. Examples of bleach activators are tetraacetylethylenediamine (TAED) and sodium nonanoyloxybenzenesulfonate (NOBS). The combination between percarbonate and a bleach activator produces peracid acid, which can provide odor control benefits. Additionally, various malodor controlling composition(s) and/or technologies can be encapsulated or incorporated into encapsulated fragrances. Some examples of this kind of technology include Deodecylix® R and S from Firmenich Inc., or Neutraq® from Givaudan. Malodor controlling technologies can work via various mechanisms including but not limited to receptor blocking, masking, complementing, adsorption/absorption, and/or chemical reaction. Any of these approaches, or a combination thereof, are contemplated herein. Such malodor controlling technologies may be broadly used in controlling a wide range of malodors, or specifically targeted towards certain malodors.

Trial Runs

The trial runs were conducted over a series of days to understand the feasibility of producing fiber sheet assemblies and to obtain enough samples of fiber sheet assemblies to conduct a consumer test as well as lab testing. The following is a summary of the trial runs:

Day 1

All three fabrics (yellow spun-bound polypropylene (e.g., backing substrate layer), white nonwoven polypropylene (e.g., core substrate layer), orange polyester mesh (e.g., permeable substrate layer)) were stacked together and test welded. Alignment of all materials was established, and a few units were manually cut. Excess tension prior to welding caused the orange polyester mesh to pull the squares in one direction, resulting in diamond shapes. The team made several adjustments to correct the issue. Ultimately, it was determined that tensioning the polypropylene rolls, while leaving the mesh roll un-tensioned, permitted the welding of stable square units.

Day 2

Application of the formulation (e.g., odor controlling composition) commenced on Day 2. It was noted that 13.33 Wt. % Popscent™ formulation” (Formula: AL-2-OG-32) separates upon freezing. When re-melted, agitation was required to mix the encapsulated fragrance back into the polyethylene glycol carrier. Formula AL-2-OG-32 used during the test run was heated and agitated immediately before adding to the hot melt unit.

When both formulations (Formula: AL-2-OG-32 and Formula: AL-2-OG-33) were applied at the same time to the yellow spun-bound polypropylene (e.g., backing substrate layer) of the 3 substrate layer welded stack formed on Day 1, the formulation product lines (Formula: AL-2-OG-32 and Formula: AL-2-OG-33) appeared too thick. The nozzle injector shims needed to be adjusted to get the product lines to the appropriate thickness. Before this could be accomplished, the sonic welding horn became disabled. A new horn needed to be installed to continue, so the test run was scheduled to continue on Day 3.

Day 3

The team worked to cut the nozzle injector shims to a size of ˜6.1 mm. On Day 3, the shim cut size had been optimized, and a new sonic horn had been installed. Finished samples were acceptable in appearance, but could not be cut due to the setup (cooling) time (˜1 minute) of the formulation. 6 foot sheets of welded fabric sheet assembly squares were cut and set aside as the production line ran. A makeshift cooling setup was established, utilizing a cabinet cooler with manifold, and a conventional floor fan.

Day 4

A final run produced the most visually appealing samples of the test run. The rotary die cutter was used to cut individual fabric sheet assembly squares. There was not enough polypropylene substrate to properly register the cutting die and ensure an accurate cut. In addition, the formula (e.g., odor controlling composition) did not have time to dry before being cut, resulting in PEG buildup on the die. Enough material was run to ensure ˜1500 high quality units, with an additional ˜1500 early run units for a consumer test.

While at least one exemplary embodiment has been presented in the foregoing detailed description of the disclosure, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the disclosure. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the disclosure as set forth in the appended claims.

Claims

1. A fabric sheet assembly for delivering malodor control in wash liquor during a laundering process, the fabric sheet assembly comprising:

one or more substrate layers including a first substrate layer configured to absorb and/or adsorb malodor compounds from the wash liquor; and

an odor controlling composition carried by the one or more substrate layers and configured to be released into the wash liquor.

2. The fabric sheet assembly of claim 1, wherein the first substrate layer is a hydrophobic substrate layer.

3. The fabric sheet assembly of claim 1, wherein the first substrate layer is an oleophilic substrate layer.

4. The fabric sheet assembly of claim 1, wherein the first substrate layer comprises non-woven fibers.

5. The fabric sheet assembly of claim 1, wherein the first substrate layer comprises polypropylene fibers.

6. The fabric sheet assembly of claim 1, wherein the first substrate layer comprises micro-porous fibers.

7. The fabric sheet assembly of claim 1, wherein the odor controlling composition comprises a fragrance, bacteria, an enzyme, zeolites, bleach, a bleach activator, metal, a metal oxide, or a combination thereof.

8. The fabric sheet assembly of claim 7, wherein the odor controlling composition is arranged in a pattern on the one or more substrate layers.

9. The fabric sheet assembly of claim 1, wherein the one or more substrate layers includes a backing substrate layer overlying the first substrate layer, and wherein the odor controlling composition is disposed on the backing substrate layer.

10. The fabric sheet assembly of claim 9, wherein the backing substrate layer comprises spunbond non-woven polypropylene fibers.

11. The fabric sheet assembly of claim 9, wherein the first substrate layer is a white color and the backing substrate layer has a relatively bright, conspicuous non-white color.

12. The fabric sheet assembly of claim 11, wherein the relatively bright, conspicuous non-white color is yellow.

13. The fabric sheet assembly of claim 9, wherein the one or more substrate layers includes a permeable substrate layer and the first substrate layer is a core substrate layer that is disposed between the backing substrate layer and the permeable substrate layer.

14. The fabric sheet assembly of claim 13, wherein the permeable substrate layer comprises a polyester mesh.

15. The fabric sheet assembly of claim 13, wherein the first substrate layer is a white color and the permeable substrate layer has a relatively bright, conspicuous non-white color.

16. The fabric sheet assembly of claim 15, wherein the relatively bright, conspicuous non-white color is orange.

17. The fabric sheet assembly of claim 13, wherein the backing substrate layer, the core substrate layer, and the permeable substrate layer are coupled together by a weld.

18. The fabric sheet assembly of claim 17, wherein the fabric sheet assembly has a perimeter edge section and the weld is formed along the perimeter edge section.

19. A fabric sheet assembly for delivering malodor control in wash liquor during a laundering process, the fabric sheet assembly comprising:

a backing substrate layer, a permeable substrate layer, and a core substrate layer that is disposed between the backing substrate layer and the permeable substrate layer, wherein the core substrate layer comprises nonwoven, micro-porous polypropylene fibers; and

one or more odor controlling compositions disposed on the backing substrate layer and comprising one or more encapsulated fragrances.

20. A method for forming a fabric sheet assembly for delivering malodor control in wash liquor during a laundering process, the method comprising the steps of:

arranging a core substrate layer between a backing substrate layer and a permeable substrate layer, wherein the core substrate layer is configured to absorb and/or adsorb malodor compounds from the wash liquor;

coupling the backing substrate layer, the core substrate layer, and the permeable substrate layer together; and

depositing one or more odor controlling compositions on the backing substrate layer, wherein the one or more odor controlling compositions are configured to be released into the wash liquor.