| abstract |
The invention is directed at a disposable dry cleansing article that is formed from a melt extruded fibrous web that has incorporated into the fibers forming the web from 0.5 to 20 percent by weight of a melt extruded lathering surfactant. The invention, dry article generally comprises a melt extruded fibrous web of a thermoplastic polymer having a basis weight of from about 10 to 200 g/m2, preferably 10 to 150 g/m2 wherein the fibers have a lathering surfactant incorporated into the fiber at a level that allows the article to be used two (2) or more times with a rinse foam volume of 15 or more, with an initial foam volume of at least 50 ml. The novel melt extruded web can be made by the following sequential steps: (a) providing to an extruder a thermoplastic resin, such as polypropylene; (b) blending into the resin a lathering surfactant at a temperature at which the surfactant is not significantly degraded; (c) forming the blend into melt extruded fibers, (d) collecting the fibers, (e) forming the fibers into a web and optionally, further treating the web by coating additional components, laminating to further layers or consolidating for strength or the like. |