Patent Application
20240336394
This application is directed to a carton for holding a product. The product can include, for example, a unit dose article.
A growing trend among consumers is the use of pre-dosed, single use products. These unit dose products are desired by consumers as they provide a convenient, efficient, and clean way of dosing the desired product. One challenge, however, for a manufacturer is how to package such products so that they are aesthetically pleasing and retain the convenience of use. This is especially true when attempting to bundle together large numbers of such products. As such, there is a need for a package for multiple single use articles which can maintain the convenience of its use.
Included herein is a carton comprising: a) a base; b) a lid having a top side and under side; c) a first side; d) a front side, wherein at least a portion of the front side is located adjacent to the first side; e) a second side, wherein at least a portion of the second side is located adjacent to the front side; and f) a back side, wherein a portion of the back side is located adjacent to the first side and a portion of the back side is located adjacent to the second side; wherein the carton comprises 2 square corners and 2 non-square corners.
Also included herein is a carton comprising: a) a base portion comprises: i) a first side; ii) a front side, wherein at least a portion of the front side is located adjacent to the first side and there is an arcuate transition between the first side and the front side; iii) a second side, wherein at least a portion of the second side is located adjacent to the front side and there is an arcuate transition between the second side and the front side; and iv) a back side, wherein a portion of the back side is located adjacent to the first side and a portion of the back side is located adjacent to the second side and the back side has no arcuate transitions between itself, the first side, or the second side; and b) a lid having a top side and underside; wherein the lid is integral with a portion of the carton.
This and other embodiments are described more fully below.
Unit dose articles, like those used in dish care and laundry, are highly desired by consumers for their convenience of use. When these types of articles are sold in bulk, they tend to be packaged in a bucketed style where the unit doses are not arranged in a particular pattern and are retrieved from a haphazard stack or pile when used. While some of this is attributable to the design of the unit dose product itself, it can lack aesthetics and not be the best option for all unit dose article types.
Some unit dose types are more amenable to ordered packaging. These can include those which are flat or substantially flat. Substantially flat unit dose types are those where the major surfaces are essentially parallel. Substantially flat unit dose types can be stacked upon one another without falling over at least 3 high. Depending on the unit dose, ordered packaging can allow for more unit doses to be put into a package than bucketing. It also allows for a more efficient use of space. Ordered packaging can also protect the unit dose from seal breakage or damage from shearing created when unit doses rub against one another.
The first part of ordered packaging is the exterior package. This is the package which encloses the product and is visible to consumers. One common exterior product package is a carton. Cartons are often square or rectangular in shape and often have a consistent shape. Here, the inventors wanted to design a carton with a distinctive shape. As can be seen in
Most cartons with a mixture of corner shapes, like both non-squared and squared corners have two distinct pieces that are formed separately as this simplifies the fitting of the lid and the base and allows for easy opening. The present design, however, can be made from a single piece of carton board. This means the lid is integral with at least a portion of the carton. This attachment of the lid to a portion of the carton gives less clearance for the lid and is a challenge to overcome. The present inventors have overcome this challenge.
For those executions with rounded corners, different curvatures can be utilized on the rounded corners on a bottom portion of a carton and the corresponding rounded corners on a lid to allow for sufficient clearance of the lid from the base portion. For example, where a lid overlaps onto an exterior of a base portion, the curvature of any rounded corners on the lid will be larger than the curvature of the corresponding rounded corners on the base portion. The opposite is true where a lid is positioned to the interior of a base portion in a closed configuration. Curvature can be measured via radius of curve. For a curve, the radius of curvature is the radius of a circle that best fits a normal section of the curve. Thus, for a rounded corner, one would find a circle that best fits a normal section of the rounded corner and look at the radius. Measuring a radius of a circle can be done in accordance with any known standard. For sufficient clearance between a lid and a base portion, a curvature difference of at least 2%, 3%, 4%, 5%, 7%, 10%, 12%, 15%, to about 50%, 70%, 80%, 90%, or 100% or more, between a lid and a base portion can be utilized.
For executions with non-square corners where a lid overlaps the exterior of the base portion and where the lid is integral with at least a portion of the carton, some additional ways to help ensure clearance of a lid from a base portion can include having a lid project beyond a base portion and having a lid with a larger area than a base (excluding any panel portions on the lid and base). For executions with non-square corners where a lid is positioned to the interior of the base portion and where the lid is integral with at least a portion of the carton, some additional ways to help ensure clearance of a lid from a base portion can include having a base portion project beyond a lid and having a base with a larger area than a lid (excluding any panel portions on the lid and base).
Another challenge encountered with this design is consistency of the shape of non-squared corners in the finished carton. Maintaining the shape of non-squared corners, like rounded corners, helps to give proper clearance for the lid, so consistency of those shapes is needed during the manufacturing process to allow for a uniform, working finished carton. To maintain consistent non-square corner shapes during manufacturing, score marks can be added to a portion of a panel and/or tab utilized to make the non-square corners to indicate where the non-square shape starts and/or stops. These marks can be visible to the human eye for manual construction of a carton and/or have enough contrast to guide automation on a manufacturing line. Preferably, these marks are not visible to a consumer in a finished carton.
When the carton is made from a single piece of paperboard, some changes to the manufacturing process also contribute to a more uniform finished carton shape. The use of a knock down flat and forming the carton in a sequenced manner allows for the carton to have non-square, ex. rounded corners, without the need for hard folds or a multi-piece assembly. A knock down flat is a collapsed parallelogram state where a carton is partially assembled at another station and/or location from the final assembly. The ordered assembly can include forming and gluing the bottom portion of the carton first and then forming and gluing the lid. Where the lid overlaps to the exterior of the bottom portion, the lid may be formed around the bottom portion to help ensure the proper non-square corner shape, ex. curvature, is maintained. Where the lid is positioned to the interior of a bottom portion, the ordered assembly can include first forming and gluing the lid and then forming the bottom portion around the lid to help maintain proper shape of non-square corners.
Once lid clearance has been established with consistent corner shapes, ex. consistent curvatures, between a bottom portion and a lid through manufacturing, that clearance needs to be maintained for filling and/or use. To maintain that clearance, the carton needs to have sufficient rigidity so that it doesn't overly distort upon filling with product, shipping, or handling by a consumer. Rigidity can be added to a carton through the material used to make the carton and/or by building structure into the carton. Here, where the material of the carton is being bent to form the carton, the amount of rigidity that can come in with the material itself is limited.
For paperboard, a minimum caliper is needed to allow for sufficient rigidity and a maximum is needed to allow for bending to form the carton. The exact caliper needed can depend upon whether the carton is utilizing support structures which contribute to the rigidity of a carton. In that instance, a lower caliper material may be used. In addition, a smaller overall package size can allow for a lower caliper material. A carton may be made of a paperboard with a caliper of about 0.008 in to about 0.028 in, 0.012 in to about 0.028 in, 0.016 in to about 0.028 in, most preferably from about 0.016 in to about 0.024 in. Paperboard can include, for example, clay coated news backboard, folding box board, solid bleached sulfate, natural kraft, coated unbleached craft, and coated recycled paperboard.
As noted above, the rigidity of a carton can be supplemented with structure if sufficient rigidity cannot be achieved by the material of the carton alone. If there is insufficient structure in the carton, the shape of the carton can be distorted and the lid clearance built in through diligent formation of the carton can be lost. Providing structure to the carton can be done in multiple ways. For example, one or more internal walls can be provided which extend from a non-square, ex. rounded, corner and are glued in place and/or structural supports can be included in the carton. Such structural supports may provide horizontal support, vertical support, or a combination thereof. Structural support can also be provided in form of internal packaging and/or internal structures which are described in more detail below.
Another part of organized packaging can include internal structures and/or internal packaging. Internal structures can include, for example, product guides and/or dividers which can help position the product during filling of the product and/or help maintain product in a desired order in a package. A product guide and/or divider can be an integral part of a carton or something added separately. In addition, these structures can be designed in a way to provide additional structure to the carton itself. For example, these structures can be in close proximity to (or even touching) the top side of a bottom portion and/or the underside of a lid to help minimize the amount those two structures will deform when pressure is applied to one or both. The same is true if these structures are placed in a horizontal fashion running from a front side to a back side where they will help minimize deformation of those portions of the carton when pressure is applied. These structures in either configuration can also help provide structure to the carton such the twisting of the carton is minimized while, for example, a carton is being handled by a consumer.
One potential issue with directly packaging product into the exterior package, however, is that if there is a problem with the packaging manufacturing process, finished product has nowhere to go and can back-up on the manufacturing line creating a cascade of issues. One solution to this issue is to utilize an internal package. The use of an internal package allows for finished product to be packaged within an internal package without interruption if there is an issue with the manufacturing of the external package. Use of an internal package also allows for the product to be stored and/or used in a modular configuration. This allows flexibility in the size of the exterior package, the number of units to include in a package, and how the internal packages can be arranged in the exterior package. For example, the product may be shipped in one configuration within the exterior package and rearranged by the consumer into a different configuration for use.
There are other potential uses for an internal package. An internal package can catch any product leakage, so that product in the remainder of the external package is not impacted. An internal package can also help hold product into the desired configuration and minimize the risk product shifts during shipping or shelf stocking. An internal package can also help prevent product from being compressed during the packaging, shipping, and/or storage.
Internal packages can include, for example, a sleeve, a carton, a tray, a bag, or a combination thereof. Sleeves and bags can be made of different materials, for example, a film, paperboard, paper, wax paper, foil, cellophane, plastic, or any combination thereof. Sleeves and bags can be helpful in maintaining fragrance longevity in a unit dose product by protecting it from exposure to air. Sleeves and bags can also include apertures to allow for controlled release of perfume contained within a unit dose product, if that is desired. Sleeves and bags may also contain a closure like, for example, a seal, a snap, a hook and loop fastener, interlocking flanges, or any combination thereof.
One example of an internal package is a tray. As noted above in general, loading product into a tray allows finished product to be accumulated and diverted away from problem areas in the manufacturing process without having to be scrapped. Another benefit of a tray or similar structure is that the trays can be made to fit different counts allowing flexibility in sizing of the exterior packaging to best meet consumer needs. Loading the product into a tray also minimizes the amount of contact between individual unit doses and helps prevent damage from such interaction. Trays can be oriented vertically or horizontally or a combination thereof to help control how sizes appear in relation to one another at the shelf. It also gives a more organized appearance to the product and a better consumer experience upon opening of the exterior package. Trays may be the same size and shape within a carton or a combination of sizes and shapes may be used in a carton.
An additional advantage of the use of an internal package, like a tray, is that the structure of the tray can be utilized to help give additional support to the exterior package. For example, a portion of a tray wall, like a side wall, can be extended such that it provides internal vertical support from the base to the lid making the whole package stronger. Packing the internal structures in way that they essentially take up most of the space in the exterior package can also provide horizontal support for the carton. These can help provide support such that unintended twisting and/or bending of the carton is avoided. An internal package can also help prevent and/or minimize deforming of a lid or a base portion when those parts are under pressure, for example, from being carried or opened. An internal package also helps to keep the weight of the product within the carton, like a unit dose, evenly distributed, helps prevent product shift during shipping, shelving, and use. Internal packaging also allows for modular use of the product. For example, a consumer may pull a tray of product from a larger package, like a carton, and store that tray close to the place or use while putting the remainder of the product in the external package in a different storage location.
When utilizing a carton with a non-uniform shape or a shape that is not compatible with the shape of a product to be loaded into the carton, additional structures can be added to the carton to allow for a more uniform loading of product. For example, in a carton with 2 non-squared corners, a structure can be added that makes the internal portion of a carton square or rectangular, for example, to allow for better packing of predominantly square and/or rectangular product. The structure can be, for example, an internal wall or compartment.
A carton is described herein with reference to the figures where indicated. A carton 10, as shown in
A carton may have a bottom portion 40 and a lid 50 as seen in
A base 60, may include one or more panels 110. The one or more panels may include walls. The one or more panels may be the first side 90, the back side 80, the front side 70, and/or the second side 100. When in a folded configuration, the first side 90, the back side 80, the front side 70, and/or the second side 100 can extend upward from the base 60. A base 60 can comprise a one or more guides. A guide may be used to help load product into a carton. For example, a guide may help with proper placement of an internal package, like a removable tray. A guide may be a panel that extends upward from a base 60. There may also be a score line 120 disposed between the base 60, the first side 90, the back side 80, the front side 70, and/or the second side 100. A score line 120 may be continuous or discontinuous. It may penetrate through a material or not. A score line 120 may be used as a fold line to delineate where a material is to be folded and/or to help provide a more uniform fold at a particular point.
A base 60 may comprise one or more structural shelves. A structural shelf may extend upward from a base 60 toward an underside of a lid 50. A structural shelf may extend to a height of at least 80% of the height between the base 60 and the underside of the lid 50. A structural shelf may extend to a height of about 80% to 100% of the height between the base 60 and the underside of the lid 50. A structural shelf may contact both the base 60 and the underside of a lid 50.
Each of the panels 110, may further comprise an additional panel. For example, a front side 70 may comprise a panel 110. This panel may, for example, form a top portion 140A of a compartment 140 on the inside of a carton 10 (see
A compartment 140 may also help with structural integrity of a carton by helping to keep internal packaging aligned. When non-squared corners are included in a package, this can create an asymmetrical shape on an interior of a package. This asymmetry can cause difficulties in packaging product. By including a compartment 140, the shape of an interior of a package can be symmetrical which can be easier to fill.
Each of the panels 110 may further comprise one or more tabs 130 extending from the panel for joining a panel to another portion of a carton. The tabs may join the portions of the carton, for example adhesively. Panels may also interlock with another portion of a carton to join the pieces together. Each panel may comprise from about 1 to about 10 tabs, from about 1 to about 8 tabs, from about 1 to about 6 tabs, from about 1 to about 4 tabs, from about 1 to about 3 tabs, from about 1 to about 2 tabs, or any combination thereof. For example, a back side 80 may comprise 1 or more tabs 130, preferably 2 tabs 130; a front side 70 may comprise 1 or more tabs 130, preferably 2 tabs 130; a panel for forming a wall 140B of a compartment 140 may comprise 1 or more tabs 130, preferably 1 tab 130.
A tab 130 extending from a wall 140B may be attached to a base 60 of a carton 10. The tab 130 extending from the wall 140B may be attached to the base 60 such that it resides inside of the compartment 140 (
A lid 50 may have a top side and an under side. In a closed configuration, a top side will be visible, while an underside will be on the interior of the closed carton. A lid 50 may be integral to the bottom portion 40 or separate from a bottom portion 40 of the carton 10. When a lid 50 is integral to the bottom portion 40, it may be attached to the first side 90, the back side 80, the front side 70, and/or the second side 100, in any configuration in which it will open to allow access to the contents of the carton 10. The lid 50 is preferably attached to one of the first side 90, the back side 80, the front side 70, or the second side 100, with a score line 120 disposed between the lid 50 and the side to which it is attached. Preferably, a lid 50 is attached to the back side 80 with a score line 120 disposed therebetween.
A lid 50 can help to define the shape of the top of a carton 10. Thus, a lid 50 may have 1 to 4 non-squared corners, preferably 1 to 3 non-squared corners, more preferably 2 to 3 non-squared corners, most preferably 2 non-squared corners. A lid 50 may have 1 to 4 rounded corners 20, preferably 1 to 3 rounded corners, more preferably 2 to 3 rounded corners, most preferably 2 rounded corners. A lid 50 may have one or more square corners 30. A lid 50 may have 1 to 3 square corners, preferably 2 to 3 square corners, most preferably 2 square corners. A lid 50 may have 1 to 4 chamfered corners 180, preferably 1 to 3 chamfered corners, more preferably 2 to 3 chamfered corners, most preferably 2 chamfered corners. A lid 50 may have 2 rounded and 2 squared corners. A lid 50 may have 2 chamfered corners and 2 squared corners. Where a base has a particular shape, a lid can mirror that shape. For example, a base 60 may have 2 rounded corners 20 and a corresponding lid 50 can have complimentary rounded corners 20 (ex.
A lid 50 may include one or more panels 110. The one or more panels 110 may include walls. The one or more panels 110 attached to the lid may have a score line 120 disposed between themselves and the lid 50. The one or more panels attached to the lid may be folded such that when the carton 10 is in a closed configuration the panels at least partially overlap one or more of the first side 90, the back side 80, the front side 70, or the second side 100 (see
A lid 50 can comprise one or more guides. A guide may be used to help load product into a carton 10. For example, a guide may help with proper placement of an internal package, like a removable tray. A guide may be a panel that extends downward from a lid 50.
A lid 50 may comprise one or more structural shelves. A structural shelf may extend downward from a lid 50 toward a base 60. A structural shelf may extend to a height of at least 80% of the height between the base 60 and the underside of the lid 50. A structural shelf may extend to a height of about 80% to 100% of the height between the base 60 and the underside of the lid 50. A structural shelf may contact both the base 60 and the underside of a lid 50.
A lid 50 may include a cutout 150 (see
When a closure tab 160 engages a cutout 150, an audible sound may be heard. Such a sound, if present, can signal to a user of a carton 10 that the carton is indeed closed. The length of the closure tab can impact how loud the audible sound is.
The interlocking of a closure tab 160 with a cutout 150 also provides additional structure for a carton 10.
A lid may also include a closure that is not a cutout or in addition to a cutout. This closure may be reusable. A closure for a lid may include, for example, a snap, a hook and loop fastener, interlocking flanges, a tab and string, press and seal, or any combination thereof.
A carton 10 can comprise a front side 70. A front side may be attached to a base 60 with a score line 120 there between. A front side 70 may be longer than a lid 50. At least a portion of a front side 70 may be located adjacent to a first side 90. There may be an arcuate transition 170 between a first side 90 and a front side 70. This arcuate transition can be formed when a portion of a front side 70 is curved toward and attached to the first side 90. It can also be formed when a portion of the first side 90 is curved toward and attached to a front side 70. The first side 90 and the front side 70 may be attached through adhesive placed on a tab on the front side 70 and adhered to the first side 90 or by adhesive placed on a tab on the first side 90 and adhered to the front side 70. This arcuate transition 170 can form a rounded corner 20 on a bottom portion 40 of a carton 10.
At least a portion of a front side 70 may be located adjacent to a second side 100. There may be an arcuate transition 170 between a front side 70 and a second side 100. This arcuate transition can be formed when a portion of a front side 70 is curved toward and attached to the second side 100. It can also be formed when a portion of the second side 100 is curved toward and attached to a front side 70. The second side 100 and the front side 70 may be attached through adhesive placed on a tab on the front side 70 and adhered to the second side 100 or by adhesive placed on a tab on the second side 100 and adhered to the front side 70. This arcuate transition 170 can form a rounded corner 20 on a bottom portion 40 of a carton 10.
A carton 10 can comprise a back side 80. When in a closed configuration, a back side 80 can be generally parallel to a front side 70. A back side 80 may be attached to a base 60. A back side may also be attached to a lid 50. It may be attached to a base 60 and/or a lid 50 with a score line 120 therebetween. A back side 80 may comprise one or more panels 110. In addition, a back side 80 may comprise one or more tabs 130. For example, a back side 80 may comprise two tabs 130. A back side 80 may be attached to one or more tabs 130 with a score line 120 therebetween. One of the tabs 130 may be folded along a score line 120 and attached to a first side 90. One of the tabs 130 may be folded along a score line 120 and attached to a second side 100. Tabs 130 may be attached to a first side 90 and/or a second side 100 with an adhesive. Tabs 130 may be attached to a first side 90 and a second side 100 such that the tabs 130 sit on the interior of the carton 10, exterior of the carton 10, or some combination thereof, when a carton 10 is in a closed configuration.
A carton 10 can comprise a first side 90. A first side 90 may be attached to a base 60 and/or a lid 50 with a score line 120 therebetween. A first side 90 can comprise one or more panels 110. In addition, a first side 90 may comprise one or more tabs 130. In a closed configuration, a first side 90 may be a wall of a carton 10. In addition, in a closed configuration, a first side 90 can be generally parallel with a second side 100. A first side 90 can help in the formation of a non-square corner and/or a square corner of a carton 10. Preferably, a first side 90 contributes to both a square and non-square corner on a carton 10.
A carton 10 can comprise a second side 100. A second side 100 may be attached to a base 60 and/or a lid 50 with a score line 120 therebetween. A second side 100 can comprise one or more panels 110. In addition, a second side 100 may comprise one or more tabs 130. In a closed configuration, a second side 100 may be a wall of a carton 10. In addition, in a closed configuration, a second side 100 can be generally parallel with a first side 90. A second side 100 can help in the formation of a non-square corner and/or a square corner of a carton 10. Preferably, a second side 100 contributes to both a square and non-square corner on a carton 10.
A carton may be coated or uncoated. In addition, only portions of a carton may be coated. A coating may include, for example, a UV coating or an aqueous coating. A coating can be used, for example, to help protect ink or pigments on a package, give the package a particular sheen (ex. matte, shiny, etc.), and/or to protect the package and/or included product from humidity/moisture.
Portions of a carton may be adhered to one another. These adhesives may be, for example, thermoset adhesives. A carton may also be dyed and/or printed.
A carton may be any desirable shape which has corners. For example, a carton may be square, rectangular, triangular, polygonal, cross, etc. For example, a carton may be rectangular with 2 non-squared corners and 2 squared corners; rectangular with 2 rounded corners and 2 square corners; rectangular with 2 chamfered corners and 2 square corners; a carton may be square with 2 non-squared corners and 2 squared corners; square with 2 rounded corners and 2 square corners; or square with 2 chamfered corners and 2 square corners. For example, a carton may be rectangular with 2 non-squared corners and 2 squared corners, where the 2 non-squared corners are adjacent one another; rectangular with 2 rounded corners and 2 square corners, where the 2 rounded corners are adjacent one another; rectangular with 2 chamfered corners and 2 square corners, where the 2 chamfered corners are adjacent one another; a carton may be square with 2 non-squared corners and 2 squared corners, where the 2 non-squared corners are adjacent one another; square with 2 rounded corners and 2 square corners, where the 2 rounded corners are adjacent one another; or square with 2 chamfered corners and 2 square corners, where the 2 chamfered corners are adjacent one another.
A carton may be oriented to sit on a base, a first side, or a second side. Preferably, a carton is oriented to sit on a first side, like a book.
Where the carton is made of a foldable material, like paperboard, the carton is assembled, at least in part, by folding and adhesively joining portions of the carton. Adhesives used for such can include, for example, thermoset, thermoplastic, or a combination thereof. The adhesives may be naturally sourced and/or biodegradable, which increases the environmental friendliness of the carton.
A unit dose product can be packaged within a carton. A unit dose product may be, for example, a foam, a sheet, a tablet, an ampule, a sachet, etc. Where a unit dose does not lend itself to stacking in a carton, the unit dose may be put into a package that will allow for stacking within a carton. This can include, for example, a blister pack, individual cartons, sleeves, etc.
Preferably, a unit dose product is a fibrous water-soluble unit dose. As used herein, the phrases “fibrous water-soluble unit dose article,” “water-soluble fibrous unit dose article”, “water-soluble fibrous unit dose”, “water-soluble fibrous structure”, and “water-soluble fibrous element” mean that the unit dose article, fibrous structure, and fibrous element are miscible in water. In other words, the unit dose article, fibrous structure, or fibrous element is capable of forming a homogeneous solution with water at ambient conditions. “Ambient conditions” as used herein means 23° C.±1.0° C. and a relative humidity of 50%±2%. The fibrous water-soluble unit dose article may contain insoluble materials, which are dispersible in aqueous wash conditions to a suspension mean particle size that is less than about 20 microns, or less than about 50 microns.
The fibrous water-soluble unit dose article may include any of the disclosures found in U.S. Patent Application Pub. No. 2018/0216052 filed on Jan. 26, 2018; U.S. Patent Application Pub. No. 2018/0216050 filed Jan. 26, 2018; and U.S. Patent Application Pub. No. 2018/0216053 filed Jan. 26, 2018; incorporated by reference in their entirety.
These fibrous water-soluble unit dose articles can be dissolved under various wash conditions, e.g., low temperature, low water and/or short wash cycles, or cycles where consumers have been overloading the machine), while providing sufficient delivery of active agents for the intended effect on the target consumer substrates (with similar performance as today's liquid products). Furthermore, the fibrous water-soluble unit dose articles described herein can be produced in an economical manner by spinning fibers.
The surface of the fibrous water-soluble unit dose article may comprise a printed area. The printed area may cover between about 10% and about 100% of the surface of the article. The area of print may comprise inks, pigments, dyes, bluing agents or mixtures thereof. The area of print may be opaque, translucent or transparent. The area of print may comprise a single color or multiple colors. The printed area may be on more than one side of the article and contain instructional text and/or graphics. The surface of the fibrous water-soluble unit dose article may comprise an aversive agent, for example a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octacetate, quinine hydrochloride, denatonium benzoate, or mixtures thereof. Any suitable level of aversive agent may be used. Suitable levels include, but are not limited to, 1 to 5000 ppm, or even 100 to 2500 ppm, or even 250 to 2000 ppm.
A fibrous water-soluble unit dose article may exhibit a thickness of greater than 0.01 mm and/or greater than 0.05 mm and/or greater than 0.1 mm and/or to about 100 mm and/or to about 50 mm and/or to about 20 mm and/or to about 10 mm and/or to about 5 mm and/or to about 2 mm and/or to about 0.5 mm and/or to about 0.3 mm.
The fibrous water-soluble unit dose articles may have basis weights of from about 500 grams/m2 to about 5,000 grams/m2, or from about 1,000 grams/m2 to about 4,000 grams/m2, or from about 1,500 grams/m2 to about 3,500 grams/m2, or from about 2,000 grams/m2 to about 3,000 grams/m2.
The fibrous water-soluble unit dose article may exhibit different regions, such as different regions of basis weight, density, caliper, and/or wetting characteristics. The fibrous water-soluble unit dose article may be compressed at the point of edge sealing. The fibrous water-soluble unit dose article may comprise texture on one or more of its surfaces. A surface of the fibrous water-soluble unit dose article may comprise a pattern, such as a non-random, repeating pattern. The fibrous water-soluble unit dose article may comprise apertures. The fibrous water-soluble unit dose article may comprise a fibrous structure having discrete regions of fibrous elements that differ from other regions of fibrous elements in the structure. The fibrous water-soluble unit dose article may be used as is or it may be coated with one or more active agents.
The fibrous water-soluble unit dose may be in the form of any three-dimensional structure. The fibrous water-soluble unit dose article can be perforated. The article can also be cut or shaped into various sizes for different intended uses. For example, the fibrous water-soluble unit dose may be in the form of a square, a rounded square, a kite, a rectangle, a triangle, a circle, an ellipse, and mixtures thereof. A fibrous water-soluble unit dose article can have a width from about 1 cm to about 11 cm; a length from about 1 cm to about 20 cm; and a height from about 0.01 mm to about 50 mm, preferably about 3.8 cm×about 3.2 cm. A fibrous water-soluble unit dose may be stackable.
The fibrous water-soluble unit dose may comprise less than 10 ingredients. The fibrous water-soluble unit dose may comprise between 3 and 9 ingredients, such as, for example, 4 ingredients, 5 ingredients, 6 ingredients, 7 ingredients, or 8 ingredients.
A fibrous water-soluble unit dose product comprises one or more fibrous elements. The fibrous elements can be associated with one another to form a structure. Fibrous structures can include particles within and/or on the structure. Fibrous structures can be homogeneous, layered, unitary, zoned, or as otherwise desired, with different active agents defining the various aforesaid portions.
A fibrous structure can comprise one or more layers, the layers together forming a ply.
The fibrous elements may be water-soluble. The fibrous elements may comprise one or more filament-forming materials and/or one or more active agents, such as a surfactant. The one or more active agents may be releasable from the fibrous element, such as when the fibrous element and/or fibrous structure comprising the fibrous element is exposed to conditions of intended use.
The fibrous elements may be spun from a filament-forming composition, also referred to as fibrous element-forming compositions, via suitable spinning process operations, such as meltblowing, spunbonding, electro-spinning, and/or rotary spinning.
“Filament-forming composition” and/or “fibrous element-forming composition” as used herein means a composition that is suitable for making a fibrous element such as by meltblowing and/or spunbonding. The filament-forming composition comprises one or more filament-forming materials that exhibit properties that make them suitable for spinning into a fibrous element. The filament-forming material may comprise a polymer. In addition to one or more filament-forming materials, the filament-forming composition may comprise one or more active agents, for example, a surfactant. In addition, the filament-forming composition may comprise one or more polar solvents, such as water, into which one or more, for example all, of the filament-forming materials and/or one or more, for example all, of the active agents are dissolved and/or dispersed prior to spinning a fibrous element, such as a filament from the filament-forming composition.
The filament-forming composition may comprise two or more different filament-forming materials. Thus, the fibrous elements may be monocomponent (one type of filament-forming material) and/or multicomponent, such as bicomponent. The two or more different filament-forming materials may be randomly combined to form a fibrous element. The two or more different filament-forming materials may be orderly combined to form a fibrous element, such as a core and sheath bicomponent fibrous element, which is not considered a random mixture of different filament-forming materials for purposes of the present disclosure. Bicomponent fibrous elements may be in any form, such as side-by-side, core and sheath, islands-in-the-sea and the like.
The fibrous elements may each contain at least one filament-forming material and an active agent, preferably a surfactant. The fibrous element may comprise at least about 5%, and/or at least about 10%, and/or at least about 15%, and/or at least about 20%, and/or less than about 80%, and/or less than about 75%, and/or less than about 65%, and/or less than about 60%, and/or less than about 55%, and/or less than about 50%, and/or less than about 45%, and/or less than about 40%, and/or less than about 35%, and/or less than about 30%, and/or less than about 25% by weight on a dry fibrous element basis and/or dry fibrous structure basis of the filament-forming material and greater than about 20%, and/or at least about 35%, and/or at least about 40%, and/or at least about 45%, and/or at least about 50%, and/or at least about 55%, and/or at least about 60%, and/or at least about 65%, and/or at least about 70%, and/or less than about 95%, and/or less than about 90%, and/or less than about 85%, and/or less than about 80%, and/or less than about 75% by weight on a dry fibrous element basis and/or dry fibrous structure basis of an active agent, preferably surfactant. The fibrous element may comprise greater than about 80% by weight on a dry fibrous element basis and/or dry fibrous structure basis of an active agent, ex. surfactant.
In general, fibrous elements are elongated particulates having a length greatly exceeding average diameter, e.g., a length to average diameter ratio of at least about 10. A fibrous element may be a filament or a fiber. Filaments are relatively longer than fibers. A filament may have a length of greater than or equal to about 5.08 cm (2 in.), and/or greater than or equal to about 7.62 cm (3 in.), and/or greater than or equal to about 10.16 cm (4 in.), and/or greater than or equal to about 15.24 cm (6 in.). A fiber may have a length of less than about 5.08 cm (2 in.), and/or less than about 3.81 cm (1.5 in.), and/or less than about 2.54 cm (1 in.).
The one or more filament-forming materials and active agents may be present in the fibrous element at a weight ratio of total level of filament-forming materials to active agents of about 2.0 or less, and/or about 1.85 or less, and/or less than about 1.7, and/or less than about 1.6, and/or less than about 1.5, and/or less than about 1.3, and/or less than about 1.2, and/or less than about 1, and/or less than about 0.7, and/or less than about 0.5, and/or less than about 0.4, and/or less than about 0.3, and/or greater than about 0.1, and/or greater than about 0.15, and/or greater than about 0.2. The one or more filament-forming materials and active agents may be present in the fibrous element at a weight ratio of total level of filament-forming materials to active agents of about 0.2 to about 0.7.
The one or more active agents may be releasable and/or released when the fibrous element and/or fibrous structure comprising the fibrous element is exposed to conditions of intended use. The one or more active agents in the fibrous element may be selected from the group consisting of surfactants, organic polymeric compounds, and mixtures thereof.
The fibrous elements may exhibit a diameter of less than about 300 μm, and/or less than about 75 μm, and/or less than about 50 μm, and/or less than about 25 μm, and/or less than about 10 μm, and/or less than about 5 μm, and/or less than about 1 μm as measured according to the Diameter Test Method described herein. The fibrous elements may exhibit a diameter of greater than about 1 μm. The diameter of a fibrous element may be used to control the rate of release of one or more active agents present in the fibrous element and/or the rate of loss and/or altering of the fibrous element's physical structure.
The fibrous element may comprise two or more different active agents, which are compatible or incompatible with one another. The fibrous element may comprise an active agent within the fibrous element and an active agent on an external surface of the fibrous element, such as an active agent coating on the fibrous element. The active agent on the external surface of the fibrous element may be the same or different from the active agent present in the fibrous element. If different, the active agents may be compatible or incompatible with one another. The one or more active agents may be uniformly distributed or substantially uniformly distributed throughout the fibrous element. The one or more active agents may be distributed as discrete regions within the fibrous element. Active agents are discussed in more detail below.
A fibrous water-soluble unit dose may also comprise one or more particles. The particles may be, for example, entangled with the fibrous elements, added after the fibrous elements are formed into a ply, added between plies, added to an exterior surface, etc. of a fibrous water soluble unit dose.
The particle may have a particle size distribution such that the D50 is from greater than about 150 micrometers to less than about 1700 micrometers. The particle may have a particle size distribution such that the D50 is from greater than about 212 micrometers to less than about 1180 micrometers. The particle may have a particle size distribution such that the D50 is from greater than about 300 micrometers to less than about 850 micrometers. The particle may have a particle size distribution such that the D50 is from greater than about 350 micrometers to less than about 700 micrometers. The particle may have a particle size distribution such that the D20 is greater than about 150 micrometers and the D80 is less than about 1400 micrometers. The particle may have a particle size distribution such that the D20 is greater than about 200 micrometers and the D80 is less than about 1180 micrometers. The particle may have a particle size distribution such that the D20 is greater than about 250 micrometers and the D80 is less than about 1000 micrometers. The particle may have a particle size distribution such that the D10 is greater than about 150 micrometers and the D90 is less than about 1400 micrometers. The particle may have a particle size distribution such that the D10 is greater than about 200 micrometers and the D90 is less than about 1180 micrometers. The particle may have a particle size distribution such that the D10 is greater than about 250 micrometers and the D90 is less than about 1000 micrometers.
Particles may contain rheology modifiers. For example, a particle may comprise an alkoxylated amine, preferably an alkoxylated polyamine, more preferably a quaternized or non-quaternized alkoxylated polyethyleneimine, wherein said alkoxylated polyalkyleneimine has a polyalkyleneimine core with one or more alkoxy side chains bonded to at least one nitrogen atom in the polyalkyleneimine core, an ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer wherein each of x1 and x2 is in the range of about 2 to about 140 and y is in the range of from about 15 to about 70, or a combination thereof.
Particles may contain a filler. Exemplary fillers include sodium carbonate, silica, zeolite-A, or a combination thereof.
The particles may contain an active agent, as described more fully below.
The fibrous water-soluble unit dose articles described herein may contain one or more active agents. Active agents may be contained within the fibrous structure, fibrous elements, in particles, or any combination thereof. Active agents may be contained in a water-soluble unit dose at a level of about 1% to about 80%, from about 2% to about 75%, from about 5% to about 70%, from about 5% to about 65%, from about 5% to about 60%, from about 5% to about 55%, from about 5% to about 50%.
One active agent useful herein is a surfactant. One suitable surfactant is an alkylalkoxylated sulfate. These types of surfactants, however, tend to undergo a highly viscous hexagonal phase at higher concentration levels (ex. About 15%). This hexagonal phase transition can cause issues when higher level of alkylalkoxylated surfactants are included in the fibrous elements. For example, if incorporated into the fibrous elements in a significant amount, alkylalkoxylated sulfates may significantly slow down the dissolution of the fibrous water-soluble unit dose in water, and worse yet, result in undissolved solids afterwards. As such, it is preferred that this particular surfactant is included in a water-soluble fibrous unit dose in particles or the amount of it is limited to less than 15% within the fibrous elements. In one embodiment, the fibrous elements may be substantially free of, or free of alkylalkoxylated sulfate. or may include alkylalkoxylated sulfate.
Additional suitable surfactants can include those with relatively low hydrophilicity which are less likely to for a viscous, hexagonal phase upon dilution. These surfactants can include, for example, unalkoxylated C6-C20 linear or branched alkyl sulfates (AS), C6-C20 linear alkylbenzene sulfonates (LAS), and combinations thereof. The surfactant may be a C6-C20 linear alkylbenzene sulfonates (LAS). LAS surfactants are well known in the art and can be readily obtained by sulfonating commercially available linear alkylbenzenes. Exemplary C6-C20 linear alkylbenzene sulfonates that can be used include alkali metal, alkaline earth metal or ammonium salts of C6-C20 linear alkylbenzene sulfonic acids, such as the sodium, potassium, magnesium and/or ammonium salts of C11-C18 or C1-C14 linear alkylbenzene sulfonic acids. The sodium or potassium salts of C12 linear alkylbenzene sulfonic acids, for example, the sodium salt of C12 linear alkylbenzene sulfonic acid, i.e., sodium dodecylbenzene sulfonate, may be used as the first surfactant.
Other suitable anionic surfactants include C6-C20 linear or branched alkyl sulfonates, C6-C20 linear or branched alkyl carboxylates, C6-C20 linear or branched alkyl phosphates, C6-C20 linear or branched alkyl phosphonates, C6-C20 alkyl N-methyl glucose amides, C6-C20 methyl ester sulfonates (MES), and combinations thereof.
Suitable nonionic surfactants include alkoxylated fatty alcohols. The nonionic surfactant may be selected from ethoxylated alcohols and ethoxylated alkyl phenols of the formula R(OC2H4)nOH, wherein R is selected from the group consisting of aliphatic hydrocarbon radicals containing from about 8 to about 15 carbon atoms and alkyl phenyl radicals in which the alkyl groups contain from about 8 to about 12 carbon atoms, and the average value of n is from about 5 to about 15. Non-limiting examples of nonionic surfactants useful herein include: C8-C18 alkylethoxylates, such as, NEODOL® nonionic surfactants from Shell; C6-C12 alkyl phenol alkoxylates where the alkoxylate units may be ethyleneoxy units, propyleneoxy units, or a mixture thereof; C12-C18 alcohol and C6-C12 alkyl phenol condensates with ethylene oxide/propylene oxide block polymers such as Pluronic® from BASF; C14-C22 mid-chain branched alcohols, BA; C14-C22 mid-chain branched alkylalkoxylates, BAE, wherein x is from 1 to 30; alkylpolysaccharides; specifically alkylpolyglycosides; polyhydroxy fatty acid amides; and ether capped poly(oxyalkylated) alcohol surfactants. Suitable nonionic detersive surfactants also include alkyl polyglucoside and alkylalkoxylated alcohol. Suitable nonionic surfactants also include those sold under the tradename Lutensol® from BASF.
Non-limiting examples of cationic surfactants include: the quaternary ammonium surfactants, which can have up to 26 carbon atoms include: alkoxylate quaternary ammonium (AQA) surfactants; dimethyl hydroxyethyl quaternary ammonium; dimethyl hydroxyethyl lauryl ammonium chloride; polyamine cationic surfactants; cationic ester surfactants; and amino surfactants, e.g., amido propyldimethyl amine (APA). Suitable cationic detersive surfactants also include alkyl pyridinium compounds, alkyl quaternary ammonium compounds, alkyl quaternary phosphonium compounds, alkyl ternary sulphonium compounds, and mixtures thereof.
Suitable cationic detersive surfactants are quaternary ammonium compounds having the general formula:
(R)(R1)(R2)(R3)N+X−
Suitable examples of zwitterionic surfactants include: derivatives of secondary and tertiary amines, including derivatives of heterocyclic secondary and tertiary amines; derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfonium compounds; betaines, including alkyl dimethyl betaine, cocodimethyl amidopropyl betaine, and sulfo and hydroxy betaines; C8 to C18 (e.g., from C12 to C18) amine oxides; N-alkyl-N,N-dimethylammino-1-propane sulfonate, where the alkyl group can be C8 to C18.
Suitable amphoteric surfactants include aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic radical may be straight or branched-chain and where one of the aliphatic substituents contains at least about 8 carbon atoms, or from about 8 to about 18 carbon atoms, and at least one of the aliphatic substituents contains an anionic water-solubilizing group, e.g. carboxy, sulfonate, sulfate. Suitable amphoteric surfactants also include sarcosinates, glycinates, taurinates, and mixtures thereof.
The active agent may be an acid. Examples of acids suitable for use include, but are not limited to, organic acids selected from the group consisting of acetic acid, adipic acid, aspartic acid, carboxymethyloxymalonic acid, carboxymethyloxysuccinic acid, citric acid, benzoic acid, formic acid, glutaric acid, glutonic acid, hydroxyethyliminodiacetic acid, iminodiacetic acid, lactic acid, maleic acid, malic acid, malonic acid, oxydiacetic acid, oxydisuccinic acid, succinic acid, sulfamic acid, tartaric acid, tartaric-disuccinic acid, tartaric-monosuccinic acid, their salts or mixtures thereof, either alone or in combination. Preferably, the acid is citric acid, lactic acid, acetic acid, and/or tartaric acid, and more preferably citric acid.
The acid can comprise a coating. The coating can help prevent the active agent from prematurely dissolving. A preferred acid is citric acid and preferred coatings include maltodextrin, waxes, citrate, sulfate, zeolites, anti-caking agents such as silicon dioxide or other desiccants. Preferred combinations include citric acid coated with maltodextrin (available under the tradename Citric Acid DC), citric acid coated with citrate (available under the tradename CITROCOAT® N), or citric acid coated with silicon dioxide (available under the tradename Citric Acid S40).
The fibrous water-soluble unit dose may comprise an active agent encapsulate. The encapsulate may comprise a core, a shell having an inner and outer surface, said shell encapsulating said core. The core may comprise any laundry care adjunct, though typically the core may comprise material selected from the group consisting of perfumes; brighteners; hueing dyes; insect repellants; silicones; waxes; flavors; vitamins; fabric softening agents; skin care agents in one aspect, paraffins; enzymes; anti-bacterial agents; bleaches; sensates; and mixtures thereof; and said shell may comprise a material selected from the group consisting of polyethylenes; polyamides; polyvinylalcohols, optionally containing other co-monomers; polystyrenes; polyisoprenes; polycarbonates; polyesters; polyacrylates; aminoplasts, in one aspect said aminoplast may comprise a polyureas, polyurethane, and/or polyureaurethane, in one aspect said polyurea may comprise polyoxymethyleneurea and/or melamine formaldehyde; polyolefins; polysaccharides, in one aspect said polysaccharide may comprise alginate and/or chitosan; gelatin; shellac; epoxy resins; vinyl polymers; water insoluble inorganics; silicone; and mixtures thereof.
Preferred encapsulates comprise perfume. Preferred encapsulates comprise a shell which may comprise melamine formaldehyde and/or cross linked melamine formaldehyde. Other preferred capsules comprise a polyacrylate based shell. Preferred encapsulates comprise a core material and a shell, said shell at least partially surrounding said core material, is disclosed. At least 75%, 85% or even 90% of said encapsulates may have a fracture strength of from 0.2 MPa to 10 MPa, and a benefit agent leakage of from 0% to 20%, or even less than 10% or 5% based on total initial encapsulated benefit agent. Preferred are those in which at least 75%, 85% or even 90% of said encapsulates may have (i) a particle size of from 1 microns to 80 microns, 5 microns to 60 microns, from 10 microns to 50 microns, or even from 15 microns to 40 microns, and/or (ii) at least 75%, 85% or even 90% of said encapsulates may have a particle wall thickness of from 30 nm to 250 nm, from 80 nm to 180 nm, or even from 100 nm to 160 nm. Formaldehyde scavengers may be employed with the encapsulates, for example, in a capsule slurry and/or added to a composition before, during or after the encapsulates are added to such composition.
Suitable capsules that can be made using known processes. Alternatively, suitable capsules can be purchased from Encapsys LLC of Appleton, Wisconsin USA. In a preferred aspect the composition may comprise a deposition aid, preferably in addition to encapsulates. Preferred deposition aids are selected from the group consisting of cationic and nonionic polymers. Suitable polymers include cationic starches, cationic hydroxyethylcellulose, polyvinylformaldehyde, locust bean gum, mannans, xyloglucans, tamarind gum, polyethyleneterephthalate and polymers containing dimethylaminoethyl methacrylate, optionally with one or more monomers selected from the group comprising acrylic acid and acrylamide.
The fibrous water-soluble unit dose and/or particles may comprise a perfume. Non-limiting examples of perfume and perfumery ingredients include, but are not limited to, aldehydes, ketones, esters, and the like. Other examples include various natural extracts and essences which can comprise complex mixtures of ingredients, such as orange oil, lemon oil, rose extract, lavender, musk, patchouli, balsamic essence, sandalwood oil, pine oil, cedar, and the like. Finished perfumes can comprise extremely complex mixtures of such ingredients. Finished perfumes may be included at a concentration ranging from about 0.01% to about 2% by weight of the detergent composition.
The fibrous water-soluble unit dose and/or particles may comprise a dye transfer inhibiting agent. Dye transfer inhibiting agents are effective for inhibiting the transfer of dyes from one fabric to another during the cleaning process. Generally, such dye transfer inhibiting agents may include polyvinyl pyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, manganese phthalocyanine, peroxidases, and mixtures thereof. If used, these agents may be used at a concentration of about 0.0001% to about 10%, by weight of the composition, in some examples, from about 0.01% to about 5%, by weight of the composition, and in other examples, from about 0.05% to about 2% by weight of the composition.
The fibrous water-soluble unit dose and/or particle may comprise a suds suppressor. The fibrous water soluble unit dose may comprise from about 0.001% to about 4.0%, by weight of the composition, of such a suds suppressor. Suds suppression can be of particular importance in the so-called “high concentration cleaning process” and in front-loading style washing machines. Examples of suds supressors include monocarboxylic fatty acid and soluble salts therein, high molecular weight hydrocarbons such as paraffin, fatty acid esters (e.g., fatty acid triglycerides), fatty acid esters of monovalent alcohols, aliphatic C18-C40 ketones (e.g., stearone), N-alkylated amino triazines, waxy hydrocarbons preferably having a melting point below about 100° C., silicone suds suppressors, and secondary alcohols.
Additional suitable antifoams are those derived from phenylpropylmethyl substituted polysiloxanes, organomodified silicone polymers with aryl or alkylaryl substituents combined with silicone resin and a primary filler, which is modified silica.
The fibrous water-soluble unit dose may comprise a suds suppressor selected from: a) mixtures of from about 80 to about 92% ethylmethyl, methyl(2-phenylpropyl) siloxane; from about 5 to about 14% MQ resin in octyl stearate; and from about 3 to about 7% modified silica; b) mixtures of from about 78 to about 92% ethylmethyl, methyl(2-phenylpropyl) siloxane; from about 3 to about 10% MQ resin in octyl stearate; from about 4 to about 12% modified silica; or c) mixtures thereof, where the percentages are by weight of the anti-foam.
If high sudsing is desired, suds boosters may be included in a fibrous water-soluble unit dose and/or particles. They may be added at a level of about 0.1% to about 2%, by weight of the fibrous water-soluble unit dose. Some examples include C10-C16 alkanolamides and the C10-C14 monoethanol and diethanol amides.
A conditioning agent may be included in a fibrous water-soluble unit dose and/or particle. Suitable conditioning agents include high melting point fatty compounds. The high melting point fatty compound useful herein has a melting point of 25° C. or higher, and is selected from the group consisting of fatty alcohols, fatty acids, fatty alcohol derivatives, fatty acid derivatives, and mixtures thereof. Suitable conditioning agents also include nonionic polymers and conditioning oils, such as hydrocarbon oils, polyolefins, and fatty esters.
Suitable conditioning agents include those conditioning agents characterized generally as silicones (e.g., silicone oils, polyoils, cationic silicones, silicone gums, high refractive silicones, and silicone resins), organic conditioning oils (e.g., hydrocarbon oils, polyolefins, and fatty esters) or combinations thereof, or those conditioning agents which otherwise form liquid, dispersed particles in the aqueous surfactant matrix herein.
The fibrous water-soluble unit dose may comprise additional components like a structurant, a builder, an organic polymeric compound, an enzyme, an enzyme stabilizer, a bleach system, a brightener, a hueing agent, a chelating agent, a humectant, a filler or carrier, an alkalinity system, a pH control system, a buffer, an alkanolamine, or any combination thereof. These materials may be present at a level of about 0.1% to about 20%, but weight of a fibrous water-soluble unit dose.
The fibrous water-soluble unit dose articles described herein may be formulated such that, during use in aqueous cleaning operations, the wash water will have a pH of between about 2.0 and about 12, and in some examples, between about 3.0 and about 12, between about 7 and about 12, about 12 or less, about 11 or less, preferably about 10 or less. Techniques for controlling pH at recommended usage levels include the use of buffers, alkalis, or acids, and are well known to those skilled in the art. These include, but are not limited to, the use of sodium carbonate, citric acid or sodium citrate, lactic acid or lactate, monoethanol amine or other amines, boric acid or borates, and other pH-adjusting compounds well known in the art.
A solution of a filament forming composition is provided. The filament forming composition can comprise one or more filament forming materials and optionally one or more active agents. The filament forming composition is passed through one or more die block assemblies comprising a plurality of spinnerets to form a plurality of fibrous elements comprising the one or more filament forming materials and optionally one or more active agents. Multiple die block assemblies can be employed to spin different layers of fibrous elements, with the fibrous elements of different layers having a composition that differ from one another or are the same as one another. More than two die block assemblies in series can be provided to form three, four, or any other integer number of layers in a given ply. The fibrous elements can be deposited on a belt moving in a machine direction (MD) to form a first ply.
Particles can be introduced into the stream of the fibrous elements between the die block assembly and the belt. Particles can be fed from a particle receiver onto a belt feeder or optionally a screw feeder. The belt feeder can be set and controlled to deliver the desired mass of particles into the process. The belt feeder can feed an air knife that suspends and directs the particles in an air stream into the fibrous elements to form a particle-fiber layer of comingled fibrous elements and particles that is subsequently deposited on the belt.
To form the water-soluble product, a first ply can be provided. A second ply can be provided separate from the first ply. The first ply and the second ply are superposed with one another. By superposed it is meant that one is positioned above or below the other with the proviso that additional plies or other materials, for example active agents and/or particles, may be positioned between the superposed plies. A portion of the first ply can be joined to a portion of the second ply to form the water-soluble product. Each ply may comprise one or more layers.
The layers may be sealed at the end using any type of seal known including and not limited to ultrasound, pressure, heat, the use of water-soluble adhesives, and combinations thereof. The seal is preferably made, for example, using a pressure seal.
Additional details regarding a method for making fibrous water-soluble unit dose may be found in U.S. Patent Pub. No. 2018/0216050 which is incorporated herein by reference.
It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
