Patent Application
20160362200
Process and apparatus for making water soluble pouches.
Water soluble pouches are widely used to dose substrate treatment compositions such as laundry detergent and dishwashing detergent. The typical process used to manufacture such pouches is to convert a web of material into individual pouches. To form a pouch from multiple webs of materials typically requires that seals between webs of material or materials need to be made to form a pouch that does not leak. Leaks that occur in seams can result in a product that is messy to store and use and may also result in a product that does not function as intended.
The converting process for forming water soluble pouches can include a fluid distribution manifold. The function of the manifold is to distribute a single stream of substrate treatment composition into multiple streams of substrate treatment composition. The streams of substrate treatment composition from the manifold are directed to particular locations on a web that are or will be formed into a pouch. The traditional method of constructing a fluid distribution manifold is to provide two solid blocks of material and machining out material from the solid blocks to provide for fluid pathways. The blocks are positioned in a facing relationship and have a gasket between the two blocks to prevent leakage from the fluid pathways into the space between the two blocks. The gasket has portions of material removed there from coincident with portions of the blocks that are machined. Together, the blocks and gasket define one or more channels in and through the manifold.
There are at least two problems that arise from the typical approach for constructing a manifold. First, the gasket is critical to maintaining function of the manifold. If the gasket is improperly aligned, has wrinkles or folds, or is degraded by the fluid with which the gasket comes into contact with, the manifold may leak via a flow pathway between the blocks of material. Second, flow pathways passing through the blocks are typically provided by drilling and or routing out material from the blocks. The intersections of channels routed out in surfaces of the solid blocks and holes drilled through the blocks tend to have sharp intersections and the cross section of the flow paths is irregular and non-circular in portions of the pathways. These sharp intersections of flow paths and irregularly shaped non-circular portions can result in uncontrollable initiation and termination of the flow of substrate treatment composition, air entrapment, and or stagnant liquid in the flow pathways.
Leaks in the manifold and uncontrollable initiation and termination of flow of the substrate treatment composition from the manifold can result in some of the substrate treatment composition ending up on the portion of the web where a seam is to be located. The presence of the substrate treatment composition in the seam area can impede the ability to make a competent seal between the webs of material used to form the pouch. This can result in the final formed pouch having a leak at the time of manufacture or a weak seal that ultimately develops into a leak after manufacture and before use by the consumer.
With these limitations in mind, there is a continuing unaddressed need for processes for manufacturing water soluble pouches that can form water soluble pouches that do not have a leak at the time of manufacture or develop a leak after manufacture and before use by the consumer.
A process for forming a plurality of water soluble pouches (50) comprising the steps of: providing a water soluble first web (30); feeding the first web onto a forming surface (140) comprising a plurality of pockets (70); thermoforming the first web to conform the first web to the pockets to form chambers (55), each of the chambers surrounded by a land area (37) of the first web; providing an assembled manifold (100), wherein the assembled manifold comprises: a frame (10); and a plurality of integrally formed fluid distributors (60) joined to the frame; wherein each of the integrally formed fluid distributors comprises a primary flow path (80); and wherein the primary flow path is in fluid communication with a plurality of secondary flow paths (90); dispensing substrate treatment composition from the secondary flow paths into the compartments; providing a water soluble second web (40); and sealing the water soluble second web to the land areas of the water soluble first web to form the plurality of water soluble pouches.
An assembled manifold comprising: a frame (10); and a plurality of integrally formed fluid distributors (60) joined to the frame; wherein each of the integrally formed fluid distributors comprises a primary flow path (80); and where the primary flow path is in fluid communication with a plurality of secondary flow paths (90).
An apparatus 1 for forming soluble unit dose substrate treatment composition pouches 50 is shown in
Once portions of the water soluble first web 30 are drawn into the pockets 70, the first web 30 can be carried beneath the frame 10 and liquid substrate treatment composition can be dispensed from the integrally formed fluid distributors 60 into the portions of the first web 30 drawn into the pockets 70. The liquid substrate treatment composition can be provided to the integrally formed distributors 60 by a feed line 20. Liquid substrate treatment composition is dispensed periodically from the fluid distributors 60. This is so that liquid substrate treatment composition is dispensed only into the portions of the first web 30 drawn into pockets 70 and the land areas between the deformed portions of the water soluble first web 30 are free from liquid substrate treatment composition. Once the fluid is dispensed from the fluid distributors 60, a water soluble second web 40 can be provided. The water soluble second web 40 can be conveyed to be on top of the water soluble first web 30 and the water soluble first web 30 and second web 40 are sealed to one another to form pouches 50. The water soluble second web 40 can be sealed to the land areas 37 of the water soluble first web 30 to form a plurality of water soluble pouches 50. Downstream of the forming surface 140 the pouches 50 can be separated from one another by cutting.
The water soluble first web 30 and water soluble second web 40 can comprise a polymer selected from the group consisting of polyvinyl alcohols, polyvinyl pyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts, polyaminoacids or peptides, polyamides, polyacrylamide, copolymers of maleic/acrylic acids, polysaccharides including starch and gelatine, natural gums such as xanthum and carragum. Suitable polymers are selected from polyacrylates and water-soluble acrylate copolymers, methylcellulose, carboxymethylcellulose sodium, dextrin, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, maltodextrin, polymethacrylates, and suitably selected from polyvinyl alcohols, polyvinyl alcohol copolymers and hydroxypropyl methyl cellulose (HPMC), and combinations thereof. The level of polymer in the water soluble first web 30 and water soluble second web 40, for example a PVA polymer, can be at least 60%. The polymer can have any weight average molecular weight, such as from about 1000 to about 1,000,000, or even from about 10,000 to about 300,000, or even from about 20,000 to about 150,000.
Suitable water soluble first web 30 and water soluble second web 40 can be webs supplied by Monosol under the trade references M8630, M8900, M8779, M8310, films described in U.S. Pat. No. 6,166,117 and U.S. Pat. No. 6,787,512 and PVA films of corresponding solubility and deformability characteristics. Further suitable sheets can be those described in US2006/0213801, WO 2010/119022 and U.S. Pat. No. 6,787,512.
Together the frame 10 and the plurality of integrally formed fluid distributors 60 form an assembled manifold, as shown in
During operation of the apparatus 1, the frame 10 may reciprocate in space so as to track the pockets 70 as they move beneath the frame 10. Advantageously, the frame 10 can be an open frame 10 so as to minimize the amount of inertia that must be overcome by the motor providing for acceleration and deceleration of the frame 10. In operation, the forming surface 140 may be continuously moving to move the first web 30 in the machine direction. As a pocket 70 approaches the integrally formed distributors 60, the frame 10 can be positioned so that a secondary flow path 90 is over the pocket 70 to be filled. As the forming surface 140 continues to drive the first web 30 in the machine direction MD, the frame 10 moves in concert with the pocket 70 and liquid is dispensed from the secondary flow path 90 to the portion of the first web 30 that is deformed into the pocket 70 to form part of the pouch 50. The liquid flow from the secondary flow path 90 is stopped before the forming surface 140 moves beyond the range of movement of the secondary flow path 90. Once liquid flow is stopped, the frame reciprocates to be in position over another portion of the first web 30 that is formed into a portion of a pouch 50 in a pocket 70 of the forming surface 140.
The integrally formed fluid distributors 60 can be joined to the frame 10. The integrally formed fluid distributors 60 and the frame 10 can be integrally formed with one another to provide for fluid distributors 60 being joined to the frame 10. The integrally formed fluid distributors 60 can be joined to the frame 10 by bolts, welding, adhesive, tape, glue, screws, rivets, press fit, and any other methods for joining or associating two adjacent articles.
The fluid distributors 60 operate to distribute liquid substrate treatment composition to multiple pouches 70 and or multiple chambers of one or more pouches 70. As shown in
As shown in
Inactive corners within the secondary flow paths 90 can results in irregular initiation of fluid dispensing from the secondary flow paths 90. The irregular initiation of fluid dispensing may occur because the gasses and or agglomerations accumulated in the inactive portions may deform or compress when pressure is applied the fluid being conducted. Further the accumulated gasses and or agglomerations may move uncontrollably within the second flow path 90 giving rise to irregular initiation of fluid dispensing.
As shown in
The integrally formed fluid distributors 60 can comprise a plurality of primary flow paths 80 aligned with one another in the cross direction CD. Each of the primary flow paths 80 can be in fluid communication with separate fluid distributors 60.
As shown in
The primary flow paths 80 and secondary flow paths 90 can be formed of a material selected from the group consisting of titanium 6-4, cobalt-chrome, and stainless steel. Any material that can be used in a process known as 3-D printing or additive manufacturing that is compatible with the liquid being transported through the fluid distributors 60 can be used. The integrally formed fluid distributors 60 can be formed by additive manufacturing, which is colloquially referred to as three-dimensional printing. So the integrally formed fluid distributors 60 can be referred to as three-dimensionally printed fluid distributors 60. In an additive manufacturing process, the fluid distributers 60 are formed by building up layers of material constituting the fluid distributors 60. The constituent material of the integrally formed fluid distributors 60 can be any material that can be used in an additive manufacturing process, has appropriate mechanical properties to be employed as an integrally formed fluid distributor 60, and is compatible with the liquid to be dispensed from the integrally formed fluid distributors 60. So the integrally formed distributors 60 can be referred to as additive manufactured integrally formed distributors 60. The integrally formed distributors 60 can also be referred to as three-dimensionally printed integrally formed distributors 60. The frame 10 and the fluid distributors 60 can be integrally formed with one another.
Each of the secondary flow paths 90 can terminate in a separate nozzle 110, as shown in
The primary flow paths 80 can have inside diameter of from about 1 mm to about 8 mm. The secondary flow paths 90 can have an inside diameter of from about 1 mm to about 6 mm. The wall thickness of the primary flow paths 80 and secondary flow paths 90 can be from about 0.2 mm to about 3 mm. The spacing between second flow paths 90 that are connected to a single primary flow path 80 can be from about 25 to about 60 mm. The length of each secondary flow path 90 can be from about 10 mm to about 60 mm. The spacing between primary flow paths 80 located in line with one another in the cross direction can be from about 25 to about 120 mm. The spacing between secondary flow paths 90 located in line with one another in the machine direction MD can be from about 25 to about 60 mm. For each nearest neighbors primary flow paths 80, the primary flow paths 80 can be from about 8 mm to about 40 mm in the machine direction MD and from about 8 mm to about 40 mm in the cross direction MD.
The behavior of flow observable in
A portion of a water soluble pouch 50 can be filled by the following process. First, an assembled manifold 100, as described herein, can be provided. Then liquid substrate treatment composition can be dispensed from the assembled manifold into a portion of the water soluble pouch 50. The portion of the water soluble pouch 50 that is formed can be the first web 30. After such portion is filled, a second web 40 can be sealed to the first web 30 to form one or more pouches 50.
The configuration of the secondary flow paths 90 shown in
A grouping of the precursor for what ultimately can become four water soluble pouches 50 is shown in
In
The secondary flow paths 90 designated B can dispense liquid simultaneously in the same manner. The secondary flow paths 90 designated A can start dispensing liquid before the secondary flow paths 90 designated B. The secondary flow paths 90 designated A can cease dispensing liquid before the secondary flow paths 90 designated B cease to dispense liquid.
Similarly, secondary flow paths 90 designated A can commence dispensing liquid before the secondary flow paths 90 designated C start to dispense liquid. The secondary flow paths 90 designated A can cease dispensing liquid before the secondary flow paths 90 designated C cease to dispense liquid. The secondary flow paths 90 designated B and D can be operated in the same manner as the secondary flow paths 90 designated A and C are operated.
The integrally formed fluid distributors 60 can distribute two or more substrate treatment compositions that differ from one another. Such an arrangement can be practical for forming a single pouch 50 that has two separate chambers 55 each of which contain a different substrate treatment composition. For instance, as shown in
The substrate treatment composition dispensed from secondary flow paths 90 designated as C can be the same as the substrate treatment composition dispensed from secondary flow paths 90 designated as A. Similarly, the substrate treatment composition dispensed from secondary flow paths 90 designated as D can be the same as the substrate treatment composition dispensed from secondary flow paths 90 designated as B. The substrate treatment composition dispensed from secondary flow paths 90 designated as A and C can differ from the substrate treatment composition dispensed from secondary flow paths 90 designated as B and D.
The substrate treatment composition can be any of the substrate treatment agents presently marketed as TIDE PODS, CASCADE ACTION PACS, CASCADE PLATINUM, CASCADE COMPLETE, ARIEL 3 IN 1 PODS, TIDE BOOST ORIGINAL DUO PACs, TIDE BOOST FEBREZE SPORT DUO PACS, TIDE BOOST FEE DUO PACS, TIDE BOOST VIVID WHITE BRIGHT PACS, DASH, FAIRY (PLATINUM, ALL-IN ONE), YES (PLATINUM ALL-IN ONE), JAR (PLATINUM, ALL-IN ONE, and DREFT (PLATINUM, ALL-IN ONE) by The Procter & Gamble Company in various geographies globally.
The pouch 50 can be sized and dimensioned to fit in an adult human hand. The pouch 50 can have a volume less than about 70 mL. The pouch 50 can have a volume less than about 50 mL. The pouch 50 can have a volume less than about 40 mL. The edges of the pouch 50 can have a length of from about 10 mm to about 70 mm. The edges of the pouch 50 can have a length of from about 20 mm to about 60 mm. The edges of the pouch 50 can have a length of from about 25 mm to about 50 mm.
The edges of the pouch 50 can each have a length less than about 100 mm, or even less than about 60 mm, or even less than about 50 mm. The plan view of the of the water soluble pouch 50 can be substantially rectangular, substantially square, substantially circular, elliptical, superelliptical, or any other desired shape that is practical to manufacture. The overall plan area of the water soluble pouch can be less than about 10000 mm2, or even less than about 2500 mm2. Sized and dimensioned as such, the water soluble pouch 50 can fit conveniently within the grasp of an adult human hand. Further, for water soluble pouches 50 intended for use in automatic dishwashing machines, such a size can conveniently fit in the detergent receptacle within the machine.
The substrate treatment composition can be selected from the group consisting of liquid laundry detergent, a liquid dishwashing detergent, a liquid bleaching agent, a powdered bleaching agent, a liquid fabric softener, a liquid laundry scent additive, a liquid fabric care benefit agent, and combinations thereof. The substrate treatment composition can be a fabric softener comprising a quaternary ammonium salt and or a dehydrogenated tallow dimethyl ammonium chloride and or a diethyl ester dimethyl ammonium chloride. A substrate treatment composition can be formulated to treat a substrate selected from the group consisting of glassware, dishware, flooring, textiles, tires, automobile bodies, teeth, dentures, skin, fingernails, toenails, hair, appliance surfaces, appliance interiors, toilets, bathtubs, showers, minors, deck materials, windows, and the like.
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.
