The present disclosure relates to a system and a related method for forming a multi-chamber package. More particularly, the present disclosure relates to a system and method for folding a single web of film material over on itself to form a multi-chamber package for use in laundry and dishwashing applications.
Various types of multi-chamber packages (e.g., unit dose packs, pods, cavity tablets, etc.) have been used for many years in the area of household care to provide a single-use, pre-dosed quantity of detergent in laundry and dishwashing applications. These types of multi-chamber packages are generally formed from multiple webs of film material that are in some way bonded together. Once the multiple webs of film material are bonded together, individual multi-chamber packages are then typically cut so that the assembled webs form the multi-chamber packages. In particular instances, some webs of film material are conventionally manufactured in contiguous 54 inch wide rolls, but are used in standard packaging equipment that can only process 26.75 inch wide films. The 54 inch rolls are then cut to a width that can be processed by this equipment. In the case of a 54 inch wide roll used with equipment that can only process up to 26.75 inch wide films, the 54 inch wide roll may be halved along its length to produce two 27 inch wide rolls. These 27 inch wide rolls may then each be further trimmed to a width of 26.75 inches in order to be processed in standard packaging equipment. However, such a process may be time consuming and wasteful of the material trimmed away from each 27 inch roll. In addition, it may be difficult to control or track a production lot of the multi-chamber packages produced from a single roll.
Accordingly, there remains a need for improved systems and methods for forming multi-chamber packages that particularly reduce waste and, thus, improve the cost and efficiency of forming multi-chamber packages.
The present disclosure relates to a system and a related method for forming a multi-chamber package. In some aspects, a system for forming a multi-chamber package comprises a single web of a film material extending in a machine direction and defining a plurality of lateral lanes extending contiguously in a cross-machine direction, orthogonal to the machine direction, a forming arrangement configured to interact with the web to form chambers along a second lane of the plurality of lateral lanes in the machine direction, a first filling device configured to deposit a first substance into one or more of the formed chambers of the second lane, and a first folding mechanism configured to form a fold between the lateral lanes in the machine direction such that a first lane of the plurality of lateral lanes is directed to overlie the one or more formed chambers of the second lane, so as to form one or more multi-chamber packages.
In further aspects, a method for forming a multi-chamber package comprises interacting a forming arrangement with a single web of film material extending in a machine direction, the web defining a plurality of lateral lanes extending contiguously in a cross-machine direction, orthogonal to the machine direction, so as to form chambers along a second lane of the plurality of lateral lanes in the machine direction, depositing a first substance into one or more of the formed chambers of the second lane with a first filling device, and forming a fold between the lateral lanes in the machine direction with a first folding mechanism such that a first lane of the plurality of lateral lanes is directed to overlie the one or more formed chambers of the second lane, so as to form one or more multi-chamber packages.
The present disclosure thus includes, without limitation, the following embodiments:
These and other features, aspects, and advantages of the present disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure or recited in any one or more of the claims, regardless of whether such features or elements are expressly combined or otherwise recited in a specific embodiment description or claim herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its aspects and embodiments, should be viewed as intended to be combinable, unless the context of the disclosure clearly dictates otherwise.
Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the disclosure are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
The present disclosure relates to a system and a related method for forming a multi-chamber package. The multi-chamber package comprises one or more substances deposited within the multiple chambers, such that the package is suitable for use in laundry and dishwashing applications. For example, the multi-chamber package is introduced into a detergent cavity in a washing machine or a dishwasher. The multi-chamber package is also usable in similar applications.
By contrast, embodiments of the system 100 disclosed herein are configured to accommodate a conventional web of film material 102 having a total width of approximately, for example, 54 inches, without the need to trim or in any way alter the web. The web of film material 102 extends contiguously in a machine direction, generally designated A, and travels in this direction during formation of the multi-chamber packages. A plurality of lanes 104A-C extending contiguously in a cross-machine direction, which is orthogonal to the machine direction A, are defined (e.g., by perforations, indentations, creases, or otherwise) by the web of film material 102. In some aspects, an axis of symmetry, generally designated B, extending in the machine direction A is defined by the web of film material 102. As such, in one aspect, the first through third lanes 104A-C are mirrored on each side of the axis of symmetry B such that all arrangements, machinery, methods, etc. disclosed herein, are mirrored on each side of the axis of symmetry B. Thus, formation speed of the multi-chambered packages is potentially doubled, as formation of the multi-chamber packages occurs in parallel processes or methods on each side of the axis of symmetry B. As such, utilizing at least substantially a full width of a conventional web of film material (e.g., web of film material 102) advantageously reduces waste and increases production efficiency in forming the multi-chamber packages, while allowing the production lot of the multi-chamber packages formed from a single roll or web of the film material to be more closely controlled or tracked.
As illustrated in
In some aspects, a forming arrangement is configured to interact with the web 102 to form chambers 106A-B along one or more of the plurality of lateral lanes 104B-C. More particularly, for example, the forming arrangement is configured to exert a negative pressure through a platen (108,
The one or more depression or cavities in the platen 108 are provided in a manner corresponding to the style of multi-chamber package to be formed. For example, where a multi-chamber package having superposed chambers is desired, the platen 108 is configured with evenly spaced cavities extending in the machine direction A and for an entirety of or a substantial entirety of the cross-machine direction relative to both the second and third lanes 104B-C. In some aspects, the cavities in the platen 108 relative to both the second and third lanes 104B-C are spaced approximately ⅜th of an inch apart from one another and are aligned in rows parallel to the machine direction A and columns parallel to the cross-machine direction.
In another example, where a multi-chamber package having side-by-side chambers is desired, the platen 108 is configured with evenly spaced cavities extending in the machine direction A and for a discrete portion, or an entirety of or a substantial entirety of the cross-machine direction relative to the second and/or third lanes 104B-104C. In this example, the platen 108 is configured such that there are only cavities in every other column in the cross-machine direction corresponding to the second lane 104B and/or the third lane 104C, such that the columns devoid of cavities relative to the second lane 104B align with the columns having cavities relative to the third lane 104C, and vice versa. Alternatively, the platen 108 is configured such that there are cavities in each column in the cross-machine direction in either one or both of the second lane 104B and the third lane 104C.
Where the cavities in the platen 108 relative to the second lane 104B and/or the third lane 104C are disposed over an entirety of or a substantial entirety of the cross-machine direction, the cavities are spaced approximately ⅜th of an inch apart from one another and are aligned in rows parallel to the machine direction A and columns parallel to the cross-machine direction. By contrast, where the cavities in the platen 108 relative to the second lane 104B and/or the third lane 104C are disposed such that there are only cavities in every other column in the cross-machine direction, the cavities relative to the second lane 104B and/or the third lane 104C are spaced approximately 0.75 inches apart from one another and are aligned in rows parallel to the machine direction A and columns parallel to the cross-machine direction. Platen 108 is also configured with other configurations, sizes, shapes, etc., of cavities or depressions. In some aspects, platen 108 is configured as having the cavities 106A relative to the second lane 104B on a plane higher than the cavities 106B relative to the third lane 104C, or vice versa. Accordingly, in some aspects, depending on the style of multi-chamber package to be formed, different platens 108 are interchangeable in the system 100.
In some aspects, the platen 108 is configured to move with the web of film material 102 in the machine direction A throughout the formation of the multi-chamber package. In other aspects, the platen 108 is configured to be stationary, with dimensions of the platen 108 extending in the machine direction A sufficient to engage the web of film material 102 until the multi-chamber package is formed. Other types of forming arrangements are also contemplated with regard to the formation of the cavities 106A-B.
In some aspects, filling devices associated with system 100 are configured to deposit substances into one or more of the formed chambers 106A-B of the second lane 104B and the third lane 104C.
In some non-limiting examples, the substance deposited into the chambers 106A-B is in the form of a powder, a liquid, a gel, a plurality of microbeads, or a combination thereof. In turn, the substance further comprises surfactants, bleaching agents, enzymes, bleach activators, corrosion inhibitors, scale inhibitors, cobuilders, dyes and/or perfumes, bicarbonates, soil release polymers, optical brighteners, dye transfer or redeposition inhibitors, defoamers, and/or mixtures thereof. In some aspects, the first filling device 110A deposits a first substance 112A into one or more of the formed chambers 106A of the second lane 104B. For example, the first filling device 110A is controlled such that the first substance 112A is only deposited into chambers 106A in every other column relative to the cross-machine direction where a side-by-side multi-chamber package is being formed. In another example, the first filling device 110A is controlled such that the first substance 112A is deposited into every chamber 106A where a superposed multi-chamber package is being formed. In some aspects, the second filling device 110B deposits a second substance 112B into one or more of the formed chambers 106B of the third lane 104C. For example, the second filling device 110B is controlled such that the second substance 112B is deposited into every chamber 106B or into chambers 106B in every other column relative to the cross-machine direction, where either a superposed or a side-by-side multi-chamber package is being formed. Notably, in some aspects, the first substance 112A is different from the second substance 112B, or the first and second substances 112A-B are the same.
In some aspects, the system 100 comprises folding mechanisms 114A-B configured to form a fold between the lateral lanes 104A-C in the machine direction A. In some aspects, the web of film material 102 is perforated in the machine direction A so as to define each of the lateral lanes 104A-C therebetween and, thus, facilitate or increase the ease at which the folding is accomplished. In various aspects, the folding mechanisms 114A-B comprise one or more rollers, rods, folding blocks, or any other suitable mechanism, configured to form a fold between lateral lanes. In other aspects, other types of folding mechanisms such as, for example, robotic arms are utilized. Otherwise, in particular aspects, the folds are formed manually by a system operator. In some aspects, a first folding mechanism 114A is disposed adjacent to the first lane 104A and the second lane 104B. The first folding mechanism 114A is configured to fold the web of film material 102 so that the first lane 104A is directed to overlie the one or more formed chambers 106A of the second lane 104B. In various aspects, such folding is simultaneously or substantially simultaneously mirrored across the axis of symmetry B. In other aspects, the second folding mechanism 114B is configured to fold the web of film material 102 so that the second lane 104B having the first lane 104A already folded thereon is directed to overlie the one or more formed chambers 106B of the third lane 104C.
In some aspects, depending on the disposition of the chambers 106A-B, the result of the two-step folding process is a multi-chamber package having chambers superposed to one another or side-by-side to one another.
With regard to the aspects shown in
As illustrated in
In various aspects, the system 100 also comprises additional elements, such as at least one sealing mechanism. The at least one sealing mechanism is integrated with or otherwise disposed separately from the folding mechanisms 114A-B. Prior to folding or during folding, once the substances 112A-B have been deposited in respective chambers 106A-B, in various aspects, the sealing mechanism is configured to apply an aqueous fluid to a substantial entirety of a surface of one or more of the lanes 104A-C such that, once the lateral lanes overlie one another, a seal is formed therebetween. In some aspects, there are one or more sealing mechanisms. For example, a first sealing mechanism is disposed relative to the first lane 104A and is configured to apply an aqueous fluid to the first lane 104A or about the formed chambers 106A of the second lane 104B in order to seal the formed chambers 106A, once the first substance 112A is deposited therein. In another example, a second sealing mechanism is disposed relative to the second lane 104B, and is configured to apply an aqueous fluid to the first lane 104A that overlies the second lane 104B or about the formed chambers 106B of the third lane 104C in order to seal the formed chambers 106B once the second substance 112B is deposited therein. In other examples, a single sealing mechanism that is configured to deposit an aqueous fluid in select locations in each of the lateral lanes 104A-C is utilized in the system 100. The at least one sealing mechanism alternatively comprises a heat sealing mechanism that is otherwise able to heatedly seal the lateral lanes to one another after the fold has been completed. Otherwise, in other aspects, the web of film material 102 is self-adhering and the system 100 does not require a sealing mechanism.
In other aspects, the system 100 further comprises at least one cleaning device. The cleaning device is integrated with or otherwise disposed separately from the folding mechanisms 114A-B and is configured to remove unwanted material from the formed chambers 106A-B. For example, any debris, extraneous aqueous fluid, scrap film material 102, etc., which may impede a successful fold and/or seal is removed by the at least one cleaning device. In some non-limiting examples, the at least one cleaning device includes a blower, a brush, a wipe, a sponge, a vacuum, etc. The at least one cleaning device is disposed, relative to the machine direction A, prior to the folding mechanisms 114A-B. For example, in some aspects, a first cleaning device is disposed prior to the first folding mechanism 114A and a second cleaning device is disposed after the first folding mechanism 114A, but before the second folding mechanism 114B. In some aspects, there is at least one cleaning mechanism on each side of the axis of symmetry B.
In still other aspects, the system 100 further comprises a cutting mechanism 118.
With regard to
In a third step, 406, the method comprises forming a fold between the lateral lanes 104A-C in the machine direction A with a first folding mechanism 114A such that a first lane 104A of the plurality of lateral lanes is directed to overlie the one or more formed chambers 106A of the second lane 104B, and so as to form one or more multi-chamber packages.
In some aspects, the method 400 further comprises forming chambers 106B along the third lane 104C in the machine direction A, depositing a second substance 112B into the one or more formed chambers 106B of the third lane 104C, and subsequently forming a second fold in the machine direction A such that the second lane 104B is directed to overlie the one or more formed chambers 106B of the third lane 104C, with the first lane 104A being disposed therebetween, so as to form one or more multi-chamber packages. Many different types or styles of multi-chamber packages are formed using such methodology, including, for example, superposed multi-chamber packages and side-by-side multi-chamber packages.
Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which these disclosure pertain having the benefit of the teachings presented in the foregoing descriptions. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application is a national stage filing under 35 U.S.C. § 371 of PCT/US2018/012298, filed Jan. 4, 2018, which International Application was published by the International Bureau in English on Jul. 12, 2018, and claims priority from U.S. Provisional Application No. 62/442,141, filed on Jan. 4, 2017, which applications are hereby incorporated by reference in their entirety in this application.
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