CN220618854U

CN220618854U - Water-soluble unit dose articles

Info

Publication number: CN220618854U
Application number: CN202321428769.4U
Authority: CN
Inventors: 何秋旸; 翁延婕; 汤鸣; R·R·F·凯勒斯; 初晓彬
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 2023-06-06
Filing date: 2023-06-06
Publication date: 2024-03-19
Anticipated expiration: 2033-06-06

Abstract

The present utility model relates to water-soluble unit dose articles for treating substrates and to a device for their preparation. The water-soluble unit dose article comprises a first water-soluble film, a second water-soluble film, and a plurality of compartments enclosed by the first water-soluble film and the second water-soluble film, wherein the plurality of compartments comprises a first compartment, a second compartment, and a third compartment, wherein the first compartment, the second compartment, and the third compartment are formed by the first water-soluble film and the second water-soluble film in a sealed plane and are formed byThe sealing portions on the sealing plane isolate each other, wherein the sealing portions comprise a central sealing member and the first, second and third compartments are further arranged around the central sealing member on the sealing plane, wherein the first, second and third compartments have a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the water-soluble unit dose article is characterized by: DL (DL) ₁ >DL ₂ >DL ₃ ；(DL ₁ ‑DL ₃ )/DL ₃ <1.01; and 0.85<(DL ₁ ‑DL ₂ )/(DL ₂ ‑DL ₃ )<1.15。

Description

Water-soluble unit dose articles

Technical Field

The present utility model relates to water-soluble unit dose articles.

Background

Water-soluble unit dose articles are favored by consumers for their convenience and ease of use. Consumers also enjoy the fact that: i.e. they do not need to measure the detergent dosage, which thus eliminates accidental spillage during dosing operations. Other dosage forms may be confusing and inconvenient. The water-soluble unit dose article comprises a water-soluble film or combination of water-soluble films shaped such that the unit dose article comprises at least one interior compartment surrounded by the water-soluble film or combination of water-soluble films. The preferred membrane material is preferably a polymeric material. As known in the art, the film material may be obtained, for example, by injection molding, blow molding, extrusion or blow-molded extrusion of a polymeric material.

The water-soluble unit dose article may comprise one or more compartments for holding the same or different substrate treatment compositions (e.g., laundry detergent compositions). The compartments may be made in various shapes. The choice of shape is often dependent on aesthetic preferences. However, some shapes desired by consumers may lead to challenges in the manufacture of unit dose articles, such as in terms of production speed. In particular, there is a speed control step in the manufacture of unit dose articles, i.e., a step of filling the substrate treatment composition into the compartments of the unit dose article. The filling step may be a batch process step or a continuous process step. Intermittent filling is less preferred because it reduces the overall linear velocity. In an exemplary filling step as part of a continuous moving process, the open compartments of the unit dose articles in the thermoforming mold are moved through a nozzle located above the thermoforming mold. When the open compartment of the unit dose article is below the nozzle, the substrate treatment composition is filled into the open compartment through the nozzle. However, the rate of movement of the unit dose article in the thermoforming mold cannot be too high because a period of time is required to fill the substrate treatment composition. In this case, the production speed is reduced due to the limited speed of movement of the unit dose article during such filling step. In particular, for unit dose articles containing multiple compartments, the shape and arrangement of the multiple compartments will have a significant impact on production speed. It is therefore desirable to provide water-soluble unit dose articles that can be manufactured at improved production speeds.

The inventors have surprisingly found that water-soluble unit dose articles having an optimised compartment shape can provide improved production speeds. Also, water-soluble unit dose articles having optimized cell shapes can be produced by molds having optimized recess shapes and orientations.

Disclosure of Invention

In one aspect, the present invention relates to a water-soluble unit dose article for treating a substrate, wherein the water-soluble unit dose article comprises a first water-soluble film, a second water-soluble film, and a plurality of compartments enclosed by the first water-soluble film and the second water-soluble film, wherein the plurality of compartments comprises a first compartment, a second compartment, and a third compartment, wherein the first compartment, the second compartment, and the third compartment are formed by the first water-soluble film and the second water-soluble film on a sealing plane and are isolated from each other by a sealing portion on the sealing plane, wherein the sealing portion comprises a central sealing member, and the first compartment, the second compartment, and the third compartment are further arranged around the central sealing member on the sealing plane, wherein the first compartment, the second compartment, and the third compartment have a first fillable length (DL) along a Machine Direction (MD), respectively ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the water-soluble unit dose article is characterized by DL ₁ >DL ₂ >DL ₃ ，(DL ₁ -DL ₃ )/DL ₃ <1.01, and 0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15. In particular, the first compartment, the second compartment and the third compartment are arranged in a side-by-side manner. The water-soluble unit dose articles according to the invention may provide improved production speeds.

In another aspect, the present invention relates to an apparatus for preparing a water-soluble unit dose article, the apparatus comprising: a thermoforming mold having a forming surface; a plurality of spaced apart depressions in the forming surface, wherein each of the depressions comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and a continuous land region surrounding the recess, wherein the recess comprises a first recess, a second recess, and a third recess, each having a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the device is characterized by DL ₁ >DL ₂ >DL ₃ ，(DL ₁ -DL ₃ )/DL ₃ <1.01, and 0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15。

In another aspect, the present invention relates to a water-soluble unit dose article for treating a substrate, wherein the water-soluble unit dose article comprises a first water-soluble film, a second water-soluble film, and a plurality of compartments enclosed by the first water-soluble film and the second water-soluble film, wherein the plurality of compartments comprises a first compartment, a second compartment, and a third compartment, wherein the first compartment, the second compartment, and the third compartment are formed by the first water-soluble film and the second water-soluble film on a sealing plane and are isolated from each other by a sealing portion on the sealing plane, wherein the sealing portion comprises a central sealing member, and the first compartment, the second compartment, and the third compartment are sealed at a seal Further arranged in plane around the central sealing member, wherein each of the first compartment, the second compartment and the third compartment has a different projected shape from each other, wherein the first compartment, the second compartment and the third compartment have a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the water-soluble unit dose article is characterized by: (a) DL (DL) ₁ ≥DL ₂ >DL ₃ Or DL ₁ >DL ₂ ≥DL ₃ The method comprises the steps of carrying out a first treatment on the surface of the And (b) (DL ₁ -DL ₃ )/DL ₃ <1.01. In particular, the first compartment, the second compartment and the third compartment are arranged in a circumferential configuration around the central sealing member.

In another aspect, the present invention relates to an apparatus for preparing a water-soluble unit dose article, the apparatus comprising: a thermoforming mold having a forming surface; a plurality of spaced apart depressions in the forming surface, wherein each of the depressions comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and a continuous land region surrounding the recess, wherein the recess comprises a first recess, a second recess, and a third recess, each having a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the continuous land area comprises a central land component and the first, second and third recesses are further arranged around the central land component on the forming surface, wherein each of the first, second and third recesses have a different projected shape from each other, wherein the device is characterized by (a) DL ₁ ≥DL ₂ >DL ₃ Or DL ₁ >DL ₂ ≥DL ₃ And (b) (DL ₁ -DL ₃ )/DL ₃ <1.01. In particular, the first, second and third recesses are arranged in a circumferential configuration around the central platform part.

At another oneIn one aspect, the present invention relates to a water-soluble unit dose article for treating a substrate, wherein the water-soluble unit dose article comprises a first water-soluble film, a second water-soluble film, and a plurality of compartments enclosed by the first water-soluble film and the second water-soluble film, wherein the plurality of compartments comprises a first compartment, a second compartment, and a third compartment, wherein the first compartment, the second compartment, and the third compartment are formed by the first water-soluble film and the second water-soluble film on a sealing plane and are separated from each other by a sealing portion on the sealing plane, wherein the sealing portion comprises a central sealing member, and the first compartment, the second compartment, and the third compartment are further arranged around the central sealing member on the sealing plane, wherein the first compartment, the second compartment, and the third compartment are arranged in a circumferential configuration around the central sealing member, wherein the first compartment, the second compartment, and the third compartment have a first fillable length (DL) along a Machine Direction (MD), respectively ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the water-soluble unit dose article is characterized by: (a) DL (DL) ₁ ＝DL ₂ ＝DL ₃ . In particular, at least two, preferably all, of the first compartment, the second compartment and the third compartment have different projection shapes.

In another aspect, the present invention relates to an apparatus for preparing a water-soluble unit dose article, the apparatus comprising: a thermoforming mold having a forming surface; a plurality of spaced apart depressions in the forming surface, wherein each of the depressions comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and a continuous land region surrounding the recess, wherein the recess comprises a first recess, a second recess, and a third recess, each having a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the continuous land area comprises a central land component and the first, second and third depressions further surround the central land on the forming surface A member arrangement wherein the first recess, the second recess, and the third recess are arranged in a circumferential configuration about a central platform component, wherein the device is characterized by (a) DL ₁ ＝DL ₂ ＝DL ₃ . In particular, at least two, preferably all, of the first, second and third recesses have different projection shapes.

These and other aspects of the invention will become more apparent upon reading the following detailed description of the invention.

Drawings

FIG. 1 illustrates an exemplary unit dose article according to the present disclosure in which the shape of the compartments is optimized.

Figure 2 shows a unit dose article having a similar shape to the unit dose article shown in figure 1 but without shape optimisation.

Figure 3 shows a schematic representation of a shape parameter test of a unit dose article.

Detailed Description

Definition of the definition

As used herein, an article comprising "a" and "an" when used in the claims is understood to mean one or more articles of manufacture that are claimed or described.

As used herein, the terms "comprising," "including," and "containing" are intended to be non-limiting, i.e., other steps and other ingredients that do not affect the end result can be added. The above terms include the terms "consisting of …" and "consisting essentially of …".

As used herein, when a composition is "substantially free" of a particular ingredient, it is meant that the composition comprises less than trace amounts, or less than 0.1%, or less than 0.01%, or less than 0.001% of the particular ingredient, by weight of the composition.

As used herein, the term "substrate" refers to a substance that requires treatment (e.g., cleaning). Such substrates may include hard surfaces and fabrics.

As used herein, the term "substrate treatment composition" refers to a composition for treating a substrate. Such compositions may be in any form suitable for treating a substrate, including granules, pourable liquids, gels, creams, and combinations thereof. The substrate treatment compositions contained in the different compartments of the unit dose article may be the same or different.

As used herein, the term "laundry detergent composition" refers to a composition for cleaning soiled materials (including fabrics). Such compositions may be used as a wash pretreatment, a wash post treatment, or may be added during the rinse or wash cycle of a wash operation. The term "liquid laundry detergent composition" herein refers to a composition in a form selected from the group consisting of pourable liquids, gels, creams, and combinations thereof. The term "unit dose laundry detergent composition" herein refers to a water-soluble pouch containing a volume of liquid and surrounded by a water-soluble film.

As used herein, the term "side-by-side" means that the first, second and third or optionally subsequent compartments are arranged adjacent to each other in the sealing plane.

As used herein, the term "stacked" refers to one or more compartments being stacked on top of other compartments. In one embodiment, the fourth compartment may overlie the first compartment, the second compartment, and the third compartment. In another embodiment, the fourth compartment and the fifth compartment may overlie the first compartment, the second compartment, and the third compartment.

As used herein, the term "alkyl" refers to a branched or straight chain, substituted or unsubstituted hydrocarbyl moiety. The term "alkyl" includes the alkyl portion of acyl.

As used herein, the term "wash solution" refers to a typical amount of aqueous solution for one laundry wash cycle, preferably 1L to 50L, alternatively 1L to 20L for hand wash and 10L to 50L for machine wash.

As used herein, the use of the term "stained fabric" is not specific and may refer to any type of natural or synthetic fiber, including natural, synthetic, and synthetic fibers, such as, but not limited to, cotton, flax, wool, polyester, nylon, silk, acrylic, and the like, as well as various blends and combinations.

Water-soluble unit dose articles

Disclosed are water-soluble unit dose articles comprising a water-soluble film and a substrate treatment composition. In particular, the substrate treatment composition is coated with a water-soluble film. The water-soluble film and substrate treatment composition are described in more detail below.

The water-soluble unit dose article comprises a water-soluble film shaped such that the unit dose article comprises at least one interior compartment surrounded by the water-soluble film. The unit dose article may comprise a first water-soluble film and a second water-soluble film sealed to each other to define an interior compartment. The water-soluble unit dose article is configured such that the substrate treatment composition does not leak out of the compartment during storage. However, when the water-soluble unit dose article is added to water, the water-soluble film dissolves and releases the contents of the internal compartment into the wash liquid.

A compartment is understood to mean the closed interior space within a unit dose article that contains a detergent composition. During manufacture, the first water-soluble film can be shaped to include an open compartment to which the detergent composition is added. A second water-soluble film is then laid over the first film in an orientation that closes the compartment opening. The first and second films are then sealed together along a sealing region.

The water-soluble unit dose article may comprise a first compartment, a second compartment, and a third compartment, wherein the first compartment contains a first substrate treatment composition, the second compartment contains a second substrate treatment composition, and the third compartment contains a third substrate treatment composition, wherein the first compartment, the second compartment, and the third compartment each have a first fillable length (DL) along a Machine Direction (MD) ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the water-soluble unit dose article is characterized by

(a)DL ₁ >DL ₂ >DL ₃ ；

(b)(DL ₁ -DL ₃ )/DL ₃ <1.01; and is also provided with

(c)0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15。

In some embodiments, the water-soluble unit dose article is characterized by (DL ₁ -DL ₃ )/DL ₃ <1.00, preferably (DL ₁ -DL ₃ )/DL ₃ <0.99, more preferably (DL ₁ -DL ₃ )/DL ₃ <0.98。

In some embodiments, the water-soluble unit dose article is characterized by 0.88<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.05, preferably 0.90<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<0.95。

In some embodiments, DL ₁ 、DL ₂ And DL (DL) ₃ Is 5mm to 60mm, preferably 10mm to 50mm, more preferably 15mm to 45mm, most preferably 18mm to 40mm.

In some embodiments, the first substrate treatment composition, the second substrate treatment composition, and the third substrate treatment composition each have a first volume (V ₁ ) Second volume (V) ₂ ) And a third volume (V ₃ ) Wherein the water-soluble unit dose article is characterized by V ₁ ≥V ₂ ≥V ₃ And (V) ₁ -V ₃ )/V ₃ <0.3. Preferably, the water-soluble unit dose article is characterized by V ₁ ≥V ₂ ≥V ₃ And (V) ₁ -V ₃ )/V ₃ <0.2. More preferably, the water-soluble unit dose article is characterized by V ₁ ≥V ₂ ≥V ₃ And (V) ₁ -V ₃ )/V ₃ <0.1. Most preferably, the water-soluble unit dose article is characterized by V ₁ ＝V ₂ ＝V ₃ 。

In some embodiments, V ₁ 、V ₂ And V ₃ Each of them is 0.5ml to 15ml, preferably 1ml to 10ml, and more preferably 1.5ml to 6ml.

In some embodiments, each of the first compartment, the second compartment, and the third compartment has a projection on the sealing plane, wherein the projection is pod, lightning, wave, leaf, crescent, drop, or yin-yang.

In some embodiments, each of the first, second, and third compartments have substantially the same projection on a sealing plane, and/or wherein each of the first, second, and third compartments have substantially the same spatial shape.

In some embodiments, the plurality of compartments further comprises one or more additional compartments. In particular, the one or more additional compartments are arranged in a side-by-side or stacked manner with respect to the first, second and third compartments. In some embodiments, the water-soluble unit dose article comprises a first compartment, a second compartment, a third compartment, and a fourth compartment, wherein the first compartment, the second compartment, and the third compartment are arranged in a side-by-side manner with respect to each other, and the fourth compartment is arranged in a superimposed position with respect to the first compartment, the second compartment, and the third compartment.

In some embodiments, the substrate treatment composition is a laundry detergent composition, preferably a liquid laundry detergent composition.

In some embodiments, the plurality of compartments comprises i compartments, wherein i is 4 or more, e.g., i is 4, 5, 6, 7, 8, 9, 10 or more. In particular, the i compartments have respectively an i-th fillable length (DL _i )。

In some embodiments, the water-soluble unit dose article comprises a plurality of compartments, wherein the number of the plurality of compartments is from 3 to 10, preferably from 3 to 7, more preferably from 3 to 5, such as 3, 4, 5, 6, 7, 8, 9, 10, and any range therebetween, and the plurality of compartments are arranged in a side-by-side manner on the sealing plane and individually contain the substrate treatment composition. In this side-by-side manner, the unit dose article is formed from two sheets of water-soluble film, which are sealed together to form a sealing web lying in a sealing plane,

in some embodiments, the substrate treatment composition contained in the water-soluble unit dose article is from 5g to 20g, preferably from 8g to 15g, of laundry detergent. Most preferably, the water-soluble unit dose article contains preferably consists of 5ml to 20ml, preferably 8ml to 15ml, of liquid laundry detergent.

The outer contour sealing region comprises or preferably consists of a flange region. A flange region is disposed about the perimeter of the water-soluble, multi-compartment unit dose article, and the flange includes a sealing film formed from two, three, or more water-soluble films. In other words, the flange region protrudes relative to the water-soluble unit dose article and includes a sealing film.

Preferably, the water-soluble multi-compartment unit dose article that does not include a flange has a length and a width, wherein each of the length and the width is independently less than 50mm. The water-soluble unit dose article preferably comprises a flange, wherein the flange has a width of from 1mm to 10mm, preferably from 4mm to 8 mm.

In some embodiments, the average seal width between compartments in the water-soluble dosage article is in the range of 1.0mm to 2.5mm, preferably 1.2mm to 2.2mm, more preferably 1.4mm to 2.0mm, e.g. 1.4mm, 1.6mm, 1.8mm, 2.0mm or any range therebetween. As used herein, the term "seal width" refers to the width of the inter-compartment seal area between compartments that is used to separate the compartments from each other.

Each compartment may contain the same or different compositions. The different compositions may all be in the same form, or they may be in different forms.

The water-soluble unit dose article may comprise a first compartment, a second compartment, and a third compartment, wherein the first compartment contains a first substrate treatment composition, the second compartment contains a second substrate treatment composition, and the third compartment contains a third substrate treatment composition, wherein each of the first compartment, the second compartment, and the third compartment have projection shapes that are different from each other, wherein the first compartment, the second compartment, and the third compartment have a first fillable length (DL) along a Machine Direction (MD), respectively ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the water-soluble unit dose article is characterized by: (a) DL (DL) ₁ ≥DL ₂ >DL ₃ Or DL ₁ >DL ₂ ≥DL ₃ The method comprises the steps of carrying out a first treatment on the surface of the And (b) (DL ₁ -DL ₃ )/DL ₃ <1.01. In some embodiments, the first compartment, the second compartment, and the third compartment are arranged in a circumferential configuration around the central seal member.

The water-soluble unit dose article may comprise a first compartment, a second compartment, and a third compartment, wherein the first compartment contains a first substrate treatment composition, the second compartment contains a second substrate treatment composition, and the third compartment contains a third substrate treatment composition, wherein each of the first compartment, the second compartment, and the third compartment have projection shapes that are different from each other, wherein the first compartment, the second compartment, and the third compartment have a first fillable length (DL) along a Machine Direction (MD), respectively ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the water-soluble unit dose article is characterized by: (a) DL (DL) ₁ ＝DL ₂ ＝DL ₃ . In some embodiments, at least two, preferably all, of the first compartment, the second compartment, and the third compartment have different projection shapes. Device for producing water-soluble unit dose articles

The present invention relates to an apparatus for producing water-soluble unit dose articles, the apparatus comprising: a thermoforming mold having a forming surface; a plurality of spaced apart depressions in the forming surface, wherein each of the depressions comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and a continuous land area surrounding the recess. In particular, the recess comprises a first recess, a second recess and a third recess, each having a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the device is characterized in that

(a)DL ₁ >DL ₂ >DL ₃ ；

(b)(DL ₁ -DL ₃ )/DL ₃ <1.01; and is also provided with

(c)0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15。

In some embodiments, the device is characterized by (DL ₁ -DL ₃ )/DL ₃ <1.00, preferably (DL ₁ -DL ₃ )/DL ₃ <0.99, more preferably (DL ₁ -DL ₃ )/DL ₃ <0.98。

In some embodiments, the device is characterized by 0.88<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.05, preferably 0.90<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<0.95。

In some embodiments, DL ₁ 、DL ₂ And DL (DL) ₃ Is 5mm to 60mm, preferably 10mm to 50mm, more preferably 15mm to 45mm, most preferably 20mm to 40mm.

In some embodiments, the first recess, the second recess, and the third recess are configured to be filled with a first substrate treatment composition, a second substrate treatment composition, and a third substrate treatment composition, and wherein the first substrate treatment composition, the second substrate treatment composition, and the third substrate treatment composition each have a first volume (V ₁ ) Second volume (V) ₂ ) And a third volume (V ₃ ) Wherein the device is characterized by V ₁ ≥V ₂ ≥V ₃ And (V) ₁ -V ₃ )/V ₃ <0.3. Preferably, the device is characterized by V ₁ ≥V ₂ ≥V ₃ And (V) ₁ -V ₃ )/V ₃ <0.2. More preferably, the device is characterized by V ₁ ≥V ₂ ≥V ₃ And (V) ₁ -V ₃ )/V ₃ <0.1. Most preferably, the device is characterized by V ₁ ＝V ₂ ＝V ₃ 。

In some embodiments, each of the projections of the first, second, and third depressions is pod, lightning, wave, leaf, crescent, drop, or yin-yang shaped.

In some implementations, each of the first, second, and third recesses have substantially the same projection, and/or wherein each of the first, second, and third recesses have substantially the same spatial shape.

In some embodiments, the continuous land area includes a central land component, and the first, second, and third depressions are further disposed about the central land component on the forming surface.

In some embodiments, each of the first compartment, the second compartment, and the third compartment have different projected shapes from each other,

in some embodiments, the first compartment, the second compartment, and the third compartment are arranged in a circumferential configuration around the central seal member.

In some embodiments, the plurality of depressions comprises i depressions, wherein i is 4 or more, e.g., i is 4, 5, 6, 7, 8, 9, 10 or more. In particular, the i depressions have an i-th fillable length (DL _i )。

The present invention also relates to an apparatus for preparing a water-soluble unit dose article, the apparatus comprising: a thermoforming mold having a forming surface; a plurality of spaced apart depressions in the forming surface, wherein each of the depressions comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and a continuous land region surrounding the recess, wherein the recess comprises a first recess, a second recess, and a third recess, each having a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the continuous land area comprises a central land component and the first, second and third recesses are further arranged around the central land component on the forming surface, wherein each of the first, second and third recesses have a different from each otherProjection shape, wherein the device is characterized by (a) DL ₁ ≥DL ₂ >DL ₃ Or DL ₁ >DL ₂ ≥DL ₃ And (b) (DL ₁ -DL ₃ )/DL ₃ <1.01。

In some embodiments, the first, second, and third recesses are arranged in a circumferential configuration around the central platform component.

The present invention also relates to an apparatus for preparing a water-soluble unit dose article, the apparatus comprising: a thermoforming mold having a forming surface; a plurality of spaced apart depressions in the forming surface, wherein each of the depressions comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and a continuous land region surrounding the recess, wherein the recess comprises a first recess, a second recess, and a third recess, each having a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) Wherein the continuous land area comprises a central land component and the first, second and third depressions are further disposed about the central land component on the forming surface, wherein the first, second and third depressions are disposed in a circumferential configuration about the central land component, wherein the apparatus is characterized by (a) DL ₁ ＝DL ₂ ＝DL ₃ 。

In some embodiments, at least two, preferably all, of the first, second and third recesses have different projected shapes.

An apparatus for forming a water-soluble unit dose article may include a first film unwind roll and a thermoforming mold. The thermoforming mold may be movable in the machine direction MD. The first unwind roll may be located upstream of the thermoforming mold. The heater may be positioned downstream of the first film unwind roller. The heater may be positioned between the first film unwind roller and the merge location. The heater may be positioned between the first film unwind roller and the dispensing apparatus. The heater may be positioned between the first film unwind roller and the vacuum source, under the influence of which the first water-soluble film is deformed into the thermoforming mold. The heater may be a non-contact heater. The heater may be an infrared heater. Optionally, the heater may be a heated roller or a heated plate. The dispensing apparatus may be positioned above the forming surface of the thermoforming mold at which point the vacuum holes in the thermoforming mold are in fluid communication with a vacuum source. The thermoforming mold may be slidably engaged with a vacuum manifold in fluid communication with each vacuum aperture. The vacuum manifold may transfer vacuum from a vacuum source to one or more depressions of the thermoforming mold. In this case, an open compartment is formed by the water-soluble film, and then the substrate treatment composition may be filled into the open compartment by the dispensing apparatus. The second film unwind roll is operatively positioned to supply a continuous web of the second water-soluble film over the forming surface downstream of the dispensing apparatus and at the combining location, the vacuum holes are in fluid communication with a vacuum source.

In particular, the dispensing apparatus may comprise one or more nozzles corresponding to one or more open compartments. In some embodiments, the nozzles fill the compartments substantially simultaneously. In some embodiments, the nozzle is static and the open compartment moves in the Machine Direction (MD) below the nozzle. When the open compartment is below the nozzle, the substrate treatment composition is filled into the open compartment. In some other embodiments, the nozzle and the open compartment are moved simultaneously in the Machine Direction (MD) during the dispensing step, and after filling, the nozzle is returned to the starting position (in other words, the nozzle is configured to reciprocate). In particular, the dispensing apparatus comprises a rotatable drum or flat conveyor on which the substrate treatment composition is filled into the open compartment through a nozzle.

Each nozzle or a plurality of nozzles together is preferably connected to a device that can precisely control the dispensing of only a set amount or volume of the composition during one revolution of each nozzle, for example in one bag. Optionally, a flow meter is employed to control the precision filling. In addition, volumetric pumps (e.g., screw pumps, sliding vane pumps, flexible vane pumps, roots pumps, rotary piston pumps, and gear pumps) may be used in the dispensing unit. In one embodiment, a gear pump is employed.

In some embodiments, the apparatus further comprises a dispensing device comprising a plurality of nozzles, wherein the plurality of nozzles are configured to fill the plurality of compartments with the substrate treatment composition, wherein the plurality of nozzles are stationary and the thermoforming mold moves in the Machine Direction (MD) during filling.

The apparatus may further comprise a cutting system downstream of the merging position. The cutting system may include one or more longitudinal cutting knives downstream of the merging location. These machine direction cutters may have a machine direction cutting direction aligned with the machine direction MD. The one or more longitudinal cutting knives may be configured to cut the joined first and second water-soluble films in the machine direction between the recesses adjacent to each other in a transverse direction orthogonal to the machine direction MD. The one or more longitudinal cutters may be rotary cutters.

The cutting system may include a plurality of transverse cutting knives downstream of the merging location. These cross-direction cutters may have a cross-direction cutting direction along a cross direction orthogonal to the machine direction MD. The one or more transverse cutting knives may be configured to cut the joined first and second water-soluble films in the transverse direction between the recesses adjacent to each other in the machine direction MD.

The continuous web of the first water-soluble film may be positioned on a first film unwind roll. The first water-soluble film may extend downstream of the combining location and may be positioned in facing relationship with a land area of the thermoforming mold downstream of the first film unwind roll. Similarly, a continuous web of the second water-soluble film may be positioned on a second film unwind roll. The second water-soluble film may extend downstream of the combining location and be positioned above the first water-soluble film downstream of the combining location.

The thermoforming mold may be mounted on a rotatable drum or on a flat conveyor. The flat conveyor may be a continuous belt or a series of linear motor vehicles that transport the molds in a straight or horizontal line in the machine direction MD through the process of making water-soluble unit dose bags. The planar conveyor may be a series of individual molds that may be positioned adjacent to one another to form the planar conveyor. The individual molds may be joined to one another to provide a continuous strip of molds. By abutting the forming surfaces of the individual moulds to each other, a flat transfer device can be formed. As the mold passes through the curve, for example, as the mold recirculates upstream, the forming surfaces of the mold may become spaced apart from each other. Optionally, if the mould is provided with a structure allowing adjacent forming surfaces to move in an articulated manner relative to each other, the forming surfaces of the mould may remain adjacent to each other as the mould is recirculated upstream.

The thermoforming mold may have a forming surface. The forming surface is the surface in contact with the first water-soluble film. The forming surface may include a plurality of spaced apart depressions. In addition, the forming surface may further comprise a continuous land area surrounding the recess. Each of these depressions may include a vacuum hole or a plurality of vacuum holes. Each vacuum port may be in fluid communication with a vacuum source.

In some embodiments, the portions of the land areas between the depressions have an average roughness Ra of 2.2 μm to 10 μm, preferably 2.2 μm to 5 μm, more preferably 2.5 μm to 3.5 μm. In some embodiments, portions of each of these recesses may have a roughness Sa of 2.2 μm to 10 μm, preferably 2.2 μm to 5 μm, more preferably 2.5 μm to 3.5 μm. Preferably, about 50% to about 100% by area of each recess may have a roughness Sa of 2.2 μm to 10 μm, preferably 2.2 μm to 5 μm, more preferably 2.5 μm to 3.5 μm. As used herein, with respect to characterizing land areas, the average roughness Ra is defined and measured according to ISO 21920-1:2021. As used herein, with respect to characterizing depressions, roughness Sa is defined and measured according to ISO 21920-1:2021.

In some embodiments, each of the depressions in the thermoforming mold has a projection on the forming surface, wherein the projection is pod, lightning, wave, leaf, crescent, drop, or yin-yang shaped.

When a heater is used in the methods of the present disclosure, the heater may be an infrared emitter, such as a lamp, a hot plate, or a combination thereof. Preferably, the heater may be an infrared lamp having a temperature of about 200 ℃ to about 1000 ℃. The first film web may be heated to a desired temperature as it passes under the heater. The distance between the heater and the first film web may be adjustable such that the temperature of the first film web may be controlled. Similarly, the temperature of the heater may be adjustable such that the temperature of the first film web may be controlled.

Regarding the vacuum applied to the first film web, recall that heat from the heater may be applied at the same time as the vacuum is applied, although this is not required. Also as previously described, heating of the first film web may occur upstream of the vacuum applied to the first film web. The first vacuum system may be used to apply a first negative gauge pressure to a first porous face of the one or more depressions. The first web may be at a first maximum temperature when a first negative gauge pressure is applied to the first porous face of the one or more depressions. As the first web is heated, the temperature of the first web may be non-uniform in the MD and CD directions. This may occur because when the web is transported by the plurality of first molds, a portion of the web rests on the land areas of the plurality of first molds and a portion of the web covers the one or more depressions. The difference in boundary conditions of the first film web in the thickness direction of the first web may cause uneven heating of the first film web. For example, a portion of the web covering the center of the depression may be at a temperature of 107 ℃, and a portion of the web on the land area may have a temperature of about 25 ℃. As another example, a portion of the web covering the center of the depression may be at a temperature of 103 ℃, and a portion of the web on the land area may have a temperature of about 26 ℃. For another example, a portion of the web covering the center of the cavity may be at a temperature of 108 ℃, and a portion of the web on the land area may have a temperature of about 24 ℃. The first maximum temperature may be about 5 ℃ to about 100 ℃, about 10 ℃ to about 100 ℃, about 20 ℃ to about 100 ℃, or about 60 to about 100 ℃. The first maximum temperature may cause the first film web to deform by thermoforming.

The first film web may be subjected to the first negative gauge pressure for about 1 second to about 10 seconds, about 2 seconds to about 5 seconds, or more preferably about 1 second to about 3 seconds. The first negative gauge pressure may be about 10 millibar to about 40 millibar lower than atmospheric pressure. The first negative gauge pressure may be about 10 millibar to about 90 millibar below atmospheric pressure, or about 25 millibar to about 35 millibar below atmospheric pressure. When the first negative gauge pressure is applied to the first film web, the first film web may have a temperature of about 5 ℃ to about 100 ℃, or even about 10 ℃ to about 100 ℃, or even about 20 ℃ to about 100 ℃. The lower the first negative gauge pressure, the faster the first film web will deform. The slower deformation may reduce the amount of microcracks in the first web formed. For lower deformation temperatures, the first negative gauge pressure may be greater, i.e., less vacuum, such that deformation of the first film web is slow, which may reduce microcracks in the first web formed. In the case where the first film web is further conveyed in the machine direction MD, a second negative gauge pressure may be applied to the first porous face of the one or more depressions when the first film web is at a second maximum temperature. The second negative gauge pressure may be applied via a second vacuum system. The second maximum temperature may be greater than the first maximum temperature. For clarity, gauge pressure is zero with respect to atmospheric pressure. Thus, if the first negative gauge pressure is 50 mbar below atmospheric pressure and the second negative gauge pressure is 100 mbar below atmospheric pressure, it can be said that the second negative gauge pressure is less than the first negative gauge pressure. And, it can be said that the gauge pressure 50 mbar lower than the atmospheric pressure is a negative gauge pressure because it is a pressure lower than the atmospheric pressure. Because the negative gauge pressure, which is 50 mbar below atmospheric pressure, is lower than atmospheric pressure, the negative gauge pressure is a vacuum. Therefore, in the case where the second negative gauge pressure is less than or equal to the first negative gauge pressure, the first negative gauge pressure may be considered to be a first vacuum degree and the second negative gauge pressure is a second vacuum degree, and the second vacuum degree is more powerful than the first vacuum degree. The second maximum temperature may be about 90 ℃ to about 150 ℃. The second negative gauge pressure may be about 150 millibar to about 400 millibar below atmospheric pressure, about 180 millibar to about 260 millibar below atmospheric pressure, about 180 millibar to about 230 millibar below atmospheric pressure, or about 210 millibar to about 230 millibar below atmospheric pressure. That is, the second negative gauge pressure pulls the first film web harder than the first negative gauge pressure. The first negative gauge pressure, the second negative gauge pressure, the first maximum temperature, and the second maximum temperature may be selected such that the compartments are well formed, the first web is not pulled into the openings in the first porous face to an unacceptable degree, and the amount of microcracking occurring during deformation of the first web is limited to an acceptable degree. In general, the higher the second temperature, the greater the second negative gauge pressure can be, as the first web can be more easily deformed at higher temperatures. It is also worth noting that combinations of vacuum and/or other sources of differential pressure may be used in the deformation of the film web disclosed herein. For example, a first pressure differential across the first film web may be provided by fluid pressure from above the die (as a non-limiting example). The fluid may be a heated fluid. The fluid pressure that can be applied to the water-soluble first film web can be provided by a gas (such as air) or a liquid. For example, the nozzle may dispense fluid (gas as a non-limiting example) under pressure in a direction toward the first film web to conform the first film web to the first porous face of the one or more cavities.

The second web may be at a temperature of about ambient temperature to about 120 ℃. The second web may be at a temperature of about 10 ℃ to about 120 ℃. The second web may be at a temperature of about 20 ℃ to about 120 ℃.

A method of orienting a thermoforming mold for preparing a water-soluble unit-dose article according to the application in an apparatus according to the application, wherein the thermoforming mold is oriented such that the direction of the fillable length coincides with the machine direction.

Water-soluble film

The water-soluble film of the present invention is soluble or dispersible in water. The water-soluble film preferably has a thickness of 20 microns to 150 microns, preferably 35 microns to 125 microns, even more preferably 50 microns to 110 microns, most preferably about 76 microns.

Preferably, the membrane has a water solubility of at least 50%, preferably at least 75% or even at least 95%, measured by the method described herein after using a glass filter having a maximum pore size of 20 microns: 5 g.+ -. 0.1 g of film material and 2 L.+ -. 5ml of distilled water are added to a pre-weighed 3L beaker. It was vigorously stirred at 30℃for 30 minutes on a magnetic stirrer of Labline model 1250 or equivalent and a 5cm magnetic stirrer set at 600 rpm. The mixture was then filtered through a pleated qualitative porous glass filter with pore size as defined above (max 20 microns). The dehydration is dried from the collected filtrate by any conventional method and the weight of the remaining material (which is the dissolved or dispersed fraction) is determined. Then, the percent solubility or percent dispersibility can be calculated.

As known in the art, the water-soluble film material may be obtained by injection molding, blow molding, extrusion or blow-molded extrusion of a polymeric material.

The water-soluble film comprises polyvinyl alcohol. The polyvinyl alcohol may be present at 50% to 95%, preferably 55% to 90%, more preferably 60% to 80% by weight of the water-soluble film. The polyvinyl alcohol preferably comprises a polyvinyl alcohol homopolymer, a polyvinyl alcohol copolymer, or a mixture thereof. Preferably, the water-soluble film comprises a blend of polyvinyl alcohol homopolymers and/or anionic polyvinyl alcohol copolymers, preferably wherein the polyvinyl alcohol copolymers are selected from sulfonated and carboxylated anionic polyvinyl alcohol copolymers, especially carboxylated anionic polyvinyl alcohol copolymers, most preferably the water-soluble film comprises a blend of polyvinyl alcohol homopolymers and carboxylated anionic polyvinyl alcohol copolymers, or a blend of polyvinyl alcohol homopolymers. Alternatively, the polyvinyl alcohol comprises an anionic polyvinyl alcohol copolymer, most preferably a carboxylated anionic polyvinyl alcohol copolymer. When the polyvinyl alcohol in the water-soluble film is a blend of a polyvinyl alcohol homopolymer and a carboxylated anionic polyvinyl alcohol copolymer, the homopolymer and the anionic copolymer are present in a relative weight ratio of from 90/10 to 10/90, preferably from 80/20 to 20/80, more preferably from 70/30 to 50/50. Without wishing to be bound by theory, the term "homopolymer" generally includes polymers having a single type of monomeric repeat unit (e.g., a polymer chain comprising or consisting of a single monomeric repeat unit). For the specific case of polyvinyl alcohol, the term "homopolymer" also includes copolymers having a distribution of vinyl alcohol monomer units and optionally vinyl acetate monomer units, depending on the degree of hydrolysis (e.g., polymer chains comprising or consisting of vinyl alcohol and vinyl acetate monomer units). At 100% hydrolysis, the polyvinyl alcohol homopolymer may comprise only vinyl alcohol units. Without wishing to be bound by theory, the term "copolymer" generally includes polymers having two or more types of monomeric repeat units (e.g., polymer chains comprising or consisting of two or more different monomeric repeat units, whether as random copolymers, block copolymers, etc.). For the specific case of polyvinyl alcohol, the term "copolymer" (or "polyvinyl alcohol copolymer") also includes copolymers having a distribution of vinyl alcohol monomer units and vinyl acetate monomer units (depending on the degree of hydrolysis) and at least one other type of monomer repeat unit (e.g., a tri (or higher) polymeric chain comprising or consisting of vinyl alcohol monomer units, vinyl acetate monomer units, and one or more other monomer units (e.g., anionic monomer units). At 100% hydrolysis, the polyvinyl alcohol copolymer may include a copolymer having vinyl alcohol units and one or more other monomer units but no vinyl acetate units. Without wishing to be bound by theory, the term "anionic copolymer" includes copolymers having anionic monomer units comprising an anionic moiety. A general class of anionic monomer units useful in anionic polyvinyl alcohol copolymers includes vinyl polymeric units corresponding to: monocarboxylic acid vinyl monomers and esters and anhydrides thereof, dicarboxylic acid monomers and esters and anhydrides thereof having a polymerizable double bond, vinylsulfonic acid monomers, and alkali metal salts of any of the foregoing. Examples of suitable anionic monomer units include vinyl polymeric units corresponding to vinyl anionic monomers including vinyl acetic acid, maleic acid, monoalkyl maleate, dialkyl maleate, monomethyl maleate, dimethyl maleate, maleic anhydride, fumaric acid, monoalkyl fumarate, dialkyl fumarate, monomethyl fumarate, dimethyl fumarate, fumaric anhydride, itaconic acid, monomethyl itaconate, dimethyl itaconate, itaconic anhydride, vinyl sulfonic acid, allyl sulfonic acid, ethanedisulfonic acid, 2-acrylamido-1-methylpropanesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, 2-thioethyl acrylate, alkali metal salts (e.g., sodium, potassium or other alkali metal salts) of the foregoing, esters (e.g., methyl, ethyl or other C1-C4 or C6 alkyl esters) of the foregoing, and combinations thereof (e.g., various types of anionic monomers or equivalent forms of the same anionic monomers). The anionic monomer can be one or more acrylamidomethylpropane sulfonic acid (e.g., 2-acrylamido-1-methylpropane sulfonic acid, 2-acrylamido-2-methylpropane sulfonic acid, 2-methacrylamido-2-methylpropane sulfonic acid), alkali metal salts (e.g., sodium salts) of the foregoing, and combinations thereof. Preferably, the anionic portion of the first anionic monomer unit is selected from sulfonate, carboxylate or mixtures thereof, more preferably carboxylate, most preferably acrylate, methacrylate, maleate or mixtures thereof. Preferably, the anionic monomer units are present in the anionic polyvinyl alcohol copolymer in an average amount in the range of from 1 to 10 mole%, preferably from 2 to 5 mole%. Preferably, the polyvinyl alcohol, and/or in the case of a polyvinyl alcohol blend, the polyvinyl alcohol polymer alone has an average viscosity (μ1) in the range of 4mpa.s to 30mpa.s, preferably 10mpa.s to 25mpa.s, as measured as a 4% polyvinyl alcohol copolymer solution in deionized water at 20 ℃. The viscosity of the polyvinyl alcohol polymer was determined by measuring freshly prepared solutions using a Brookfield LV-type viscometer with UL adapter as described in the british standard EN ISO 15023-2:2006Annex EBrookfield test method. The international convention specifies the viscosity of a 4% aqueous solution of polyvinyl alcohol at 20 ℃. It is well known in the art that the viscosity of an aqueous solution of a water-soluble polymer (polyvinyl alcohol or other substance) is related to the weight average molecular weight of the same polymer, and that viscosity is generally used as a representation of weight average molecular weight. Accordingly, the weight average molecular weight of the polyvinyl alcohol may be in the range of 30,000 to 175,000, or 30,000 to 100,000, or 55,000 to 80,000. Preferably, the polyvinyl alcohol, and/or in the case of a polyvinyl alcohol blend, the polyvinyl alcohol polymer alone has an average degree of hydrolysis in the range of 75% to 99%, preferably 80% to 95%, most preferably 85% to 95%. A suitable test method for measuring the degree of hydrolysis is according to the standard method JIS K6726.

Preferably, the water-soluble film comprises a non-aqueous plasticizer. Preferably, the non-aqueous plasticizer is selected from the group consisting of polyols, sugar alcohols, and mixtures thereof. Suitable polyols include polyols selected from the group consisting of: glycerol, diglycerides, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycols having a molecular weight up to 400, neopentyl glycol, 1, 2-propanediol, 1, 3-propanediol, dipropylene glycol, polypropylene glycol, 2-methyl-1, 3-propanediol, trimethylolpropane and polyether polyols, or mixtures thereof. Suitable sugar alcohols include sugar alcohols selected from the group consisting of: isomalt, maltitol, sorbitol, xylitol, erythritol, adonitol, hexitol, pentaerythritol and mannitol, or mixtures thereof. More preferably, the non-aqueous plasticizer is selected from the group consisting of glycerol, 1, 2-propanediol, dipropylene glycol, 2-methyl-1, 3-propanediol, trimethylolpropane, triethylene glycol, polyethylene glycol, sorbitol, or mixtures thereof, most preferably from the group consisting of glycerol, sorbitol, trimethylolpropane, dipropylene glycol, and mixtures thereof. One particularly suitable plasticizer system includes a blend of glycerin, sorbitol, and trimethylolpropane. Another particularly suitable plasticizer system includes a blend of glycerin, dipropylene glycol, and sorbitol. Preferably, the film comprises from 5% to 50%, preferably from 10% to 40%, more preferably from 20% to 30% by weight of the film of the non-aqueous plasticizer.

Preferably, the water-soluble film comprises a surfactant. Preferably, the water-soluble film comprises surfactant in an amount of from 0.1% to 2.5%, preferably from 1% to 2% by weight of the water-soluble film. Suitable surfactants may include nonionic, cationic, anionic and zwitterionic species. Suitable surfactants include, but are not limited to, polyoxyethylenated polyoxypropylene glycols, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionic), polyoxyethylenated amines, quaternary ammonium salts and quaternized polyoxyethylenated amines (cationic), and amine oxides, N-alkyl betaines and sulfobetaines (zwitterionic). Other suitable surfactants include sodium sulfosuccinate, lactic acid fatty acid esters of glycerol and propylene glycol, lactic acid esters of fatty acids, sodium alkyl sulfate, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerol and propylene glycol, and acetylated esters of fatty acids, and combinations thereof.

Preferably, the water-soluble film according to the present invention comprises a lubricant/release agent. Suitable lubricants/mold release agents may include, but are not limited to, fatty acids and salts thereof, fatty alcohols, fatty esters, fatty amines, fatty amine acetates, and fatty amides. Preferred lubricants/release agents are fatty acids, fatty acid salts and fatty amine acetates. The amount of lubricant/release agent in the water-soluble film is in the range of 0.02% to 1.5%, preferably 0.1% to 1% by weight of the water-soluble film.

Preferably, the water-soluble film comprises a filler, extender, antiblocking agent or mixtures thereof. Suitable fillers, extenders, antiblocking agents or mixtures thereof include, but are not limited to, starches, modified starches, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metal oxides, calcium carbonate, talc and mica. Preferred materials are starch, modified starch and silica. Preferably, the amount of filler, extender, antiblocking agent or mixtures thereof in the water-soluble film is in the range of from 0.1% to 25%, preferably from 1% to 10%, more preferably from 2% to 8%, most preferably from 3% to 5% by weight of the water-soluble film. In the absence of starch, one preferred range of suitable fillers, extenders, antiblocking agents or mixtures thereof is from 0.1% to 1%, preferably 4%, more preferably 6%, even more preferably 1% to 4%, most preferably 1% to 2.5% by weight of the water soluble film.

Preferably, the water-soluble film according to the present invention has a residual moisture content of at least 4%, more preferably in the range of 4% to 15%, even more preferably 5% to 10% by weight of the water-soluble film, as measured by Karl Fischer titration.

Preferred membranes exhibit good dissolution in cold water (i.e., unheated distilled water). Preferably, such films exhibit good dissolution at 24 ℃, even more preferably at a temperature of 10 ℃. Good dissolution means that the membrane exhibits a water solubility of at least 50%, preferably at least 75% or even at least 95%, as measured by the method described herein after using a glass filter having a maximum pore size of 20 micrometers, as described above.

Preferred membranes include those provided by Monosol under the trade names M8630, M8900, M8779, M8310.

The film may be opaque, transparent or translucent. The film may include a printed area. The printed areas may be realized using standard techniques, such as flexographic printing or inkjet printing. Preferably, the ink for the print zone comprises 0ppm to 20ppm, preferably 0ppm to 15ppm, more preferably 0ppm to 10ppm, even more preferably 0ppm to 5ppm, even more preferably 0ppm to 1ppm, even more preferably 0ppb to 100ppb, most preferably 0ppb of dioxane. Those skilled in the art will know the known methods and techniques for determining the dioxane content of an ink formulation.

The film may comprise an aversive agent, such as a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octaacetate, quinine hydrochloride, benidiammonium or mixtures thereof. Any suitable level of aversive agent may be used in the film. Suitable levels include, but are not limited to, 1ppm to 5000ppm, or even 100ppm to 2500ppm, or even 250rpm to 2000rpm.

Preferably, the water-soluble film or the water-soluble unit dose article or both is coated with a lubricant, preferably wherein the lubricant is selected from talc, zinc oxide, silica, siloxane, zeolite, silicic acid, alumina, sodium sulfate, potassium sulfate, calcium carbonate, magnesium carbonate, sodium citrate, sodium tripolyphosphate, potassium citrate, potassium tripolyphosphate, calcium stearate, zinc stearate, magnesium stearate, starch, modified starch, clay, kaolin, gypsum, cyclodextrin or mixtures thereof.

Preferably, the water-soluble film and its various individual components independently comprise 0ppm to 20ppm, preferably 0ppm to 15ppm, more preferably 0ppm to 10ppm, even more preferably 0ppm to 5ppm, even more preferably 0ppm to 1ppm, even more preferably 0ppb to 100ppb, most preferably 0ppb of dioxane. Those skilled in the art will know the known methods and techniques for determining the dioxane content of water-soluble films and their components.

Substrate treatment composition

The water-soluble unit dose article comprises a substrate treatment composition. In particular, the substrate treatment composition may be a liquid laundry detergent composition, which refers to any laundry detergent composition comprising a liquid capable of wetting and treating fabrics, and includes, but is not limited to, liquids, gels, pastes, dispersions, and the like. The liquid detergent composition may be used in a fabric hand washing operation or may be used in an automatic machine fabric washing operation.

The substrate treatment composition may comprise from 0.1% to 70%, preferably from 1% to 60%, more preferably from 5% to 50%, most preferably from 10% to 45% by weight of the composition of surfactant, and from 1% to 50%, preferably from 4% to 40%, more preferably from 7% to 35%, most preferably from 10% to 30% (e.g. 10%, 15%, 20%, 25%, 30% or any range therebetween) by weight of the composition of non-aqueous solvent.

Preferably, the surfactant is selected from C ₆ -C ₂₀ Alkyl dimethyl amine oxide, C _6-20 Amidoalkyl dimethyl amine oxide, C ₆ -C ₂₀ Linear Alkylbenzene Sulfonate (LAS), C ₆ -C ₂₀ Alkyl Sulfate (AS), C ₆ -C ₂₀ Alkyl Alkoxylated Sulphates (AAS), C ₆ -C ₂₀ Methyl Ester Sulfonate (MES), C ₆ -C ₂₀ Alkyl Ether Carboxylates (AEC), fatty acids, alkyl alkoxylated alcohols, alkyl alkoxylated phenols, alkyl polysaccharides, alkyl polyglycosides, methyl ester ethoxylates, polyhydroxy fatty acid amides, alkoxylated fatty acid esters, sucrose esters, sorbitan esters and alkoxylated derivatives of sorbitan esters, and any combination thereof, and the nonaqueous solvent is selected from the group consisting of monohydric alcohols, glycols, polyols, glycol ethers, and any combination thereof. More preferably, the surfactant comprises C ₆ -C ₂₀ Alkyl dimethyl amine oxide, C ₆ -C ₂₀ LAS, C having a weight average degree of alkoxylation in the range of 1 to 20 (preferably a weight average degree of ethoxylation in the range of 1 to 20) ₆ -C ₂₀ Alkoxylated alcohols, C ₆ -C ₂₀ Alkyl Alkoxylated Sulfates (AAS) (preferably C with a weight average degree of ethoxylation ranging from 1 to 5 ₆ -C ₂₀ Alkyl ethoxylated sulfates), fatty acids, and any combination thereof, and the nonaqueous solvent is selected from the group consisting of ethanol, propanol, isopropanol, terpineol, ethylene glycol, 1, 2-propanediol, 1, 3-propanediol, butanediol, glycerol, butanetriol, pentaerythritol, dipropylene glycol (DPG), tripropylene glycol (TPG), polypropylene glycol (PPG), n-butoxypropoxypropanol (nBPP), diethylene glycol, 2-ethoxyethanol, 2-butoxyethanol, polyethylene glycol, and any combination thereof.

Preferably, the liquid laundry detergent composition comprises from 7% to 18%, preferably from 8% to 15% (e.g. 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15% or any range therebetween) of water by weight of the liquid laundry detergent composition.

The liquid laundry detergent composition may comprise a cleaning or care polymer, preferably wherein the cleaning or care polymer is selected from ethoxylated or mixed ethoxylated/propoxylated polyethylenimine, alkoxylated polyalkylphenols, amphiphilic graft copolymers, optionally anionically modified polyester terephthalates, optionally cationically modified hydroxyethyl cellulose, carboxymethyl cellulose or mixtures thereof.

The water-soluble unit dose article may comprise an adjunct ingredient selected from the group consisting of hueing dyes, polymers, builders, dye transfer inhibiting agents, dispersants, enzymes, enzyme stabilizers, catalytic materials, bleaching agents, bleach activators, polymeric dispersing agents, anti-redeposition agents, suds suppressors, aesthetic dyes, opacifiers, perfumes, perfume delivery systems, structurants, hydrotropes, processing aids, pigments and mixtures thereof.

Preferably, the laundry detergent composition has a pH of 6 to 10, 6.5 to 8.9 or 7 to 8, wherein the pH of the laundry detergent composition is as measured at 10% product concentration in deionized water at 20 ℃.

In some embodiments, the liquid laundry detergent composition is newtonian.

In some other embodiments, the liquidThe laundry detergent composition is non-newtonian. Without wishing to be bound by theory, the non-newtonian fluid has properties different from newtonian fluids, more specifically, the viscosity of the non-newtonian fluid depends on the shear rate, while the newtonian fluid has a constant viscosity independent of the shear rate applied. The liquid laundry detergent composition may have a viscosity of at least 2pa.s at a shear rate of 0.5s "1, as measured using a TA Rheometer AR2000 at 25 ℃, preferably wherein the liquid detergent composition is at 0.5s ^-1 Has a viscosity at a shear rate of 2pa.s to 35pa.s, preferably 2.5pa.s to 30pa.s, more preferably 3pa.s to 25pa.s, even more preferably 5pa.s to 20pa.s, most preferably 10pa.s to 16pa.s, as measured using a TA Rheometer AR2000 at 25 deg.c. Liquid laundry detergent compositions may be characterized as having a viscosity of about 1000 seconds ^-1 And a high shear viscosity in the range of about 100 to about 900 mPas, preferably about 150 to about 800 mPas, more preferably about 200 to about 600 mPas, measured at a temperature of about 20 ℃. The fluid may preferably be a non-Newtonian fluid having shear-thinning properties, and thus may be further characterized as having a shear-thinning behavior at about 0.5 seconds ^-1 A low shear viscosity in the range of about 1000mpa.s to about 10000mpa.s, preferably about 1500mpa.s to about 7500mpa.s, more preferably about 2000mpa.s to about 5000mpa.s, as measured at a shear rate of about 1000 mpa.s.

Washing method

Another aspect of the present invention is a washing method comprising the steps of: the water-soluble unit dose article according to the invention is added to sufficient water to dilute the liquid detergent composition by at least 300 times, thereby producing a wash liquor, and the items to be washed are contacted with the wash liquor.

Packaging product

Another aspect of the invention is a packaged product comprising a reclosable container and at least one water-soluble unit dose article according to the invention comprised therein.

The person skilled in the art will know the relevant storage containers. Preferably, the storage container is flexible (preferably a resealable bag), rigid (preferably a reclosable keg) or mixtures thereof, preferably wherein the storage container comprises a child-resistant closure. Those skilled in the art will know of suitable child resistant closures.

The package may be made of any suitable material. The container may be made of a metal material, aluminum, plastic material, cardboard material, laminate material, cellulose pulp material or mixtures thereof. The package may be made of a plastic material, preferably a polyolefin material. The package may be made of polypropylene, polystyrene, polyethylene terephthalate, PVC or mixtures thereof or more durable engineering plastics such as Acrylonitrile Butadiene Styrene (ABS), polycarbonate, polyamide, etc. The materials used to make the container may contain other ingredients such as colorants, preservatives, plasticizers, UV stabilizers, oxygen, fragrances, moisture resistant recycled materials, and the like.

Fig. 1 shows an exemplary unit dose article 1 according to the present disclosure, which may have improved production speeds. The unit dose article 1 comprises a first compartment 11, a second compartment 12 and a third compartment 13, all of which are crescent shaped and have the same volume (about 3.3 ml). The sealing plane 14 is a plane formed by sealing the first water-soluble film and the second water-soluble film. The sealing plane 14 comprises a central sealing member 15. To improve the production speed of the unit dose article, the shape of the compartment is optimized by optimizing the shape of the mold without significantly changing the overall shape (i.e., maintaining the crescent shape). In particular, the optimization comprises a modification of shape parameters comprising a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ ) To satisfy (DL) ₁ -DL ₃ )/DL ₃ <1.01 and 0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15.

Fig. 2 shows a unit dose article 2 currently on the market, which has a very similar shape as the unit dose article 1, but the former is produced at a much slower rate than the latter.

Fig. 3 shows a schematic diagram of a shape parameter test for an exemplary unit dose article 1. Showing the projection of the first compartment 11 and the third compartment 13 . The first compartment, the second compartment and the third compartment each have a first fillable length (DL) in the Machine Direction (MD) ₁ ) 31, second fillable length (DL ₂ ) 32 and third fillable length (DL ₃ ) 33, wherein DL ₁ >DL ₂ >DL ₃ ，(DL ₁ -DL ₃ )/DL ₃ <1.01, and 0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15. According to test 1: shape parameter testing, identifying a first fillable length (DL ₁ ) 31, second fillable length (DL ₂ ) 32 and third fillable length (DL ₃ )33。

Test method

Test 1: shape parameter testing

To characterize the shape of a unit dose article comprising at least three compartments, the following parameters were measured in this test: a first fillable length (DL) along the Machine Direction (MD) ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ )。

In software Ansys SpaceClaim (2022, R1), a 3D model of a compartment in a unit dose article or a depression in a mold is entered. The projected plane of the compartment (the plane corresponding to the projection of the recess in the forming surface of the mould) is then processed by the software.

First, the Machine Direction (MD) is determined by software. For a certain shape of the unit dose article there are a number of possible directions in the projection plane along which the unit dose article moves during production. The machine direction is determined as the direction along which the difference in the fillable lengths of the three compartments is smallest. In particular, for any possible orientation, the intersection plane that can divide the compartment into two parts of equal volume is determined by software, and the fillable length of the compartment is determined as the intersection of such intersection plane with the projection of the compartment. The fillable lengths of the three compartments are calculated along any possible direction by using software, and the direction along which the difference between the maximum fillable length and the minimum fillable length of the three compartments is smallest is determined as the machine direction.

Subsequently, along the above-determinedIs determined by software, a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ )。

Furthermore, if there are more than 3 compartments up to i compartments or recesses, then follow as above for DL ₁ 、DL ₂ And DL (DL) ₃ The corresponding DL is determined in the same manner as defined.

Examples

Example 1: optimized cell shape in unit dose articles

The inventors have surprisingly found that water-soluble unit dose articles having an optimised compartment shape can provide improved production speeds. In particular, the unit dose article 1 comprises a first compartment 11, a second compartment 12 and a third compartment 13, which are all crescent shaped, optimized for increasing the production speed as shown in fig. 1. Surprisingly, although the overall shape of the compartments remains very similar, the following requirements can be met by controlling the fillable length: (DL) ₁ -DL ₃ )/DL ₃ <1.01; and 0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15, thereby significantly improving the production speed of the unit dose article. The shape parameters before and after optimization were tested as described in test 1 and shown below. As shown below, the number of unit dose articles produced per lane reached 48 after optimization and 30 before optimization.

TABLE 1 mould shape parameters

	DL ₁	DL ₂	DL ₃	(DL ₁ -DL ₃ )/DL ₃	(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )
						Before optimization	32.3mm	27.3mm	16.0mm	1.02	0.44
After optimization	35.9mm	27.4mm	18.2mm	0.97	0.92

TABLE 2 production speed

	Production speed (product/min)
		Before optimization	30
After optimization	48

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Rather, unless otherwise indicated, 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 "40mm" is intended to mean "about 40mm".

Each document cited herein, including any cross-referenced or related patent or application, and any patent application or patent for which this application claims priority or benefit, is incorporated by reference in its entirety unless expressly excluded or otherwise limited. Citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that any such invention is taught, suggested, or disclosed alone or in any combination with any other reference or references. Furthermore, if 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.

Claims

1. A water-soluble unit dose article for treating a substrate, characterized in that the water-soluble unit dose article comprises a first water-soluble film, a second water-soluble film, and a plurality of compartments enclosed by the first water-soluble film and the second water-soluble film, wherein the plurality of compartments comprises a first compartment, a second compartment, and a third compartment,

wherein the first compartment, the second compartment and the third compartment are formed on a sealing plane by the first water-soluble film and the second water-soluble film and are isolated from each other by a sealing portion on the sealing plane,

wherein the sealing portion comprises a central sealing member and the first, second and third compartments are further arranged around the central sealing member on the sealing plane,

Wherein the first compartment, the second compartment and the third compartment each have a first fillable length (DL) in the Machine Direction (MD) ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ )，

Wherein the water-soluble unit dose article is characterized by:

DL ₁ >DL ₂ >DL ₃ ；

(DL ₁ -DL ₃ )/DL ₃ <1.01; and is also provided with

0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15。

2. The water-soluble unit dose article of claim 1, wherein

(DL ₁ -DL ₃ )/DL ₃ <1.00; and/or

0.88<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.05。

3. The water-soluble unit dose article of claim 1 or 2, wherein DL ₁ 、DL ₂ And DL (DL) ₃ Each of which is 5mm to 60mm.

4. The water-soluble unit dose article according to claim 1 or 2, wherein the first compartment contains a first substrate treatment composition, the second compartment contains a second substrate treatment composition, and the third compartment contains a third substrate treatment composition,

wherein the first substrate treatment composition, the second substrate treatment composition, and theThe third substrate treatment compositions each have a first volume (V ₁ ) Second volume (V) ₂ ) And a third volume (V ₃ )，

Wherein the water-soluble unit dose article is characterized by V ₁ ≥V ₂ ≥V ₃ And (V) ₁ -V ₃ )/V ₃ <0.3。

5. The water-soluble unit dose article of claim 1 or 2, wherein the plurality of compartments comprises i compartments, wherein i is 4 or more, wherein the i compartments each have an i-th fillable length (DL _i )，

Wherein the water-soluble unit dose article is characterized by:

DL ₁ >DL ₂ >DL ₃ …>DL _i ；

(DL ₁ -DL _i )/DL _i <1.01; and is also provided with

0.85<(DL _x-2 -DL _x-1 )/(DL _x-1 -DL _x )<1.15, wherein x is any value between 3 and i,

wherein the first compartment contains a first substrate treatment composition, the second compartment contains a second substrate treatment composition, the third compartment contains a third substrate treatment composition, … and the i-th compartment contains an i-th substrate treatment composition,

wherein the first, second, third, and ith substrate treatment compositions each have a first volume (V ₁ ) Second volume (V) ₂ ) Third volume (V ₃ ) … and ith volume (V _i )，

Wherein the water-soluble unit dose article is characterized by V ₁ ≥V ₂ ≥…V _i And (V) ₁ -V _i )/V _i <0.3。

6. The water-soluble unit dose article of claim 4, wherein V ₁ 、V ₂ 、V ₃ … and V _i Each of which is 0.5ml to 15ml.

7. The water-soluble unit dose article of claim 5, wherein V ₁ 、V ₂ 、V ₃ … and V _i Each of which is 0.5ml to 15ml.

8. The water-soluble unit dose article of claim 1 or 2, wherein each of the first, second, and third compartments has a projection on the sealing plane.

9. The water-soluble unit dose article of claim 1 or 2, wherein each compartment of the plurality of compartments has substantially the same projection on the sealing plane, and/or wherein each compartment of the plurality of compartments has substantially the same spatial shape.

10. The water-soluble unit dose article of claim 1 or 2, wherein the plurality of compartments further comprises one or more additional compartments arranged in a stacked fashion relative to the first, second, and third compartments.

11. The water-soluble unit dose article of claim 1 or 2, wherein the substrate treatment composition is a laundry detergent composition.

12. An apparatus for preparing a water-soluble unit dose article, the apparatus comprising:

a thermoforming mold having a forming surface;

a plurality of spaced apart depressions in the forming surface, wherein each of the depressions comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and

a continuous land area surrounding the recess,

wherein the concave part comprises a first concave part and a second concave partA recess and a third recess, each of the first recess, the second recess and the third recess having a first fillable length (DL ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ )，

Wherein the device is characterized in that

DL ₁ >DL ₂ >DL ₃ ；

(DL ₁ -DL ₃ )/DL ₃ <1.01; and is also provided with

0.85<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.15。

13. The apparatus of claim 12, wherein

(DL ₁ -DL ₃ )/DL ₃ <1.00; and/or

0.88<(DL ₁ -DL ₂ )/(DL ₂ -DL ₃ )<1.05。

14. The apparatus of claim 12 or 13, wherein the apparatus further comprises a dispensing device comprising a plurality of nozzles, wherein the plurality of nozzles are configured to fill the plurality of compartments with a substrate treatment composition,

wherein the plurality of nozzles substantially simultaneously fills the compartment.

15. The apparatus of claim 12 or 13, wherein the apparatus further comprises a dispensing device comprising a plurality of nozzles, wherein the plurality of nozzles are configured to fill the plurality of compartments with a substrate treatment composition,

wherein the plurality of nozzles are stationary and the thermoforming mold moves in the Machine Direction (MD) during the filling.

16. A water-soluble unit dose article for treating a substrate, characterized in that the water-soluble unit dose article comprises a first water-soluble film, a second water-soluble film, and a plurality of compartments enclosed by the first water-soluble film and the second water-soluble film, wherein the plurality of compartments comprises a first compartment, a second compartment, and a third compartment,

wherein each of the first compartment, the second compartment and the third compartment has a different projected shape from each other,

Wherein the water-soluble unit dose article is characterized by:

DL ₁ ≥DL ₂ >DL ₃ or DL ₁ >DL ₂ ≥DL ₃ The method comprises the steps of carrying out a first treatment on the surface of the And is also provided with

(DL ₁ -DL ₃ )/DL ₃ <1.01。

17. The water-soluble unit dose article of claim 16, wherein the first, second, and third compartments are arranged in a circumferential configuration about the central seal member.

18. The water-soluble unit dose article of claim 16 or 17, wherein DL ₁ 、DL ₂ And DL (DL) ₃ Each of which is 5mm to 60mm.

19. An apparatus for preparing a water-soluble unit dose article, the apparatus comprising:

a thermoforming mold having a forming surface;

a continuous land area surrounding the recess,

wherein the recess comprises a first recess, a second recess and a third recess, each having a first fillable length (DL) along a Machine Direction (MD) ₁ ) Second fillable length (DL ₂ ) And a third fillable length (DL ₃ )，

Wherein the continuous land area comprises a central land component and the first, second and third depressions are further disposed about the central land component on the forming surface,

wherein each of the first recess, the second recess and the third recess has a projection shape different from each other,

wherein the device is characterized in that

(DL ₁ -DL ₃ )/DL ₃ <1.01。

20. The device of claim 19, wherein the first, second, and third recesses are arranged in a circumferential configuration about the central platform component.

21. A water-soluble unit dose article for treating a substrate, characterized in that the water-soluble unit dose article comprises a first water-soluble film, a second water-soluble film, and a plurality of compartments enclosed by the first water-soluble film and the second water-soluble film, wherein the plurality of compartments comprises a first compartment, a second compartment, and a third compartment,

wherein the first compartment, the second compartment and the third compartment are arranged in a circumferential configuration around the central seal member,

Wherein the water-soluble unit dose article is characterized by:

DL ₁ ＝DL ₂ ＝DL ₃ 。

22. the water-soluble unit dose article of claim 21, wherein at least two of the first compartment, the second compartment, and the third compartment have different projected shapes.

23. The water-soluble unit dose article of claim 21 or 22, wherein DL ₁ 、DL ₂ And DL (DL) ₃ Each of which is 5mm to 60mm.

24. An apparatus for preparing a water-soluble unit dose article, the apparatus comprising:

a thermoforming mold having a forming surface;

a continuous land area surrounding the recess,

Wherein the first, second and third recesses are arranged in a circumferential configuration around the central platform part,

wherein the device is characterized in that

DL ₁ ＝DL ₂ ＝DL ₃ 。

25. The device of claim 24, wherein at least two of the first recess, the second recess, and the third recess have different projected shapes.