Multi-compartment water-soluble capsule

Abstract

A three-compartment water-soluble capsule, each compartment containing a portion of a liquid cleaning agent composition, the compartments being arranged side-by-side to provide a central compartment side-by-side by a first side compartment and a second side compartment on respective sides, the capsule being formed of two water-soluble films sealed together to form a sealing mesh surrounding each compartment, the sealing mesh being located within a sealing plane, each of the three compartments extending at a maximum equal distance above and below the sealing plane, wherein the sealing mesh includes an annular sealing mesh defining the periphery of the capsule, and two inner sealing meshes, each extending through the capsule, each inner sealing mesh serving to connect the central compartment to the adjacent side compartment and to separate its contents, wherein each inner sealing mesh has a continuously curved shape.

Description

Technical Field

[0001] This invention relates to multi-compartment water-soluble capsules made of a water-soluble film, each compartment containing a portion of a cleaning agent composition. It also relates to the preparation of such capsules and related manufacturing equipment, as well as the uses of such capsules. Background Technology

[0002] Multi-compartment water-soluble detergent capsules made from water-soluble films are well known. The water-soluble film is typically polyvinyl alcohol. A preferred method of capsule manufacturing involves thermoforming the film. Thermoforming refers to a process in which a first sheet of film undergoes a molding process to form recesses in the film. This process includes heating the film to soften it and applying a vacuum to hold the film in a mold. The recesses are then filled. The capsule is completed by covering the filled recesses with a second sheet and sealing it to the first sheet of film around the edges of the recesses to form a flat, sealing web.

[0003] When the vacuum is released from the first film in the mold, the relaxation of the first film typically causes the applied second film to bulge out. When the capsule is removed from the mold, it is cut to leave a flat sealing mesh portion as an annular "skirt" surrounding each capsule. While the sealing mesh is flat in the mold, it may deform slightly when removed. Similarly, the capsule's outline typically relaxes and deviates slightly from its "perfectly shaped" form after being removed from its mold. In cases where this specification refers to a flat sealing mesh and / or a sealing plane associated with the sealing mesh, it refers to molding a flat sealing mesh. Similarly, in cases where this specification refers to aspects of the capsule's shape or configuration, it refers to a capsule formed in a mold having that shape or configuration. However, some aspects of shape and configuration can be embodied in the capsule itself, for example, due to the relaxation of the film associated with each compartment and the effects of the liquid composition within the compartment.

[0004] Multi-compartment capsules are suitable for delivering main laundry compositions to automatic washing machines and even for hand wash applications. While multi-compartment constructions are more difficult to manufacture than single-compartment ones, they are a viable option because the components of the detergent composition need to be mixed upon use and / or have reduced stability when stored together. It also adds aesthetic appeal to the capsules, as different compartments can be filled with contents of different colors.

[0005] EP1375637 and EP1394065 (Unilever) disclose multi-compartment water-soluble detergent capsules comprising 2 to 5 compartments obtained by thermoforming water-soluble films. EP1394065... Figure 1 A is copied here as Figure 1The diagram also shows a two-compartment capsule 101. Each of the two compartments 102, 103 contains a different portion of the cleaning composition, and the compartments are connected to and separated from each other by at least one flat, sealed area. One compartment may contain the liquid portion of the cleaning composition, and the other compartment may contain the particulate portion of the composition, such as bleach or a detergent builder. As described in most of the disclosed embodiments, the problem with capsules having compartments separated by a flat sealing mesh 104 extending through the capsule is that they are flimsy because they fold along the flat seal, causing a portion of the capsule to sag. This folding has been found to cause operational problems, and consumers dislike flimsy capsules.

[0006] Products sold as "Tide Pods" or "Ariel Pods" consist of two thermoformed "capsules" assembled to form a multi-compartment capsule. The first "capsule," containing two smaller liquid compartments joined together by a foldable, planar seal, then seals (closes) the larger compartment. This stacked configuration prevents the seal from folding. However, this method has drawbacks, including a complex manufacturing process and a sealing area with three layers of film. To avoid dissolution problems caused by this three-layer seal, a thinner film than usual must be used, which leads to leakage problems during manufacturing due to pinholes in other parts of the capsule caused by the thinner film.

[0007] Polyvinyl alcohol (PVA) films cannot completely prevent the contents of one liquid compartment from migrating into another. In any capsule in which liquid compartments are separated from other components by only a single thin layer of PVA film, effective isolation requires the ability to remain separated until the components being used are inevitably impaired. For example, in the “Tide Pod” capsule, the contents of only the two smaller liquid compartments can be considered effectively isolated.

[0008] WO2014 / 202412 discusses the folding problem in the case of a two-compartment capsule containing a liquid composition in the first compartment and a particulate / powder composition in the other compartment. WO2014 / 202412 Figure 7 Here as Figure 2A copy is shown, illustrating a rectangular two-compartment capsule 201, wherein the two compartments are arranged such that a small inner compartment 202 is completely surrounded by a larger outer compartment 203. The inner compartment contains a granular or powdered composition, and the outer compartment contains a liquid composition. The outer compartment is said to be separated from the inner compartment by a continuous segmented sealing region, which is substantially rectangular and located in a first plane. The outer compartment has a generally rectangular outer periphery 204 with rounded corners and a substantially uniform cross-section cut along a plane perpendicular to the first plane and perpendicular to the inner seal (radially) separating the inner and outer compartments. A rectangular skirt 205 corresponds to a cutting pattern used for manufacturing the capsule.

[0009] WO2014 / 170882 (Rideau) discloses a three-compartment capsule, in which the compartments are arranged such that only one seal always extends from one side of the product to the other. This design typically consists of a central compartment that not only mates with the side compartments but is actually surrounded by them. This is a solution to the sagging problem of multi-compartment capsules. The only design in which the seal extends from one side to the other without splitting is Figure 14, which is a double-compartment system. In all other designs, the central compartment is used to provide stability against sagging.

[0010] The sagging problem also occurred in the commercially available "three-in-one" capsules sold by El Corte Ingles (Spain), as illustrated in the diagram. Figure 3 Provided in China. The capsule 301 has a rectangular skirt 302 and three straight-sided compartments 303, 304, and 305 of substantially the same size.

[0011] Another "real" problem with water-soluble detergent capsules (including those for automatic washing machines) is that consumers don't carefully read the instructions and may therefore misuse them. It's known that capsules are placed in the washing machine's dispenser drawer when they should be added directly to the drum, and it's also known that capsules used in overly water-saving washing machines may be exposed to relatively little water. Therefore, rapid and complete dissolution of the capsules and mixing of the composition from different compartments are important. In fact, incomplete dissolution of the water-soluble film can be a problem, especially where the annular skirt—which is relatively thick due to being formed from two pieces of film—is wide and / or has thick corners. Incomplete dissolution can result in film residue remaining on clothes. In fact, dissolution can be further hindered in the early stages of the wash cycle, or when the capsule is placed on the clothes to be washed, as the film adheres to the garment and dissolves more difficult when it is sticky or partially embedded. The problem of film sticking or tangling with clothes can be even greater if the skirt is wide and / or has thick corners. Summary of the Invention

[0012] This application and the solutions described herein aim to address one or more of the above-mentioned problems and / or seek to provide improved capsules (especially those related to material and energy efficiency in production; operation; consumer experience; and performance in use).

[0013] This application provides the capsule according to claim 1.

[0014] The present invention provides a product that is easier for the user to manipulate and also has a superior feel. Products with many compartments often feel over-designed because many compartments are included merely for visual appeal. The present invention solves this problem by allowing the user to hold a side compartment and preventing the product from folding over itself. This is particularly problematic when the side compartment is large enough for the consumer to hold the product through it, and often results in the product feeling so loose that the consumer feels it is not well-made.

[0015] The product design is limited to multi-chamber products with a sealing plane (which is essentially located in the middle of the product when viewed from the side along the machine direction). The machine direction refers to the direction of travel during the manufacturing process. In other words, the compartments extend above and below the sealing plane by similar amounts, i.e., the compartments extend above and below the sealing plane.

[0016] Each preferred embodiment relates to specific aspects of the shape, structure, or construction of a side-by-side three-compartment water-soluble capsule.

[0017] Preferably, the central compartment is significantly larger than each of the side compartments, and particularly, the volume of the central compartment is greater than the combined volume of the side compartments. This allows for a fuller, more rounded shape; better handling; and an improved consumer experience.

[0018] Preferably, the central compartment is separated from each side compartment by a corresponding sealing mesh formed of a water-soluble film, each sealing mesh having a substantially continuously curved shape. This has been found to counteract folding or sagging of the capsule.

[0019] Preferably, the three compartments have outward-facing edges whose contours are curved substantially along their entire length. This can create resistance to folding or sagging and contribute to a fuller, more rounded shape, better handling, improved consumer experience, and better washing performance. The substantially continuously curved outer edges can be configured such that they generally define an imaginary circle or ellipse surrounding all three compartments.

[0020] Preferably, the side profile of the central compartment is defined by a corresponding sealing mesh located between the central and adjacent side compartments. It is suggested that each side profile has a recessed recess, and adjacent side compartments each have a protruding portion whose curvature is complementary to the curvature of the recessed recess of the central compartment, such that the protruding portion is received within the recessed recess of the central portion. This achieves efficient packaging of the compartments within the available capsule footprint (i.e., within the boundaries of the cutting pattern) and / or can promote rapid dissolution and mixing of the composition, as the central compartment is partially “wrapped” relative to the side compartments and the composition is spatially intercalated in adjacent compartments. It can also aid mixing and dissolution by promoting localized agitation of water flow along the tortuous channels formed by the adjacent protruding and recessed features.

[0021] Preferably, the shape of the capsule's outer edge contour is defined by an annular sealing mesh or skirt (which surrounds all three compartments in the sealing plane), the skirt being formed by merging and sealing two pieces of water-soluble film together, thereby defining the compartments and sealing their contents. It is suggested that the outward-facing edge of the skirt has a hexagonal shape. This can contribute to efficient manufacturing, particularly due to the complete fit of the hexagonal shape, resulting in little or no waste of the water-soluble film. It also avoids or improves incomplete dissolution of the (relatively thick) annular sealing mesh, and provides a smoother, less harsh appearance where the annular sealing mesh is less prominent.

[0022] Preferably, in a continuous or semi-continuous production process, filling of one compartment (suitably the central compartment) begins shortly before filling of the other compartments. This staggered arrangement allows for efficient capsule filling, where the arrangement of the central compartment relative to the side compartments causes the central compartment to spend a longer time under the filling device than the individual side compartments. This is particularly suitable, for example, for capsules in which, according to the first scheme, the central compartment is significantly larger than the individual side compartments. This allows the same liquid dispensing rate for all three compartments (and therefore for the associated dispensing pump system). Furthermore, efficient filling can be achieved despite the different compartment sizes; and no additional filling device is required and / or the filling device must be moved.

[0023] Preferably, in a continuous or semi-continuous production process, the capsule array is filled at a filling station comprising a movable filling device. Specifically, this movable filling device is configured to fill a first capsule in a first column of capsules, move to align with a second column of capsules, and then fill the capsules in the second column. This is particularly useful in cases where adjacent columns overlap, for example, where the capsules have a hexagonal shape and the orientation of the hexagons results in a hexagonal interlocking configuration that causes the adjacent columns to overlap such that the side compartments of the first column are in close contact with the adjacent columns.

[0024] Tri-compartment capsules

[0025] The aspects of the invention described herein provide a three-compartment water-soluble capsule, each compartment containing a portion of a liquid cleaning agent composition, the three compartments being arranged side-by-side to provide a central compartment adjacent to a first side compartment and a second side compartment on respective sides, the capsule being formed of two water-soluble films sealed together to form a sealing mesh surrounding each compartment, the sealing mesh being substantially within a sealing plane, wherein each of the three compartments extends above and also suitably below the sealing plane.

[0026] Figure 4 A capsule according to the present invention is shown. Figure 4 The coordinate axes in the x, y, and z directions are shown to help explain the relative arrangement of the capsule's features. In fact, this is discussed here... Figure 4 To aid in understanding the subsequent discussion of the shape and configuration of the three-compartment capsule of the present invention. Figure 4 Capsule 401 includes a left compartment 402, a central compartment 403, and a right compartment 404. The three compartments are arranged side by side on an imaginary line extending across the width (x-direction) of the capsule. Each of the three compartments 402, 403, and 404 is elongated because it has a length (y-direction) greater than its width (x-direction). The major axis of each compartment lies in the y-direction.

[0027] The sealing mesh 405 is formed during capsule manufacturing by fusing (e.g., thermoforming) first and second water-soluble films. The sealing mesh 405 includes an annular sealing mesh or skirt 406 located in the xy-plane (and referred to herein as the sealing plane). The sealing mesh 405 also includes two inner sealing meshes 407, 408. These also extend downward in the sealing plane along the capsule's longitudinal direction (y-direction) to define the side edges 409, 410 of the central compartment 403 and the inward side edges 411, 412 of the side compartments 402, 404. Thus, the left side compartment 402 and the central compartment 403 are connected and separated from each other by the first inner sealing mesh 407; and the right side compartment 404 and the central compartment 403 are connected and separated from each other by the second inner sealing mesh 408.

[0028] Each of the three compartments 402, 403, and 404 extends similarly above and below the sealing plane (in the z-direction).

[0029] Therefore, the width of a feature mentioned herein (e.g., the width of a compartment) refers to a dimension in the x-direction, which is parallel to the sealing (x, y) plane. The length of a feature mentioned herein (e.g., the length of a compartment, or the length direction or major axis of a compartment) refers to a dimension in the y-direction. The depth of a feature mentioned herein, or the extension of a feature “above” or “below”, refers to a dimension in the z-direction, i.e., perpendicular to the sealing plane (xy plane). Of course, the terms “above,” “below,” “upward,” “downward,” etc., are relative rather than absolute terms, and they are used accordingly herein and are helpful for understanding.

[0030] In the first aspect corresponding to the first scheme, the central compartment is significantly larger than each of the first and second side compartments.

[0031] In a second aspect corresponding to the second scheme, the sealing mesh includes a generally annular sealing mesh defining the periphery of the capsule, and two inner sealing meshes (each extending through the capsule), each inner sealing mesh for connecting the central compartment with an adjacent side compartment and for separating the contents of the central compartment and the adjacent side compartment, wherein each inner sealing mesh has a substantially continuously curved shape.

[0032] In the third aspect corresponding to the third scheme, the sealing mesh comprises a generally annular sealing mesh that defines the outward-facing edge of each of the three compartments, wherein the profile of the outward-facing edge of each of the three compartments is substantially continuously curved. That is, each outward-facing edge is curved substantially over its entire length.

[0033] In the fourth aspect corresponding to the fourth scheme, the central compartment has a recessed portion in each edge facing the side compartments, and each side compartment has a protruding portion, wherein the protruding portion of each side compartment is received in the corresponding recessed portion of the central compartment.

[0034] In the fifth aspect corresponding to the fifth scheme, the sealing mesh comprises a generally annular sealing mesh or skirt, wherein the outward-facing edge of the annular sealing mesh is hexagonal. The shape of the outward-facing edge of the annular sealing mesh generally corresponds to a cutting pattern used to separate the capsule before ejection from the mold, and in this case, the cutting pattern is hexagonal.

[0035] In the sixth aspect corresponding to the sixth scheme, the central compartment is substantially elongated, the outer edge of the capsule has a hexagonal shape, and the central compartment is arranged such that its long axis is perpendicular to a pair of opposite sides of the hexagon.

[0036] In the seventh aspect corresponding to the seventh embodiment, a method for manufacturing a capsule as described herein is provided, wherein the filling of one of the compartments (appropriately the central compartment) begins before the filling of the other compartments.

[0037] In an eighth aspect corresponding to the eighth embodiment, a method for manufacturing a capsule as described herein is provided, wherein a mold assembly includes at least first and second rows of molds, and each mold includes a cavity, a water-soluble film disposed in each cavity to provide a recess for receiving a liquid composition, wherein the mold assembly moves along a processing direction to pass under a filling station and the filling station dispenses the liquid composition into the recesses of the moving molds, wherein at least one filling device of the filling station fills the recesses in the first row of molds, moves substantially perpendicular to the processing direction, and then fills the recesses in the second row of molds.

[0038] In the ninth aspect, which relates to some of the previous aspects, the central compartment has an S-shaped form, and each side compartment is designed to conform to an S-shaped recess and is at least partially located within that recess. Invention Details

[0040] volume

[0041] In some embodiments, the central compartment has a volume significantly larger than each of the first and second side compartments. The volume is conveniently calculated based on the volume of the corresponding cavity in the mold used to manufacture the capsule. The volume includes the liquid composition and any air or other gases that may be present (e.g., headspace from the filling process).

[0042] In some embodiments, the ratio of the central compartment volume to each of the first and second side compartment volumes is ≥1.5. In some embodiments, the ratio is ≥2, ≥2.5, or ≥3:1. In some embodiments, the ratio is ≤5, ≤4.5, ≤4, or ≤3.5. In some embodiments, the ratio is approximately 3.

[0043] In some embodiments, the ratio of the central compartment volume to the combined volume of the first and second side compartments is ≥1.2. In some embodiments, the ratio is ≥1.3, ≥1.4, or ≥1.5. In some embodiments, the ratio is ≤3, ≤2.5, ≤2, or ≤1.8. In one embodiment, the ratio is approximately 1.5.

[0044] In some embodiments, the central compartment volume is ≥10 ml, preferably ≥12 ml, ≥14 ml, ≥16 ml, or ≥17 ml. In some embodiments, the central compartment volume is ≤30 ml, ≤26 ml, ≤24 ml, ≤22 ml, ≤20 ml, or ≤19 ml. In some embodiments, the central compartment volume is in the range of 10 to 22 ml, 12 to 22 ml, 14 to 20 ml, 16 to 20 ml, or 17 to 19 ml.

[0045] In some embodiments, the volumes of each of the first and second side compartments are independently selected from ≥3 ml, ≥4 ml, ≥5 ml, and ≥6 ml. In some embodiments, the volumes of each of the first and second side compartments are independently selected from ≤12 ml, ≤10 ml, ≤9 ml, ≤8 ml, and ≤7 ml. In some embodiments, the volumes of each of the first and second side compartments are independently selected from the range of 4 to 10 ml, 4 to 9 ml, 4 to 8 ml, 5 to 8 ml, and 5 to 7 ml.

[0046] In some embodiments, the volume of the first side compartment is substantially the same as the volume of the second side compartment. In such embodiments, the volume of each side compartment is suitably in the range of 4 to 9 ml, or 5 to 7 ml.

[0047] In some embodiments, the total compartment volume (the total volume of all three compartments) is ≥10 ml, ≥15 ml, ≥20 ml, ≥22 ml, ≥24 ml, ≥26 ml, or ≥28 ml. In some embodiments, the total compartment volume (the total volume of all three compartments) is ≤40 ml, ≤38 ml, ≤36 ml, ≤34 ml, ≤32 ml, ≤30 ml, ≤28 ml, ≤26 ml, or ≤25 ml. In some embodiments, the total compartment volume (the total volume of all three compartments) is in the range of 15 to 36 ml, 20 to 36 ml, 22 to 36 ml, 24 to 34 ml, 28 to 32 ml, or 22 to 26 ml.

[0048] In some implementations, the central compartment volume is in the range of 16 to 20 ml; the first and second compartment volumes are substantially the same and in the range of 4 to 9 ml.

[0049] Regarding the degree of filling (fill level), in some embodiments, the amount of liquid cleaning agent composition as a percentage of the total volume of any given compartment is at least 60%, suitably at least 70%, 80% or 90%, preferably at least 92%, 94%, 96% or 98%. Suitably, the percentage is substantially the same for all three compartments.

[0050] Size and shape

[0051] In some embodiments, each of the three compartments extends above the sealing plane such that the portion of each compartment furthest from the sealing plane in a direction perpendicular to the sealing plane is Zn, where n=1 represents the first side compartment, n=2 represents the central compartment, and n=3 represents the second side compartment, where Z2>Z1 and Z2>Z3. In some embodiments, Z2≥1.1×Z1 and ≥1.1×Z3; Z2≥1.2×Z1 and ≥1.2×Z3; Z2≥1.3×Z1 and ≥1.3×Z3; Z2≥1.4×Z1 and ≥1.4×Z3; or Z2≥1.5×Z1 and ≥1.5×Z3.

[0052] In some embodiments, as measured in a direction perpendicular to the sealing plane, each compartment extends ≥5 mm, ≥6 mm, ≥7 mm, ≥8 mm, or ≥9 mm above the sealing plane, and suitably ≤30 mm, ≤25 mm, or ≤22 mm. In some embodiments, each compartment extends ≥5 mm, ≥6 mm, ≥7 mm, ≥8 mm, or ≥9 mm below the sealing plane, and suitably ≤30 mm, ≤25 mm, or ≤22 mm. As stated elsewhere, the terms “above” and “below” are relative rather than absolute terms and are used accordingly; here they can be understood to refer to the relative direction perpendicular to the sealing plane.

[0053] In the case of a central compartment, in some embodiments, the central compartment extends ≥9mm, ≥10mm, ≥11mm, ≥12mm, ≥14mm or ≥16mm above the sealing plane, but suitably ≤30mm, ≤25mm or ≤22mm; and suitably ≥9mm, ≥10mm, ≥11mm, ≥12mm, ≥14mm or ≥16mm below the sealing plane, but suitably ≤30mm, ≤25mm or ≤22mm.

[0054] In some embodiments, the first and second side compartments each extend at least 5 mm above and below the sealing plane, and the central compartment extends at least 10 mm above and below the sealing plane.

[0055] In some implementations, each compartment is substantially symmetrical about the sealing plane.

[0056] In some embodiments, the first side compartment has substantially the same shape as the second side compartment. The orientation of the shape of the first side compartment may be the same as or different from the orientation of the shape of the second side compartment. In some embodiments, the first and second compartments have substantially the same shape but different orientations, such that the shape of the first side compartment is reversed relative to the shape of the second side compartment.

[0057] In some embodiments, the capsule has a maximum linear dimension ≥40 mm, suitably ≥50 mm, ≥60 mm, ≥70 mm, or ≥75 mm. In some embodiments, the maximum linear dimension is ≤100 mm, suitably ≤90 mm, ≤85 mm, or ≤80 mm. For example, in embodiments where the capsule has a hexagonal shape, the maximum linear dimension corresponds to the distance between opposite vertices of the hexagon.

[0058] In some implementations, the maximum linear dimension of the capsule lies in the sealing plane, which appropriately corresponds to the diameter of the capsule.

[0059] Regarding the dimensions of the compartments, in some embodiments, each compartment has a maximum linear dimension independently selected from ≥20mm, ≥25mm, ≥30mm, and ≥35mm. In some embodiments, each compartment has a maximum linear dimension independently selected from ≤85mm, ≤80mm, ≤75mm, ≤70mm, ≤68mm, and ≤66mm.

[0060] Side compartment

[0061] In some embodiments, at least one, preferably two, side compartments have bulbous end portions and conical end portions.

[0062] In an embodiment where the two side compartments have the bulbous and conical end portions, the side compartments are suitably opposite to each other, such that the bulbous end portion of the first side compartment is located adjacent to one end portion of the central compartment, and the bulbous end portion of the second side compartment is located adjacent to the opposite end portion of the central compartment.

[0063] In some embodiments, each of the first and second side compartments has a teardrop shape in cross-section of the sealing plane (i.e., defined by an annular sealing mesh and an inner sealing mesh). Suitably, the teardrop shape of the first side compartment is reversed relative to the teardrop shape of the second side compartment.

[0064] In some implementations, the first and / or second side compartments have a maximum linear dimension of ≤55mm, ≤50mm, ≤48mm, or ≤46mm. Typically, the maximum linear dimension is the maximum linear dimension in the sealing plane, for example, the major axis of a teardrop shape. Appropriately, this corresponds to the length (y-direction) of the side compartment.

[0065] Central compartment

[0066] In some embodiments, the central compartment has first and second relatively wide end regions (appropriately earth root-like end regions), and a relatively narrow central region connecting the relatively wide end regions to each other.

[0067] In some embodiments, when viewed from the side, in a cross-section perpendicular to the sealing plane, the central compartment has a bulbous end region and a relatively narrow central region interconnected with the bulbous end region.

[0068] In some embodiments, when viewed in a plane, in a cross-section within the sealing plane, the central compartment has a bulbous end region and a relatively narrow central region interconnected with the bulbous end region.

[0069] In some embodiments, the width (i.e., within the sealing plane) and depth (i.e., perpendicular to the sealing plane) of each of the bulb-shaped end regions are greater than the width and depth of the central region, respectively.

[0070] This allows for a dumbbell-shaped configuration of the central compartment. This provides a pleasant tactile and visual experience for the consumer. Compared to, for example, a simple rectangular compartment (where the maximum depth is located at a single point in the central region of the compartment), it allows for a slightly reduced maximum depth (in the z-direction) of the capsule. This configuration can help provide curved capsules with surprisingly modest dimensions. When offered in consumer packaging, this, in turn, can help provide a higher capsule packing density; and thus offer relevant advantages in terms of packaging and transportation costs as well as energy requirements.

[0071] It also serves to provide a relatively deep (z-direction) area to the edges / periphery of the capsule, which is not possible with conventional configurations. This provides stability to the capsule when placed on a horizontal surface, such as when temporarily placed on a kitchen or bathroom counter, or at the bottom of a container containing the capsule. Specifically, the bulbous end of the central compartment prevents or reduces the "wobbling" associated with conventional pillow-shaped configurations, which tend to tip over or tilt when placed on a flat, horizontal surface. On the other hand, conventional configurations with lower fill power and / or more mechanical flexibility can be compressed against / conform to the surface under their own weight, making them more likely to stick, especially if the surface is wet. This, in turn, increases the likelihood of breakage. Even without breakage, the user may feel stickiness or resistance when removing the capsule from the surface. A related issue mentioned herein is that film residue may remain on clothing due to the increased difficulty in dissolving the adhesive film and the capsule sticking to clothing. Providing multiple bonding sites (which in some embodiments correspond to the bulbous area) reduces the likelihood of adhesion to the surface.

[0072] The setting of bulbous end regions can improve the firmness and fullness of the capsule, such as greater stretch and filling volume due to the application of the water-soluble film at those end (peripheral) regions.

[0073] It also provides a larger surface area for interaction with water in the washing machine. In other words, simply put, the composition in any of the three compartments is not far from the water. By selectively positioning the composition on the outside or periphery, less composition is "embedded" in the center of the capsule. This, in turn, facilitates the rapid dissolution and / or dispersion of both the water-soluble film and the liquid detergent composition.

[0074] Regarding the extent to which the bulbous end region is deeper (in the z-direction) than the central region, in some embodiments, the distance by which the bulbous end portion extends above and / or below the sealing plane (e.g., measured perpendicular to the sealing plane) is at least 10%, 20%, or 30% greater than the corresponding distance of the central region. In absolute terms, in some embodiments, the distance of one or each bulbous end portion is at least 1 mm, at least 2 mm, or at least 3 mm greater than the corresponding distance of the central region.

[0075] Regarding the extent to which the bulbous end region is wider (in the x-direction) than the central region, in some embodiments, the width of each bulbous end portion, as measured in the sealing plane, is at least 10%, 20%, or 30% greater than the width of the central region. In absolute terms, in some embodiments, each bulbous end portion is at least 1 mm, at least 2 mm, or at least 3 mm wider than the central region.

[0076] Appropriately, the bulbous region is substantially the same depth or deeper (in the z-direction) than the side compartments. That is, it is substantially the same distance or greater than the distance each side compartment extends from the sealing plane in the direction perpendicular to the sealing plane.

[0077] In the case of a dumbbell-shaped configuration in the sealing plane, this configuration provides recesses formed in the opposite sides of the central compartment, which accommodate adjacent side compartments, particularly the bulbous regions of the side compartments. In some embodiments, the recesses on one side of the central compartment are offset relative to the recesses on the opposite side of the central compartment. This staggering or offset of the recesses allows for a corresponding staggering or offset of the bulbous portions of the side compartments. This, in turn, is used to position the liquid composition in a manner that can promote faster mixing of the liquid composition in use.

[0078] A dumbbell-like configuration in both depth and width—a bulbous end portion and a narrower, constricted central portion—can provide a saddle-shaped area for the central compartment on one or both of the upper and lower surfaces of the capsule. Similarly, this can contribute to a more rounded and smoother profile, thus providing favorable visual and tactile signals.

[0079] In practice, it is generally preferred that the central compartment has a shape in the sealing plane where its respective side edges define recessed areas. Suitably, the corresponding side edges define both recessed and protruding areas.

[0080] The central compartment may be S-shaped, and particularly has an S-shaped cross-section in the sealing plane. The S-shape provides recessed areas or recesses on each side of the "S" and corresponding protruding areas on the directly opposite sides of the "S". In some embodiments, the S-shape accommodates at least a portion of a corresponding side compartment in each of its two concave areas. Suitably, each side compartment has a bulbous portion as described herein, and it is this bulbous portion that is accommodated in the recessed area or recess. In practice, suitably, each of the first and second side compartments has a protruding portion whose curvature substantially matches the curvature of the recessed portion of the central compartment.

[0081] Alternatively or additionally, the protruding portion of the central compartment (appropriately S-shaped) may accommodate corresponding curved portions of one or both side portions. In particular, when the side compartments include tapered portions as described herein (appropriately including (tapered) pointed end portions), the tapered portions adapt to the protruding portion of the central compartment. Appropriately, the curvature of the tapered portions substantially conforms to the curvature of the protruding portion of the central compartment.

[0082] In some embodiments, each side compartment has a recessed portion typically formed by a tapered portion, and the protruding portion of the central compartment is accommodated by the recessed portion of the side compartment.

[0083] In some embodiments, the curvature level of the recessed or protruding portion, as described herein, is such that the radius of curvature of the recessed or protruding portion is in the range of 10 mm to 25 mm or 12 mm to 22 mm.

[0084] This configuration, along with the function of the central compartment at least partially surrounding or enclosing one or two side compartments (and vice versa), facilitates the mixing of the three liquid compositions from each of the central and side compartments. This configuration also visually and operationally communicates to the consumer that the three compositions are positioned relative to each other to aid in mixing.

[0085] Providing both curved sealing meshes and bulbous end regions in adjacent central and side compartments can further contribute to anti-sagging. Furthermore, the close proximity of the bulbous, highly stretched, and filled regions of adjacent central and side compartments can also impart greater resistance to sagging. Additionally, the anti-sagging effect can be further enhanced by offsetting the two recesses (e.g., formed as recessed portions) on the respective opposite sides of the central compartment to be located in the respective opposite end regions of the central compartment (i.e., provided at a position offset from the imaginary line extending across the capsule).

[0086] Three compartments

[0087] In some implementations, the outward-facing edges of each of the three compartments are curved, appropriately and substantially continuously curved.

[0088] In some embodiments, the curvature and arrangement of the outward-facing edges define an approximate imaginary circle. In some embodiments, at least a majority of the curvature of each outward-facing edge of each compartment substantially conforms to the curvature of the imaginary circle.

[0089] The side-by-side configuration described herein facilitates the rapid delivery of detergent containing all three components of the liquid detergent composition in a washing machine. Specifically, when dirty clothes are laid roughly flat on the drum of, for example, a washing machine, the rise in water level caused by the (partial) filling of the drum with water at the start of the wash cycle can cause all three components of the liquid composition to dissolve and / or diffuse simultaneously from their respective compartments. Even if water is introduced into the drum in other ways, it is possible that all three compartments are presented to the currently introduced water, causing the dissolution and diffusion of all three compartments and their contents to begin at almost the same time. Similarly, for those wash cycles in which the drum moves during the filling phase to agitate the clothes, the capsule, even when tumbling, will present all three compartments to the water.

[0090] A further advantage of the side-by-side configuration described herein is that only two water-soluble films are required to provide three compartments. Furthermore, for each of the three compartments, a significantly larger surface area is provided, enabling faster dissolution in use compared to, for example, capsules and / or compartments requiring three layers of water-soluble films with common walls or significant surfaces (walls or surfaces that are water-inaccessible, resulting in slower and / or uneven dissolution and / or diffusion of the composition and wall materials).

[0091] In some implementations, the ratio of the area of ​​the central compartment to the side compartments in the sealing plane is from 10:1 to 1:1, from 5:1 to 1:1, from 3:1 to 1:1, from 3:1 to 1.2:1, from 3:1 to 1.4:1, or from 2.5:1 to 1.5:1.

[0092] Water-soluble film

[0093] As described herein, the capsule is manufactured using two water-soluble films: a first film is applied to a cavity in a mold to form a recess, the recess is filled with a liquid composition, and a second film is applied to the filled recess to seal the liquid composition and thereby form a compartment.

[0094] In some implementations, the thickness of the first film (before thermoforming) is 50 to 150 micrometers, 60 to 120 micrometers, or 80 to 100 micrometers. After capsule manufacturing, the average thickness of the first film is typically 30 to 90 micrometers or 40 to 80 micrometers.

[0095] The second film is typically of a similar type to that used for the first film, but slightly thinner. Therefore, in some embodiments, the second film is thinner than the first film. In some embodiments, the ratio of the thickness of the first film to the thickness of the second film is 1:1 to 2:1.

[0096] In some implementations, the thickness of the second film (before thermoforming) is 20 to 100 micrometers, 25 to 80 micrometers, or 30 to 60 micrometers.

[0097] In some embodiments, the water-soluble film comprises polyvinyl alcohol or a polyvinyl alcohol derivative. This film material can be produced, for example, by blow molding or casting.

[0098] Water-soluble films may also contain plasticizers, defoamers, antioxidants, surfactants, fragrances, etc.

[0099] Suitable films include Monosol M4045 and Monosol M8045 (75, 82, 88 and 90 micrometers) and Aicelle PT films (PT 75 and 90).

[0100] Sealing mesh

[0101] In some implementations, the sealing mesh includes a generally annular sealing mesh surrounding all three compartments, and two inner sealing meshes (each extending through the capsule), each inner mesh serving to connect and separate the central compartment from the adjacent side compartments.

[0102] Skirt / Ring Sealing Mesh

[0103] In some implementations, the annular sealing mesh or skirt has a diameter of ≤1500 mm. 2 ≤1400mm 2 ≤1300mm 2 ≤1200mm 2 ≤1100mm 2 or ≤1000mm 2 The area of ​​the skirt area (also known as the flange area) is ideal for the reasons described in this article: to reduce waste and the likelihood of unwanted residue, as well as to improve the consumer's perceived and operational experience.

[0104] In some embodiments, the maximum width of the skirt is ≤12mm, ≤10mm, ≤9mm, ≤8mm, or ≤7mm. At any location on the periphery of the capsule, the width of the annular sealing mesh is the distance between the outermost edge of the compartment defining the inner edge of the annular mesh at said location and the outermost edge of the annular mesh at said location, measured radially along an imaginary line extending from the center of the capsule in the sealing plane to said outermost edge.

[0105] While a narrower skirt is required for aesthetic and performance reasons, it is important to provide a robust seal. Therefore, in some implementations, the maximum width of the annular sealing mesh is ≥1mm, ≥2mm, or ≥3mm.

[0106] In embodiments where the outward-facing edge of the annular sealing mesh is hexagonal, the width of the annular sealing mesh along at least the main portion of each side of the hexagon is suitably ≤7 mm, ≤6 mm, ≤5 mm, or ≤4 mm. Suitably, the main portion of each side of the hexagon is at least 55%, preferably at least 60%, of the length of the hexagonal side. In this way, the width of the annular sealing mesh (skirt) surrounding most of the periphery of the capsule can be narrow, further contributing to providing consumers with pleasing tactile and visual cues and minimizing the amount of water-soluble film used.

[0107] In practice, more generally and regardless of the shape of the outward-facing edge of the annular sealing mesh, preferably for the main portion of the capsule periphery, the width of the annular sealing mesh is ≤7 mm, ≤6 mm, ≤5 mm, or ≤4 mm. Suitably, the main portion of the capsule periphery is at least 55% of the circumference, preferably at least 60%.

[0108] In some implementations, the outward-facing edge of the annular sealing mesh is hexagonal. This hexagon can be regular or irregular. Suitablely, the hexagon is a regular hexagon (all sides have equal length).

[0109] The annular sealing mesh or skirt defines the perimeter of the capsule, thus giving the capsule a hexagonal shape.

[0110] In some embodiments, the side length of each side of the hexagon is ≥20mm, ≥25mm, ≥28mm, ≥30mm, ≥32mm, ≥34mm, ≥35mm, or ≥37mm. In some embodiments, the side length of each side of the hexagon is ≤50mm, ≤45mm, ≤43mm, ≤41mm, or ≤40mm. In some embodiments, the side length of each side is in the range of 30mm to 45mm, 32mm to 42mm, or 35mm to 40mm.

[0111] As mentioned above, suitably, the hexagon is a regular hexagon, and in some embodiments, the side length of the regular hexagon is in the range of 37mm to 42mm, for example, about 39mm.

[0112] Other shapes were also envisioned, such as squares, circles, and ovals.

[0113] Internal sealing mesh

[0114] In some embodiments, at least 90% of the length of each inner sealing mesh is curved, preferably at least 95%, and more preferably substantially all of each inner sealing mesh is curved. The length of each inner sealing mesh is measured between the respective endpoints where the inner sealing mesh joins (becomes) the annular sealing mesh at the “top” and “bottom” of the capsule.

[0115] In some implementations, each internal sealing mesh has a substantially continuously curved shape within the sealing plane.

[0116] In some implementations, the internal sealing mesh has virtually no straight sections.

[0117] In some implementations, at least a portion of each internal mesh has a curved profile with a radius of curvature ranging from 10 mm to 25 mm or from 12 mm to 22 mm.

[0118] In some embodiments, the width of each internal sealing mesh (i.e., within the sealing plane) is substantially constant. In some embodiments, the width of each internal sealing mesh is ≤3 mm or ≤2 mm.

[0119] In some embodiments, the spacing between the two inner sealing meshes is such that a first spacing is present at the respective outer (suitably bulbous) ends of the central compartment, and a second spacing is present at the central (e.g., relatively narrow necked) region of the central compartment, wherein the first spacing or each of the first spacings is greater than the second spacing. That is, suitably, the spacing between the two inner sealing meshes decreases as the inner sealing meshes traverse the capsule from an outer (starting) position toward a radially inward position approximately at the midpoint of the length of the inner sealing meshes, at which point the inner sealing meshes extend from the annular sealing mesh. Suitably, this reduction in the mesh spacing contributes to an anti-sagging effect.

[0120] In some embodiments, the degree of variation in the spacing between the inner sealing meshes is ≥10%, ≥15%, ≥20%, ≥25%, or ≥30%. A 10% value represents a 10% reduction compared to the first (outer end) spacing; for example, a 30mm spacing at the outer end of the central partition shrinks to 27mm at the midpoint of the inner sealing mesh. In absolute terms, the variation in the spacing between the inner sealing meshes is appropriately within the range of 1 to 15mm, 1 to 12mm, 2 to 12mm, 4 to 12mm, 5 to 12mm, 6 to 12mm, or 8 to 12mm.

[0121] rotational symmetry

[0122] In some embodiments, the capsule has approximately rotational symmetry (point symmetry), suitably second-order rotational symmetry, rotating in the first (sealing plane). Suitably, the origin is the center point of the capsule in the sealing plane. Thus, in some embodiments, rotating the capsule 180 degrees about its center point will cause the rotating compartment to overlap the rotating front compartment. This is a characteristic of the convex and concave features of the preferred opposite construction of the reverse side compartment and the central compartment.

[0123] This can also help consumers have a positive feeling about the capsule and / or eliminate any notion of the “correct position”, since the capsule looks the same when viewed from different directions.

[0124] In some embodiments, the capsule has no plane of symmetry (mirror or reflective symmetry) other than the sealing plane. In particular, as can be clearly seen from the discussion herein regarding the preferred configurations of the central and side compartments, the capsule appropriately lacks a plane of symmetry in a plane perpendicular to the sealing plane.

[0125] Embedded Qualification

[0126] In some implementations, the footprint of the capsule, defined by the outer edge of the annular sealing mesh, can be tessellated. This avoids waste of water-soluble film during capsule production.

[0127] In some implementations, the capsule has a 6-sided (i.e., hexagonal) shape. A hexagon can be approximated as a regular hexagon (all sides are approximately equal in length; all interior angles are approximately equal).

[0128] The embedding pattern relates to the method of manufacturing the capsule, and particularly to the efficiency of the method, at least in terms of the use of materials.

[0129] The inventors have discovered that the hexagonal shape offers an excellent balance between production efficiency, consumer experience, and the rapid and complete dissolution of water-soluble films during use. Regarding production efficiency, at least material waste and the relative complexity and reliability of the cutting table are relevant factors.

[0130] In this respect, as mentioned above, commercially available capsules—including “stacked” 3-film capsules and 2-pickled film capsules—have square or rectangular footprints (cutting patterns), which is effective in avoiding waste during manufacturing because the squares or rectangles can be easily arranged into a two-dimensional array, for example on a mold tray, or on a continuously moving surface with a mold array, such as the surface of a rotating drum. The cutting table is linear because only one set of vertical cuts and one set of horizontal cuts are needed.

[0131] However, even if the compartments of such rectangular-footprint capsules are circular, consumers find the rectangular footprint unattractive. As discussed here, this may cause some consumers to avoid using the capsules, thus prolonging issues of spillage and incorrect dosage associated with user-dispensed compositions. In such capsules, the protruding corners of the skirt are not only not unattractive, but are also relatively large, making them less likely to dissolve completely, especially since they are more likely to stick to clothing in the initial stages of a wash cycle, further increasing the likelihood of incomplete dissolution.

[0132] To try and improve the effect of the rectangle, the corners can be rounded. However, this increases the complexity of the cutting process and also produces waste in the form of small scraps.

[0133] On the other hand, capsules with round footprints are already available and are considered attractive and suitable by consumers. However, they present problems of considerable cutting complexity and waste.

[0134] The inventors have discovered that the hexagonal shape provides an excellent solution to the seemingly contradictory needs between consumers and the production process. The hexagonal shapes fit together to eliminate waste. The opposing vertices (points) of the hexagons are aligned to form the imaginary top and bottom of the capsule (when the mold is viewed in a plan view; see...). Figure 4 In the case of ), and in which the opposite sides of the hexagons are aligned so as to be at the imaginary top and bottom of the capsule (when the mold is viewed in a plan view; see Figure 4 In the case of ), an embedded qualified bureau is realized.

[0135] Because hexagons have larger interior angles than squares, their vertices are less noticeable to consumers. Furthermore, the larger interior angles make it easier to accommodate compartments. That is, compartments can extend further into the vertices; the vertices provide more usable space. Additionally, the arrangement of six sides softens the overall impression of the capsule and brings it closer to a circular shape.

[0136] In practice, when the capsule is ejected from the mold (e.g., when the vacuum closes so the capsule is no longer forced to conform to the mold's shape), the strict hexagonal shape softens due to the internal forces within the water-soluble film. After the thermoforming process, the film attempts to relax back to its original shape to some extent, which may distort the capsule to the point that it no longer conforms to the mold's shape. This, along with the filling of the compartments, can cause convergence or wrinkling of the annular sealing mesh, particularly making the vertices less noticeable. It also seems less likely for the consumer to discern discontinuous edges. Instead, the consumer perceives the outer edges of the annular sealing mesh as conforming to the shape of the outer edges of the compartments. As described herein, in some embodiments, the shape and configuration of the three compartments are chosen such that the outer edges of these compartments fit together in a generally continuous and approximate manner to define an imaginary circle or ellipse. Thus, the hexagonal footprint combined with the preferred arrangement of the three compartments presents the consumer with a capsule that is perceived as circular or elliptical. Therefore, there is no need to trim or round the vertices, and thus no waste.

[0137] The cutting process is undoubtedly more complex than for a square footprint, but its complexity is much less than that for a circular footprint. Similar to a square footprint, only straight-line cutting is required. Three pairs of cutting blades can be provided, which engage with the periphery of the mold during use to produce the corresponding opposite sides of the hexagonal annular sealing mesh of the capsule. The three pairs of blades can operate simultaneously to produce all six sides substantially simultaneously or sequentially, thus producing the corresponding pairs of sides in turn.

[0138] In some embodiments, the mold is provided with recesses corresponding to the position and orientation of the blade, and thus has the desired hexagonal shape of an annular sealing mesh. In this way, the blade and / or water-soluble film can enter the corresponding recesses in a short distance to effectively cut the water-soluble film and / or prevent the blade from directly impacting the surface of the mold.

[0139] Thermoforming

[0140] Tri-compartment capsules are produced by thermoforming. This process can advantageously include the following steps to form the tri-compartment capsule:

[0141] (a) Place the first water-soluble polyvinyl alcohol film on a mold having multiple sets of cavities, each set comprising three cavities arranged side by side;

[0142] (b) Heating and applying a vacuum to the film to mold the film into the cavity and hold it in place to form three recesses in the film; a first side recess, a central recess, and a second side recess, the central recess being connected to the corresponding side recesses via the film;

[0143] (c) Fill the side recess and the central recess with three different portions of liquid detergent composition, which together form a complete detergent composition;

[0144] (d) A second film is sealed over a first film across the recess to create a three-compartment capsule having first and second side compartments located on opposite sides of a central compartment, such that the central compartment is side-connected to the corresponding first and second side compartments, wherein the three compartments are connected and separated from each other by a continuous sealing mesh.

[0145] (e) Cut between the capsules to form a series of three-compartment capsules, each capsule containing a portion of the cleaning composition in three compartments (one central compartment and two side compartments).

[0146] As discussed herein, the cutting (step (e)) suitably includes cutting according to a hexagonal cutting pattern. In some embodiments, this step includes providing a cutter configured to provide simultaneous or sequential cuts corresponding to each of the six sides of the hexagon. In some embodiments, the cutter has three pairs of parallel blades to achieve cuts on corresponding pairs of opposite sides of the hexagon.

[0147] Sealing can be achieved by any suitable method, such as heat sealing, solvent sealing, or UV sealing. Water sealing is particularly preferred. Water sealing can be achieved by applying moisture to the second film before sealing the second film onto the first film to form a sealed area.

[0148] A preferred thermoforming process uses a rotating roller, on which the forming cavity is mounted. Vacuum thermoforming machines using such rollers are available from Cloud LLC. The capsules according to the invention can also be manufactured by thermoforming on a linear array of cavity segments. Machines suitable for this type of process are available from Hoefliger. The following exemplary description of a centralized rotary process will be appreciated by those skilled in the art, as it can be adapted to a linear array process without inventive effort.

[0149] Liquid cleaning composition

[0150] The liquid cleaning composition can be any type of cleaning composition, where it is desirable to deliver its dosage in a water-soluble capsule. The three-compartment capsule contains three distinct portions of the cleaning composition. All three portions are liquid.

[0151] Suitable cleaning compositions for use in this invention, which can be divided into different components, include those intended for use in laundry (fabric cleaning, softening, and / or treatment) or machine dishwashers. Laundry compositions, particularly laundry cleaning compositions, are preferred.

[0152] A three-compartment capsule contains three distinct parts of a cleaning agent composition, which together constitute the complete cleaning agent composition. This means that each part of the cleaning agent composition is formulated differently in its physical form (e.g., viscosity), composition, or color. Sometimes minor differences between the parts of the cleaning agent composition (e.g., color, fragrance, etc.) are sufficient. However, generally, visible differences are advantageous.

[0153] The central compartment may contain chelating agents, enzymes, bleaching catalysts, fragrances, detergents, etc.

[0154] The central and side compartments of the three-compartment capsule will be filled with liquid. "Filled" means that the compartments contain liquid and may also contain air bubbles. Due to their compressibility, the presence of air bubbles provides some protection against compartment compression. The gas is preferably air trapped in the compartments during manufacturing.

[0155] As described in this article, the liquid-containing compartments are separated by a sealing mesh.

[0156] The preferred liquid has a viscosity in the range of 100 to 1000 cPs.

[0157] The liquid composition in each compartment preferably has less than 10 wt%, more preferably from 0.5 to 9 wt% water, and most preferably from 1 to 7 wt% low water content.

[0158] surfactants

[0159] The cleaning composition may contain one or more organic surfactants. Many suitable cleaning active compounds are available and well described in the literature, for example, Schwartz, Perry, and Berch, “Surface-Active Agents and Detergents,” Volumes I and II. The organic surfactant may be anionic (soap or non-soap), cationic, amphoteric, amphoteric, nonionic surfactants, or mixtures of two or more of these. Preferred organic surfactants are soaps, synthetic non-soap anionic and nonionic compounds, optionally mixtures with amphoteric surfactants.

[0160] The amount of anionic surfactant may be from 0.5 to 50 wt% of the detergent composition, preferably from 2 wt% or 4 wt% to a maximum of 30 wt% or 40 wt%. Suitable examples include alkylbenzene sulfonates, particularly linear alkylbenzene sulfonates with alkyl chain lengths of C5-C15; olefin sulfonates; alkane sulfonates; dialkyl sulfosuccinates; and fatty acid ester sulfonates.

[0161] Suitable nonionic surfactant compounds particularly include reaction products of compounds having hydrophobic groups and reactive hydrogen atoms (e.g., aliphatic alcohols, acids, amides, or alkylphenols) with alkyl oxides (especially ethylene oxide). Specific nonionic surfactant compounds are alkyl (C8-22)phenol-ethylene oxide condensates, condensation products of straight-chain or branched aliphatic C8-20 primary or secondary alcohols with ethylene oxide, and products obtained by condensation of ethylene oxide with the reaction products of propylene oxide and ethylenediamine.

[0162] In fabric washing detergent compositions, these organic surfactants preferably comprise 5-50 wt% of the detergent composition. In machine washing compositions, organic surfactants may comprise 0.5 to 8 wt% of the detergent composition, and are preferably composed of a single nonionic surfactant or a mixture with anionic surfactants.

[0163] Detergent builders and chelating agents

[0164] Detergent compositions may contain so-called detergent builders, which are used to remove or isolate calcium and / or magnesium ions in water. Soluble builders may be added to the liquid composition. For example, sodium citrate or soluble chelating agents, such as Dequest 2066, may also help stabilize the liquid.

[0165] The detergent builder or chelating agent material is preferably completely soluble to eliminate the possibility of unwanted and unsightly residues on the fabric. Therefore, alkali metal aluminum silicates are not advantageous.

[0166] Non-phosphorus water-soluble cleaning builders can be organic or inorganic. Possible inorganic builders include alkali metal (typically sodium) carbonates; while organic builders include polycarboxylic acid polymers such as polyacrylates, acrylic / maleic acid copolymers and phosphonates, monomeric polycarboxylic acid esters such as citrates, gluconates, oxydisuccinates, glyceryl mono, di, and trisuccinates, carboxymethyloxysuccinates, carboxymethoxymalonates, pyridine dicarboxylic acids, and hydroxyethyliminodiacetic acids. Electrolytes such as sodium carbonate are not preferred due to their inhibitory effect on the dissolution of polyvinyl alcohol.

[0167] bleaching system

[0168] The cleaning agent composition may contain a bleaching system. This is preferably composed of an air bleaching catalyst. For example, the catalyst is a ligand of formula (I) complexed with a transition metal selected from Fe(II) and Fe(III).

[0169]

[0170] R1 and R2 are independently selected from:

[0171] C1-C4 alkyl,

[0172] C6-C10-aryl, and

[0173] A heteroatom-containing group capable of coordinating with a transition metal, wherein at least one of R1 and R2 is a heteroatom-containing group; preferably, at least one of R1 or R2 is pyridin-2-ylmethyl. More preferably, the catalyst is a catalyst wherein R1 is pyridin-2-ylmethyl. Most preferably, R1 is pyridin-2-ylmethyl and R2 is methyl;

[0174] R3 and R4 are independently selected from hydrogen, C1-C8 alkyl, C1-C8-alkylene-O-C1-C8-alkyl, C1-C8-alkylene-O-C6-C10-aryl, C6-C10-aryl, C1-C8-hydroxyalkyl, and -(CH2). n C(O)OR5;

[0175] R5 is independently selected from: hydrogen, C1-C4-alkyl, n is 0 to 4, and mixtures thereof; preferably R3 = R4 = -C(O)OMe, and

[0176] Each R is independently selected from: hydrogen, F, Cl, Br, hydroxyl, C1-C4-alkyl-O-, -NH-CO-H, -NH-CO-C1-C4-alkyl, -NH2, -NH-C1-C4-alkyl, and C1-C4-alkyl; preferably each R is hydrogen.

[0177] X is selected from C=O, -[C(R6)2] y - where Y is 0 to 3, preferably 1, each R6 is independently selected from hydrogen, hydroxyl, C1-C4 alkoxy and C1-C4 alkyl, and preferably X is C=O.

[0178] The most preferred catalyst is ([Fe(N2py3o)Cl]Cl) with structure (II):

[0179]

[0180] Also known as iron salt (1+), chloro[rel-1,5-dimethyl(1R,2S,4R,5S)-9,9-dihydroxy-3-methyl-2,4-di(2-pyridyl-kN)-7-[(2-pyridyl-kN)methyl]-3,7-diazabicyclo[3.3.1]nonane-1,5-dicarboxylic acid-kN3,kN7]-, chloride (1:1), (OC-6-63) [CAS Registry No. 478945-46-9].

[0181] To avoid potential gas release from the components, it is preferable to avoid using peracids or peracids as bleaching agents in the capsules.

[0182] Other optional ingredients

[0183] Decontamination enzymes can be used in the composition.

[0184] The composition may also contain a fluorescent agent (fluorescent brightener), such as Tinopal (trademark) DMS or Tinopal CBS, available from Ciba-Geigy AG, Basel, Switzerland. Tinopal DMS is disodium 4,4'-bis(2-morpholino-4-anilino-s-triazine-6-ylamino)stilbene disulfonate; and Tinopal CBS is disodium 2,2'-bis-(phenylstyryl)disulfonate.

[0185] When organic surfactants are present, it is advantageous to include defoaming materials, especially if the detergent composition is primarily intended for use in front-loading, drum-type automatic washing machines. Soap is a suitable defoamer.

[0186] Other ingredients that may optionally be used in the laundry detergent compositions of the present invention include anti-redeposition agents (such as sodium carboxymethyl cellulose, linear polyvinylpyrrolidone, and cellulose ethers such as methylcellulose and ethyl hydroxyethyl cellulose), fabric softeners, fragrances, and colorants or colored specks.

[0187] Capsule use

[0188] The capsules described herein are suitable for cleaning methods and, appropriately, washing methods. Therefore, another aspect of the invention provides the use of the capsules as described herein in cleaning methods (and, appropriately, washing methods). Suitably, this method includes placing the capsules in the drum of a washing machine before starting the washing cycle.

[0189] Three-compartment capsules are particularly suitable for (fabric) washing machines and dishwashers, as well as other applications. They can also be used for manual laundry and dishwashing operations. In use, the capsules according to the invention are preferably and conveniently placed directly into the liquid to which the detergent solution will be formed or into the area where such liquid will be introduced. The capsules dissolve upon contact with the liquid, thereby releasing the detergent composition from the individual compartments and forming the desired detergent solution.

[0190] One particular advantage of these capsules is that they can be optionally placed in a dispensing drawer, the type found in automatic washing machines, through which water flows. Surprisingly, the capsules have been found to dispense efficiently from such drawers.

[0191] Packaging containing capsules

[0192] The three-compartment capsules described herein can be provided in any suitable packaging, such as a box or other container. Therefore, another aspect of the invention provides packaging comprising a plurality of capsules as described herein.

[0193] Methods for preparing capsules

[0194] The three-compartment capsules described herein can be prepared by any suitable method, and particularly by the methods described herein. Therefore, another aspect of the invention provides a method for preparing the capsules as described herein.

[0195] Capsules obtained by preparation method

[0196] Another aspect of the present invention provides a three-compartment capsule obtained by the method for preparing the capsule as described herein.

[0197] Mold / Cavity Section

[0198] This document describes a mold or cavity segment, characterized by having a cavity configured to provide the three-compartment capsules described herein. Therefore, another aspect of the invention provides a mold or cavity segment for preparing capsules as described herein, characterized in that the cavity of the mold or cavity segment is configured in a shape and configuration to produce the compartments of these capsules.

[0199] In a further aspect, a method for preparing a capsule as described herein or a mold for mounting onto a rotating surface of a rotating cylindrical roller as described herein is provided, wherein the mold includes a set of cavities including a first side cavity, a central cavity, and a second side cavity, the first and second side cavities being located on opposite sides of the central cavity such that the central cavity is side-connected to the respective first and second side cavities, and wherein the mold is hexagonal to allow multiple identical molds to fit together, thereby forming an array of fitted molds.

[0200] In some implementations, the central cavity is substantially elongated, and the long axis of the central cavity is aligned perpendicular to a pair of opposite sides of the hexagon.

[0201] Rollers with an array of hexagonal mold / cavity sections

[0202] As described herein, the hexagonal shape of the capsules and associated mold / cavity segments allows for fitting when arranged on a surface, thereby minimizing waste of the water-soluble film. Therefore, another aspect of the invention provides a rotating cylindrical roller comprising an array of hexagonal molds or cavity segments as described herein.

[0203] In some embodiments, the rotating cylindrical roller has an outer surface that is a rotating surface that rotates in the processing direction during use, wherein the outer surface has an array of molds mounted thereon, each mold having a hexagonal shape, the molds being fitted together such that each hexagonal mold has a pair of opposing sides aligned perpendicular to the processing direction.

[0204] The use of hexagonal cutting pattern in capsule production

[0205] This article describes hexagonal capsules and their production. Therefore, another aspect of the invention provides the use of a hexagonal cutting pattern in the preparation of multi-compartment (suitably three-compartment) capsules.

[0206] Combination of multiple aspects

[0207] This paper describes multiple schemes and aspects that are intended to be combined to achieve improved or cumulative benefits. Therefore, any one aspect can be combined with any other aspect. Similarly, optional features associated with any one aspect can be applied to any other aspect. Attached Figure Description

[0208] The invention will now be further described with reference to the following non-limiting embodiments and the accompanying drawings, wherein:

[0209] Figure 1 It is a two-compartment capsule of existing technology, which is EP1394065. Figure 1 A copy;

[0210] Figure 2 It is a two-compartment capsule of existing technology, which is WO2014 / 202412. Figure 7 Copying;

[0211] Figure 3 This is a schematic diagram of a prior art three-compartment capsule available from El Corte Ingles (Spain).

[0212] Figure 4 This is a perspective view of the capsule according to the present invention;

[0213] Figure 5 This is a top view of the capsule according to the present invention;

[0214] Figure 6 It is along Figure 5 The line II-II in the middle is intercepted Figure 5 A cross-sectional view of the capsule shown;

[0215] Figure 7 yes Figure 6 and 7 The side view of the capsule shown;

[0216] Figure 8 This is a perspective view of a three-cavity mold according to the present invention;

[0217] Figure 9 It is a perspective view of a rotating cylindrical roller, which includes an array of hexagonal molds on the surface;

[0218] Figure 10 yes Figure 9 Alternate perspective view of the rotating cylindrical drum;

[0219] Figure 11 yes Figure 10 Side view of a rotating cylindrical roller;

[0220] Figure 12 yes Figure 8 A schematic diagram of the cavity configuration in the mold; and

[0221] Figure 13 This is a schematic diagram of the optional configurations of the cavity in the mold. Detailed Implementation

[0222] We will now discuss each diagram in turn.

[0223] Discussed Figure 1 , 2 And 3. Similarly, Figure 4 It has already been discussed.

[0224] Now turn to consideration Figures 5 to 7 This illustrates an additional capsule 501 according to the invention, which is related to... Figure 4 The capsules shown are largely the same.

[0225] Capsule 501 comprises three discontinuous compartments 502, 503, and 504, each compartment defining a corresponding substantially liquid-impermeable and hermetically sealed chamber containing a liquid product of corresponding volumes 505, 506, and 507, such as... Figure 6 The crossed shaded areas are schematically represented. The compartments are arranged side by side adjacent to each other in an imaginary row, as described in more detail below. Thus, the central compartment 502 is located between a pair of side compartments 503, 504.

[0226] Understandably, each compartment 502, 503, 504 is defined between an upper and lower PVA film and sealed around its respective periphery by the fusion of the two films. More specifically and referring to... Figure 5It can be noted that the upper and lower film layers are fused together around the three compartments to form a generally annular mesh 508 extending around all compartments 502, 503, and 504, and having hexagonal outer edges 509, as determined by the aforementioned cutting process. The upper and lower film layers are also fused together to form a pair of thin additional meshes 510, which are integrally formed with the annular mesh 508 and extend through the capsule 501 in a spaced-apart relationship. Each additional mesh 510 serves to separate the central compartment 502 from the corresponding side compartments 503, 504.

[0227] As from Figure 5 Most clearly visible is the central compartment 502, which is significantly larger than the two side compartments 503, 504. Therefore, the central compartment 502 can be considered to define the main chamber, while the two side compartments 503, 504 can be considered to define corresponding secondary chambers. It is conceivable that in some embodiments, the two side compartments 503, 504 may have the same size and volume. In the specific embodiment shown, the central compartment 502 is configured to accommodate a larger volume of liquid product 505 than each of the two side compartments 503, 504. In a specific embodiment, it is conceivable that the volume of liquid product 5 provided within the central compartment 502 may be approximately three times larger than the volume of liquid cleaning products 506, 507 provided in each of the side compartments 503, 504. Figure 6 As shown, the corresponding small volumes of air 511, 512, 513 may be trapped inside each compartment 502, 503, 504 during the manufacturing process.

[0228] like Figure 5 As most clearly shown, the central compartment 502 has a slightly S-shaped profile in the plan view, defining a relatively narrow central region 514 that interconnects a pair of relatively wide end regions 515. This relatively narrow central region 514 is defined between a pair of opposing side edges 516 of the central compartment, which are defined by corresponding additional meshes 510. Each side edge 516 is shaped to include a corresponding protrusion 517 and a corresponding recess 518. The recess 518 of each side edge 516 serves to define a recess along each side of the central compartment 502.

[0229] like Figure 5As most clearly shown, each side compartment 503, 504 is shaped to be at least partially located within a corresponding recess defined along the side of the central compartment 502. In this respect, it should be noted that each side compartment 503, 504 has a slightly teardrop-shaped profile in the plan view, thereby defining a relatively bulbous region 519 at one end and a relatively narrow and slightly pointed region 520 at the opposite end. Because the profile of the central compartment 502 is slightly S-shaped as described above, the two side compartments 503, 504 are opposite to each other in order to be positioned within the aforementioned recess, such that the bulbous region 519 of the left side compartment 503 is located adjacent to an end region 515 of the central compartment 502, and the bulbous region 519 of the right side compartment 504 is located adjacent to the opposite end region 515 of the central compartment 502. Thus, as noted, the bulbous region 519 of each side compartment is located adjacent to the recessed region 518 of the corresponding side edge 516 of the central compartment 502, while the opposing pointed region 520 of each side compartment is located adjacent to the protruding region 517 of the corresponding side edge 516 of the central compartment 502. The respective inwardly pointing side edges 521 of the two side compartments 503, 504 are arranged adjacent to and facing the side edge 516 of the central compartment 502, and have substantially the same profile, such that the additional mesh 510 of the fusion material separating each side compartment 503, 504 from the central compartment 502 has a substantially uniform width along its length.

[0230] The central compartment 502 has a pair of outwardly pointing end edges 522 at its opposing ends, and each side compartment 503, 504 has a corresponding outwardly pointing side edge 523. Since the teardrop-shaped side compartments 503, 504 are at least partially located within a recess formed along the side of the S-shaped central compartment 502, it can be understood that the outwardly pointing edges 522, 523 of the compartments fit together in a generally continuous and approximate manner to define an imaginary circle 524, such as... Figure 5 As shown by the dashed line in the image.

[0231] Now turn to consideration Figure 7 Capsule 501 is shown in its side profile. As can be noticed, the vertical dimension of the end region 515 of the central compartment 502 is slightly larger than that of the central region 514, because the end region 515 is naturally larger in volume than the central region 514. Therefore, small recesses or indentations 525 are formed on the top and bottom of the central compartment 502.

[0232] For example Figure 7 As shown, each side compartment 503, 504 ( Figure 3Only one is shown in the figure, which is configured such that the maximum depth in its side profile coincides with its bulbous and therefore largest volume region 519. The side profile depth of each of the side chambers 503 and 504 narrows from the bulbous region to the relatively narrow and slightly pointed end region 520. In a preferred embodiment, it is envisioned that the maximum side profile depth of each side chamber 503 and 504 will be less than or substantially equal to the minimum side profile depth of the central chamber 502, as shown.

[0233] Production

[0234] Figure 8 A mold or cavity segment 601 for thermoforming a first film to manufacture the three-compartment capsule of the present invention is shown. The mold 601 has a hexagonal shape (defined by six equal-length outer sidewalls 605), which allows it to be fitted within an array of hexagons of the same mold. The mold has a first teardrop-shaped side cavity 602, an S-shaped central cavity 603, and a second teardrop-shaped side cavity 604. The second teardrop-shaped cavity 602 is opposite in direction to the first teardrop-shaped cavity 603. Each cavity is provided with a plurality of conduits (not shown) through which a vacuum can be applied.

[0235] Figure 9 Multiple such hexagonal mold / cavity segments 601 are shown, arranged in a regular array on the outside of the rotating cylindrical roller 606. The hexagonal molds are arranged in rows.

[0236] Figure 10 It shows from different perspectives Figure 9 A rotating cylindrical roller 606. Here, array 607 is schematically shown with a simple square. The roller has a horizontal axis 608.

[0237] Figure 11 A rotating cylindrical roller 606 is shown from the side. A first film 609 is supplied from a supply roller (not shown) to a heating roller (not shown), the nominal surface temperature of which is between 90 and 150°C. When the first film used is, for example, Aiello PT90, the temperature of the heating roller is maintained between 120 and 140°C. Immediately after passing through the heating roller, the hot base film is supplied to the cavity section, which is part of the array of such molds surrounding the rotating roller.

[0238] The rotation of the cylinder causes the cavity to reach point 610, ensuring that the heated first film completely covers the cavity section. At point 705, a vacuum is then applied to the cavity section through its conduits. The vacuum is applied to all conduits simultaneously. The vacuum draws the first film into cavities 602, 603, and 604 (as shown). Figure 8(As shown) and hold it there. At this stage, the film typically retains some elasticity. This results in a tighter capsule, which is preferred for continued online handling and durability, as well as for consumer feel.

[0239] Once the cavity is thermoformed and held in place under vacuum, the three compartments 602, 603, and 604 are filled. Filling takes place at the apex of the cylinder 611.

[0240] The liquid composition allocated to each of the three compartments is as follows:

[0241]

[0242]

[0243] In other embodiments, the composition of side compartment #1 is modified to include encapsulated fragrance.

[0244] The composition for side compartment #1 is formulated by using an opaque agent to provide a white, opaque composition. The composition for the central compartment is formulated by providing a suitable dye to provide blue. The composition for side compartment #2 is formulated by providing a suitable dye to provide purple.

[0245] The fill volume is designed to be at least 80% of the full volume. For example, for a 28ml liquid fill, the cavity volume is therefore a maximum of 35ml.

[0246] The volume of side compartment #1 is approximately 6 ml. The volume of side compartment #2 is also approximately 6 ml. The volume of the central compartment is approximately 18 ml.

[0247] The filling of the center compartment 603 begins shortly before the filling of the side compartments. This is because, since the center compartment is longer than the side compartments, it is located just below the filling station at apex 611, preceding the side compartments, and the orientation of the compartment relative to the direction of roller rotation aligns the long axis of the compartment with the direction of roller rotation. Figure 9 As shown. The alignment of the three compartments (strictly speaking, the three cavities that will form the compartments) is also... Figure 12 As shown in the image.

[0248] The filling station provides three filling nozzles, each of which is positioned in the corresponding first side compartment, central compartment, and second side compartment.

[0249] Three filling nozzles are arranged side by side in a straight line, which is perpendicular to the direction of the roller rotation.

[0250] In other arrangements, one of the filling nozzles may step forward or backward from the straight line, for example, by a distance corresponding to the interval between the leading edges of the side compartments and the central compartment along the direction of roller rotation. For example, the central compartment filling nozzle may retract from the two side compartment filling nozzles, such that the leading edge of each of the three compartments arrives substantially simultaneously below its respective filling nozzle.

[0251] In the preferred straight arrangement, the central compartment will reach below its filling nozzle earlier than the individual side compartments. This can be achieved from... Figure 12 The diagram illustrates a direction of travel of 620. Therefore, advantageously, filling of the central compartment can begin before filling of the side compartments. To facilitate this, the central compartment filling nozzle is controlled so that it can operate independently of the side compartment filling nozzles (i.e., dispensing the liquid composition). Optionally or additionally, the operation of the central compartment filling nozzle is controlled so that it begins dispensing at a different time than the side compartment filling nozzles, appropriately before the side compartment filling nozzles and appropriately at a predetermined time prior to the side compartment filling nozzles. Thus, the operation of the central and side compartment nozzles can be synchronized to provide this staggered (temporally) dispensing.

[0252] The device includes the control nozzle control system configured to provide a central compartment filling nozzle.

[0253] Similarly, the duration for which the central compartment filling nozzle is activated (i.e., dispenses the liquid composition) can be controlled to differ from the corresponding activation time (dispensing time) of the side compartment filling nozzle.

[0254] In particular, considering the larger volume and / or greater length of the central compartment compared to the side compartments (aligned with the direction of drum rotation) (see... Figure 12 The central compartment filling nozzle is controlled to have a longer activation (dispensing) time. This allows, for example, the central compartment to be filled for a longer period of time, and thus to hold a larger volume of liquid composition. Therefore, a longer "filling zone" 621 for the central compartment 603 is obtained compared to the filling zone 622 for the side compartments 602, 604. Figure 12 As shown.

[0255] Figure 13 The image shows an optional capsule (mold) arrangement 701, in which three compartments 702, 703, and 704 have... Figure 12 The same general configuration and relationships discussed result in a filling zone 705 for the central compartment 703 being significantly longer than the filling zone 706 for the side compartments 702 and 704. Furthermore, this is achieved through independent control of the filling nozzles.

[0256] As described herein, the filling rate of the central compartment filling nozzle may differ from, for example, be greater than, the filling rate of the side compartment filling nozzle.

[0257] Back Figure 11 Immediately after filling the liquid compartment, the second film 612 is placed on the filling cavity. Just prior to this, the second film is passed through a water bath (not shown). This wets the lower surface of the second film 612, which acts as a mechanism to seal the second film against the first film it contacts, thus forming a sealed area. This second film is of a similar type to the one used for the first film, but slightly thinner, for example, 60 micrometers of Aiello. The sealed area is secured by the pressure applied by the sealing roller at position 613.

[0258] After sealing, the capsule filled at position 614 is cut from the sheet. This is done using a cylindrical cutter 615. Figure 10 This is achieved through horizontal and inclined cuts (as shown in the diagram). Therefore, as... Figure 9 As shown, the horizontal cuts correspond to the opposite horizontal (perpendicular to the direction of travel) sides of the hexagon, and the angled cuts correspond to the other two pairs of opposite sides, as follows: Figure 9 The diagram is tilted. For those implementations that require square or rectangular footprints, the cylindrical cutter 615 can provide only horizontal cuts. If required (e.g., for square cut patterns), vertical cuts are provided by the static blade 616.

Claims

1. A three-compartment water-soluble capsule, each compartment containing a portion of a liquid cleaning agent composition, the three compartments being arranged side-by-side to provide a central compartment side-by-side by a first side compartment and a second side compartment on respective sides, the capsule being formed of two water-soluble films sealed together to form a sealing mesh surrounding each compartment, the sealing mesh being located within a sealing plane, each of the three compartments extending above and below the sealing plane at a maximum equal distance, wherein the sealing mesh includes a generally annular sealing mesh defining the periphery of the capsule, and two inner sealing meshes, each extending through the capsule in a machine direction, each inner sealing mesh for connecting the central compartment to an adjacent side compartment and for separating the contents of the central compartment and the adjacent side compartment, wherein each inner sealing mesh has a continuously curved shape; At least a portion of each inner mesh has a curved profile with a radius of curvature ranging from 12 mm to 22 mm; and The width of each internal sealing mesh is constant, and the width of each internal sealing mesh is ≤3 mm. The spacing between the two inner sealing meshes decreases as the inner sealing mesh traverses the capsule from its outer position (where the spacing is integral with the annular sealing mesh) towards its radially inner position at the midpoint of its length; and The capsule is obtained by a method comprising the following steps: (a) Place the first water-soluble polyvinyl alcohol film on a mold having multiple sets of cavities, each set comprising three cavities arranged side by side; (b) Heating and applying a vacuum to the film to mold the film into the cavity and hold it in place to form three recesses in the film: a first side recess, a central recess, and a second side recess, the central recess being connected to the corresponding side recesses through the film; (c) Fill the side recess and the central recess with three different portions of the liquid cleaning composition, which together form a complete cleaning composition; (d) A second film is sealed across the formed recess onto the first film to create a three-compartment capsule having first and second side compartments located opposite to a central compartment, such that the central compartment is laterally connected to the corresponding first and second side compartments, wherein the three compartments are connected and separated from each other by a continuous sealing mesh; and (e) Cutting between the capsules to form a series of three-compartment capsules, each capsule containing a portion of the cleaning agent composition in the three compartments.

2. The three-compartment water-soluble capsule according to claim 1, wherein the internal sealing mesh has no straight sections.

3. The three-compartment water-soluble capsule according to claim 1, wherein the reduction in the distance between the two inner sealing meshes is in the range of 6 to 12 mm.

4. The three-compartment water-soluble capsule according to any one of the preceding claims, wherein the capsule has second-order rotational symmetry.

Images