Apparatus for preparing unit dose products

Abstract

An apparatus for discretizing a dose of particles to be placed on a water-soluble substrate, the apparatus comprising a hopper feeder that provides a continuous flow of particles on a belt to a discretization unit wherein the discretization unit in funnel form converts the continuous flow of particles from the feeder system into individual doses, where the individual doses are separated from the feeder system. The particle is received through an inlet and the individual dose is delivered through an individual outlet to a substrate that moves synchronously on a belt within the funnel.

Description

Technical Field

[0001] A device for preparing fibrous water-soluble products using discrete units. Background Art

[0002] Water soluble products are gaining more and more attention from consumers. The technology associated with these products continues to advance in providing the desired active agents in the products, allowing consumers to accomplish the tasks they want to accomplish in the manner they want.

[0003] In the consumer goods sector, delivering the right active agent is not enough to satisfy consumers. The appearance and texture of a product is often very important to consumer perception and can arouse the desire to purchase the product.

[0004] Substrates used in unit dose applications have historically been used in consumer products such as dryer sheets, toilet articles and wipes. Such products tend to be floppy and hang down around the consumer's hands or fingers when the product is used. This can make it difficult or a poor experience for the consumer to handle the product. For products containing active agents, it may be desirable to limit contact between the consumer's hands and the active agent, which is difficult to do with floppy products.

[0005] Manufacturing multilayer sheet products from substrates can be challenging because the individual layers of the product often need to be bonded to each other to form a cohesive product. Bonding and cutting multilayer sheet products can be difficult if the thickness of the individual products varies across the surface of the product. This can easily happen when the product is loaded with particles. In addition, loading water-soluble products with particles can also pose challenges to the dissolution of the product.

[0006] In view of these limitations, there remains an unmet need for methods of preparing water-soluble unit dose products having particles that can be manufactured economically, have consumer-preferred handleability, and / or maintain acceptable solubility. Summary of the invention

[0007] The present invention includes an apparatus for discretizing a dose of particles, the apparatus comprising: a. a feeder system comprising a feeder, wherein the feed system provides a continuous particle flow to a discretization unit; and b. a discretization unit, wherein the discretization unit converts the continuous particle flow from the feed system into individual particle doses, receives the particle doses through an inlet, and delivers the individual doses to a moving substrate through individual outlets.

[0008] This document also includes an apparatus for discretizing particles into a single dose, the apparatus comprising: a) a feed system, wherein the feed system provides a continuous stream of particles to a discretization unit; and b) a discretization unit, the discretization unit comprising a track and one or more movable pockets, wherein the one or more pockets convert the continuous stream of particles from the feed system into individual particle doses and deliver the individual doses to a substrate.

[0009] These and other iterations will be described more fully below. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a representation of an apparatus for depositing discretized particle doses on a discontinuous substrate;

[0011] Figure 2 is a representation of an apparatus for depositing discretized particle doses on a continuous substrate;

[0012] Figure 3 is a schematic view of a weir system on a hopper;

[0013] Figure 4 is a schematic view of a method for forming a single substrate into multiple substrates;

[0014] Figure 5 is a micro-CT image of a fibrous water-soluble product with particles

[0015] Figure 6 is a schematic view of a method for preparing a water-soluble product, wherein the pocket travels towards and contacts the water-soluble substrate during application of the particles;

[0016] Figure 7 is a schematic view of a method for preparing a water-soluble product, wherein the water-soluble substrate contacts the pocket during application of the particles and then descends away from the pocket;

[0017] Figure 8 is a schematic view of a method for preparing a water-soluble product, wherein two adjacent pockets contact each other during receipt of the particles;

[0018] Figure 9 is a schematic view of a method for preparing a water-soluble product, wherein at least a portion of the pocket (such as a shield) travels towards and contacts the water-soluble substrate during application of the particles;

[0019] Figure 10 is a top view of a schematic view of a method for preparing a water-soluble product, wherein the discretization unit operates in a loop configuration

[0020] Figure 11 is a top view of a unit for depositing particles onto a substrate using a plurality of feed systems in an in-line configuration;

[0021] Figure 12 is a top view of a unit that deposits particles onto a substrate using a plurality of feed systems in a radial configuration; and

[0022] Figure 13 is a representation of adjacent pockets of flashing in a minimum spacing configuration and a maximum spacing configuration. DETAILED DESCRIPTION

[0023] Manufacturing water-soluble products can be a delicate balance of materials and processes to achieve the desired end product, functionality, performance, and meet the economic requirements of mass production. Previous methods for manufacturing water-soluble products with particles included directly incorporating a small amount of particles into the substrate, such as by incorporating the particles into the substrate during the substrate preparation method, or spraying the particles onto the finished substrate. However, these methods have some disadvantages. When particles are incorporated into the substrate during the manufacture of the substrate, the particles can interfere with the capture and entanglement methods for preparing the substrate. This can lead to inadequate or uncontrolled dissolution of the substrate and / or the inability to actually form the substrate. These problems greatly limit the types and properties of particles that can be added in such methods. These potentially limiting particle properties can include particle size, particle size distribution, chemical composition, particle surface properties (such as adhesion and cohesion), particle stability during the substrate preparation method, the difficulty of separating incompatible particles, etc. This method of addition also increases the cost of the manufacturing method, as it may require dissolving solid components to add them to the substrate. Another disadvantage is the difficulty in controlling the location where the particles are added to the substrate, and this can create sealing problems when the particles reach the areas of the substrate to be sealed.

[0024] Despite the many difficulties with known manufacturing methods, there is still a desire to be able to load larger amounts of particles, different types of particles, control the location of the particles within the water-soluble product, and achieve these goals in an economically viable manner. This allows for greater product flexibility. After reviewing possible solutions for in-industry unit dose application devices, no intermittent particle application device was found that could meet the following basic requirements: dose frequency, individual dose mass (mass flow rate), dosing coverage area, and manufacturing flexibility within practical limits. For example, the application of a screw-based intermittent particle filling machine is typically limited to an operating frequency of 3.33 doses / second - approximately half of the target starting rate of 6 doses / second. Using this technology would require a large capital investment to "add" units in series in an attempt to reach the 6 doses / second target starting rate.

[0025] Another challenge in adding particles to a water-soluble product is the manufacture of the water-soluble product. For example, one way to prepare a water-soluble product is to use a continuous substrate. However, this continuous substrate is used to prepare discrete products. This means that even though the substrate is continuous, particles need to be applied intermittently to produce discrete products. To produce discrete products on a continuous substrate, the particles need to be delivered to the substrate in such a way that they predominantly stay in a defined area, i.e., the target area. Other devices for delivering particles, such as rotary feeders, are typically designed for overall flow control and not for producing uniform discrete doses. In the absence of controlled particle delivery, this can result in varying amounts of particles in different products or the inability to form discrete products because the particles are in areas required for sealing.

[0026] Another challenge in controlling the delivery of particles to a substrate is observed in the case where the substrate is moving. This requires coordinating the delivery of particles to the substrate and the positioning of the substrate using a delivery mechanism. For unit dose applications, the intermittency of dosing is synchronized with the positioning of the location of the substrate product to be cut on the substrate to form discrete units. Therefore, the timing of particle dose delivery and substrate movement needs to be coordinated to allow for the formation of discrete units.

[0027] Furthermore, the movement of the substrate during and after particle application can make attempts to deliver particles to the desired portion of the substrate worse because the particles may roll and / or splash when they land on the moving substrate or as they continue to move with the substrate to complete the manufacturing process. Additionally, an inability to control the coverage area of the particles deposited on the substrate can result in some particles flowing into the area used to seal the substrate, thereby producing a water-soluble product. While a small amount of particles in this area may be tolerated, too many particles in this area will interfere with the sealing and can cause product failure or the inability to form a product. Ideally, these issues are controlled through manufacturing conditions without the need to add corrective steps such as vacuum treatment to remove loose particles, thereby allowing for more cost-effective and faster production of products.

[0028] When looking for a solution, the present inventors deliberately sought something that could be used for intermittent particle delivery and had the ability to precisely control the deposition of particles into the target area of the substrate. Additionally, it was desired to be able to accommodate many different types of particles, not just those that are free-flowing. It was also desired that the method be less sensitive to variations in manufacturing rate and product size. The method solution is referred to as a travelling mask.

[0029] Generally speaking, in a traveling mask method, a continuous particle feed is provided and the continuous particle feed is separated into discretized doses by using a discretization unit with pockets (explained in more detail below). The main speed limiting factor of the traveling mask is gravity, since gravity is the main force used to deposit the particles onto the substrate, but other forces can also be used.

[0030] Specifically, the rate at which gravity can pull the particles through the discretization unit pockets and onto a moving or stationary substrate is a limiting factor. Given a particular pocket design and particle type, the time required for the particles to pass through the discretization unit pockets and onto the substrate is relatively fixed. When attempting to speed up the production method, this time can become a system limiting factor due to the physical properties of the particle stream. However, the traveling mask concept allows this fixed time component to be accounted for without fundamentally affecting the other parameters of the system. All that is required is to increase the dwell time for a given pocket to be properly aligned with the substrate. In a linear production method, this costs a relatively small longitudinal distance.

[0031] Through the design of the feed system and the discretization unit, the traveling mask concept also allows for the accommodation of a wider range of particles. By manipulating certain properties, the system can accommodate particles that exhibit a variety of flow characteristics from cohesive to free-flowing. This can be achieved to a large extent while still maintaining the independence of the three operations (discretization, controlling the particle stream, and controlling particle deposition) taking place in the system.

[0032] Given the ability to independently control the exit design of the pockets through the pockets themselves (e.g., shape, exit arrangement, baffles, etc.) and system design (e.g., the height from the pocket exit to the top of the substrate), it is possible to design essentially quickly to meet changing end product requirements. For example, currently, a water-soluble product may have dimensions of approximately 76×76 mm, and if this form is compressed to a 60×60 mm area, the particles need to be applied with a smaller coverage area. This can be achieved, for example, by making a single design change to the exit of the pocket while keeping all other design aspects fixed.

[0033] In addition, the traveling mask operation is rather insensitive to the substrate type, although the substrate type can play a role in the coverage area of the particles. Therefore, when designing a traveling mask, the properties of the target substrate can be considered. For example, the coefficient of restitution between the particles and the substrate can vary depending on the properties of the substrate. However, the traveling mask system can be optimized to offset and / or cooperate with these types of properties. In addition, the substrate can be modified to assist in particle deposition and / or distribution. For example, the substrate can be at least partially coated with a material to help the particles stick to the substrate and / or minimize the bounce of the particles when applied to the substrate. This can include any material that makes the substrate itself sticky, such as water or any material that partially wets the particles and makes the particles themselves sticky. These materials can be, for example, other liquid active substances such as fragrances, silicones (e.g., antifoaming agents), etc. Such substances can also be, for example, adhesives. Suitable adhesives can be found in "Viscoelastic Windows of Pressure-Sensitive Adhesives", E.P. Chang, J. Adhesion 34 (1991) 189-200. These materials can be applied to the substrate, for example, by atomization. This can be in a pattern or randomly. Additionally, a vacuum can be applied to the substrate to help pull the particles onto the substrate and / or hold them in place.

[0034] Accordingly, what the inventors have discovered is a method that separates a continuous particle feed into discrete individual doses, controls the mass flow rate and / or volume flow rate of the particles, and controls the deposition of the particles on a substrate.

[0035] Equipment

[0036] The apparatus used in conjunction with the traveling mask method can include, for example, a feed system and a discretization unit. Generally, the feed system can be used to control the mass flow rate and / or volume flow rate of the particles. Another task that the feed system can perform, if needed, is to spread the particles laterally ("CD"). On the other hand, the discretization unit receives the particle feed and converts it into individual particle doses.

[0037] The feed system 300 can include, for example, a feeder 505, a conveying device 400, or a combination thereof. The discretization unit can include a conveyor system, one or more pockets, guards, or any combination thereof. The apparatus can include multiple feed systems and / or multiple components of a single feed system and multiple discretization units and / or multiple components of a single discretization unit. The distance from the particle outlet of the feed system (such as from the conveying device or the particle feeder) to the inlet of the discretization unit can be, for example, from about 0 m to about 1.0 m.

[0038] In the case of depositing particles onto a substrate using a traveling mask system, the substrate can be provided, for example, in the form of a roll. The substrate can be fed into the traveling mask system in order to receive particles and / or to form water-soluble unit doses containing particles. For example, the substrate roll can be fed into the system using rollers, belts, conveyors, or any combination thereof in order to deliver particles. Additionally, the substrate can be fed into the system and / or passed through the system under tension. The tension can be set, for example, by using a vacuum conveyor.

[0039] Feeding system

[0040] The feed system can include a feeder and / or conveying equipment (see Figure 1 ). The feed system 300 can include one or more feeders 505 and one or more conveying equipment 400. The feeder and the conveying equipment can be in the same or different configurations. For example, the feeder and / or the conveying equipment can be arranged in-line to allow adding particles to the same pocket or different pockets in the discretization unit (e.g., Figure 11 ). Additionally, multiple feeders and / or conveying equipment can provide the same particles or different particles. The feeder and / or the conveying equipment can also be arranged in a radial configuration, where they can deliver the same or different particles (e.g., Figure 12 ). The feed system can also be configured such that one provides a first particle feed and the second provides a second particle feed. The first particle feed and the second particle feed can be deposited on the same or different substrates. Additionally, the first particle feed and the second particle feed can lead to the same or different pockets. The first particle feed and the second particle feed can be the same or different in composition.

[0041] When utilized, the conveying equipment 400 conveys particles from the feeder 505 to the discretization unit 700. The conveying function of the conveying equipment can be passive or active, depending on the system setup. The conveying equipment 400 can include, for example, belts, slides, troughs, trays, or combinations thereof. The conveying equipment can be stationary or in motion. When in motion, the motion can be rotational, reciprocating, oscillating, translational, vibrating, etc.

[0042] An example of a feeder in the feed system is a hopper. The hopper 500 can hold particles for application to the substrate. The hopper 500 can be of any suitable shape. For example, the hopper can have one straight up-and-down vertical wall and another inclined vertical wall, as Figure 1 can be seen. In Figure 1 , the rear wall 510 of the hopper 500 slopes towards the front wall 520. The rear wall can be inclined at an angle of, for example, about 60 degrees or greater with respect to the horizontal plane. The presence of an inclined surface in the rear wall helps prevent particles from rolling back in the hopper and helps prevent clogging.

[0043] The front wall 520 of the hopper 500 may include an opening. The opening may be, for example, a vertical slot 530 or a horizontal slot (not shown). The vertical and horizontal slots may have dimensions that conform to the particles and the manufacturing setup. The slot has a certain size, and its cross-sectional area can be used as an extrusion method. Knowing the area (m 2 ), the belt speed (m / s), and the particle density, the volumetric flow rate (m 3 / s) and the mass flow rate can be estimated. Therefore, the height and width of the slot can be adjusted to obtain the best particle and manufacturing options.

[0044] The slot can be of any suitable shape. The most common shape is rectangular. The horizontal slot may be, for example, from about 20 mm to about 500 mm in the CD direction, or about 25 mm in the CD direction, and the height is adjustable.

[0045] The hopper can be part of a more complex feeder, such as part of a point source feeder or a wide front particle feeder. In these more complex feeders, the hopper can act as a particle reservoir, and another part of the feeder moves the particles out of the hopper. These can include screw feeders, belts, or combinations thereof, etc. Some examples of more complex feeders with hoppers can include, for example, point source feeders and wide front feeders. The feeder can use motion (such as vibration and / or friction) to move the particles out of the hopper, and / or can use a combination of mechanical and motion.

[0046] The point source feeder and the wide front feeder can distribute the particles across the CD either individually or in combination with other components of the feeding system. The particle profile can cover most of the CD length of one or more pockets, or can be split / segmented to produce separate particle streams entering separate discretization units. For example, spreading the particle stream across the CD can allow more than one particle feeder to be positioned side by side and thus have greater manufacturing capacity.

[0047] The feeder can supply the particles onto the conveying device 400 or directly into the discretization unit. The outflow of the particles from the opening of the hopper 500 can be controlled, for example, by a weir 540. The weir 540 is a dam-like device that can be used to regulate the amount of particles that can be discharged from the opening. As Figure 3 can be seen, the weir 540 may include, for example, a gate 550 that can be adjusted up and down by a mechanism.

[0048] The hopper 500 may be in contact with the belt 600 and / or with a part of the discretization unit (such as a pocket). This contact can be a press fit. A press fit is generally a situation where the hopper or an extension of the hopper (such as an elastomeric blade) contacts the conveying device (such as a belt) or a part of the discretization unit (such as a pocket) to prevent or at least minimize particle leakage and / or spillage. This allows for more control over the particles and the location where the particles flow out of the hopper 500.

[0049] When using a conveying device, as the particles leave the feeder (such as hopper 500), the particles can come into contact with the conveying device. If the conveying device is belt 600, it will typically be moving, preferably in the longitudinal direction. However, the direction of the conveying device can be adjusted as needed to a position, for example, between the longitudinal direction and perpendicular to the longitudinal direction, to help deliver the particles to the discretization unit most efficiently. The speed of the conveying device can also be adjusted.

[0050] The particles can travel along the conveying device (such as belt 600) and spill onto the discretization unit 700 at the edge of the conveying device. In the case where the conveying device is belt 600 or a similar device, it can form a continuous loop that picks up the particles from hopper 500 and delivers the particles to the discretization unit 700.

[0051] In the case of not using a conveying device, the particles leave the feeder and enter the discretization unit.

[0052] Discretization unit

[0053] The discretization unit 700 receives a stream of particles from the feeder and / or the conveying device and separates the stream of particles into discrete particle loads. When looking at disposable consumer products, these discrete particle loads can be, for example, from about 0.1 g to about 30 g. The size of the discrete particle loads can vary greatly depending on the use of the final product. The discretization unit can be a single unit, multiple units in a row, multiple units side by side, or even a combination of units in a row and side by side to form an array.

[0054] The discretization unit can include a conveyor system, one or more pockets, guards, or any combination thereof. The discretization unit or any part thereof can be in motion. For example, the discretization unit or any part thereof can move in the same direction as the belt (i.e., the longitudinal direction (“MD”)) or in the opposite direction. Additionally, the discretization unit or any part thereof can move in the vertical direction.

[0055] The conveyor system may include, for example, tracks. One or more pockets may be movably or statically attached to the tracks. The conveyor system may be used to move one or more pockets attached to the conveyor system. The conveyor system may move one or more pockets in a set pattern (e.g., in a loop). The conveyor system may be used to move one or more pockets to a position where they can receive particles from a feeder and / or a conveying device. The conveying system may also move in a vertical direction, thereby allowing it to move closer to or farther from the feeder and / or the conveying device to receive particles into one or more pockets. The conveying system may also move in a vertical direction to move one or more pockets closer to a substrate for particle deposition. The vertical movement may allow for better control of the delivery of particles to both the discretization unit and the substrate. For example, the conveyor system may move one or more pockets closer to the feeder or the conveying device when picking up particles and then lower to move one or more pockets closer to the target substrate for particle application.

[0056] Additionally, the discretization unit or any part of the discretization unit may contact, for example, a feeder, a belt, a target substrate, or any combination thereof. The contact between these entities may help minimize the spillage of particles into or out of the pockets of the discretization unit or away from the target substrate during particle transfer.

[0057] The discretization unit may include a shield. The shield may be used, for example, to help guide particles into and / or out of the pockets and onto the substrate, to help dissipate kinetic energy, for splash / bounce protection, and / or for deposition control. The shield may contact the feeder, the conveying device, the substrate, the pockets, or any combination thereof. The shield may be attached to any part of the discretization unit, such as to a pocket. The shield may be attached to the pocket. The shield may be movably attached to the pocket. For example, when the pocket receives particles, the shield may be in one position, and when the pocket deposits particles onto the substrate, the shield may be in another position. The shield may be made of a flexible material, a rigid material, or a combination thereof. For example, a part of the shield that contacts the feeder, the conveying device, and / or the substrate may be flexible, while the remaining part may be rigid.

[0058] As described above, the discretization unit 700 may include one or more pockets 710. Each pocket may have a height and a width. The height and / or width of the pocket may be adjustable. Each pocket may receive particles from a single particle stream or multiple particle streams. When from multiple particle streams, the particles may be the same or different. One or more pockets may have an inlet 720 and an outlet 730. The inlet and the outlet may be different or the same. Additionally, the inlet and the outlet may have different sizes and / or shapes. For example, the inlet 720 may be larger than the outlet 730. Additionally, the inlet may be smaller than the outlet. The outlet may have a smaller surface area than the inlet. The inlet may have a characteristic length (e.g., diameter, width, etc., depending on the shape of the inlet), such as from about 15 mm to about 150 mm, preferably about 76 mm, and / or a diameter from about 5 mm to about 150 mm.

[0059] One or more pockets may be in motion. The pockets may move vertically and / or horizontally. One or more pockets may move in the machine direction ("MD") or in the opposite direction. One or more pockets may move in the CD. Additionally, any one of the one or more pockets may contact, for example, a feeder, a conveying device, a target substrate, other pockets, or any combination thereof. Contact with these entities may help minimize particle spillage into or out of the pockets and off the target substrate.

[0060] The pockets may contact each other to minimize or eliminate the gap between two or more adjacent pockets, e.g., as Figure 1 shown. The pockets may contact one or more sides completely or only a portion of one or more sides. This close fit (kissing) of at least a portion of two or more pockets prevents particle loss between the pockets, especially when the particles are loaded into one or more pockets.

[0061] The pockets may be rigid, flexible, or a combination thereof. For example, one or more sides of the pocket may have flexible portions that allow compression and / or contraction of at least one pocket. This compression or contraction allows two pockets to have a smaller spacing (i.e., the distance from the center of one pocket to the center of an adjacent pocket). The ability to adjust this spacing gives the method manufacturing flexibility. For example, if there is misalignment between the unit dose and the cutting device, the ability to adjust the spacing of one or more pockets may mitigate and / or minimize such misalignment.

[0062] In cases where the pockets are rigid and they contact during receiving of the particles, it is difficult to make any significant adjustment to the spacing. Another way to allow adjustment of the spacing even without compressing the pockets is by deliberately designing a gap space between the pockets. However, as described above, leaving only a gap will allow many particles to enter between the pockets, resulting in waste and chaos in the production method. Considering the desire to create some space between the pockets, but allowing minimization of particle spillage between two adjacent pockets, cover sheets can be used. Figure 13 An example of a cover sheet 750 on a pocket and how it can be used to help adjust the spacing can be seen in

[0063] It can also be used to force particles in a given feed stream to self-separate into one pocket or the other. The pockets can contact the feeder, conveying equipment, and / or the substrate. When the pockets contact the target substrate, they can act as a shield to dissipate any kinetic energy remaining in the particles, which can induce the particles to bounce or otherwise move out of their intended deposition area due to falling from the feeder and / or conveying equipment. This implementation allows for higher specificity of particle deposition onto the target substrate. This can even allow for particle printing, where, with an appropriate design of the exits of the pockets on the discretization unit (e.g., adding a screen), patterns are made on the target substrate with the particles.

[0064] The inlet 720 is part of the discretization unit 700 that receives particles from the feeder and / or conveying equipment. For example, as Figure 1 can be seen, multiple pockets 710 in the discretization unit travel under a conveying equipment (i.e., belt 600), where the particles are received into one or more pockets 710 through the inlet 720. The inlet can have any acceptable shape. In cases where adjacent pockets are desired to contact to minimize particles entering between adjacent pockets, the adjacent pockets should have complementary shapes. Complementary shapes can include nested shapes, for example, at least the parts of adjacent pockets that will contact during particle delivery can be flat. The inlet of one or more pockets can be square, rectangular, hexagonal, octagonal, etc.

[0065] While it is important to inhibit and / or prevent particle movement when applying the particles to the target substrate, it is also desirable to maintain particle movement until this moment in the method. This is more important for particles with low mobility, as particles that slow down too much or stop during the movement from the feeder to the pockets have the opportunity to form particle bridges and / or interlocking arch structures, which can clog the feeder, conveying equipment, and / or the pockets. The pockets can be designed to help promote particle flow and / or minimize clogging. This can be achieved, for example, by the shape of the pockets. The pockets can, for example, have one or more inclined sides. The pockets 710 can have any acceptable shape for delivering the particles to the substrate 800. For example, one or more pockets 710 can be in a funnel shape, as Figure 1 can be seen.

[0066] One way to facilitate the flow of particles through the pocket is by designing the slope of one or more walls of the pocket. For example, a slope of about 70° to about 120° with respect to the horizontal plane will help to keep the particles flowing through the pocket. The exit size is also helpful. An exit size of at least 3X the maximum particle size deposited on the target substrate can help to minimize bridging and / or jamming.

[0067] In addition, the interior of the pocket may include design features such as baffles. These design features can be used, for example, to direct the particles to the exit, control the energy of the particles between the inlet and the exit, minimize jamming, etc.

[0068] The particles pass through at least one of the one or more pockets 710 to reach the exit 730, where they leave the one or more pockets 710 and are deposited on the substrate 800. The distance from the exit of the pocket to the substrate can be, for example, about -50 mm to about 50 mm. A negative value confirms that when the pocket and / or the guard and the substrate are in contact, the substrate can be compressed and below the substrate plane to reach a negative value. In addition, a negative value indicates a situation where the exit of the pocket may extend into a cavity formed in the substrate and is also below the substrate plane.

[0069] Once the particles are deposited on the substrate, the substrate can be folded onto itself to produce a cover. A second substrate or multiple substrates can be placed on the particle-containing substrate to form a cover. The second substrate or multiple substrates used as the cover can be introduced, for example, via their own rollers and unwinders. The second substrate or multiple substrates can travel with the substrate on which the particles are deposited and are stacked on the particle-containing substrate through, for example, folding plates, idler wheels, etc.

[0070] Once the cover is in place, the cover can be sealed to the particle-containing substrate to form a unit dose. The substrate can be sealed by any conventional method, such as heat sealing. A heat sealer can also be used as a way to separate individual unit doses from a continuous substrate, or a separate cutting step can be utilized. In use, the separate cutting step can include a die cutter.

[0071] In addition to the equipment described above with respect to the traveling mask method, adding equipment can also be used to start and / or end the manufacture of the final product. For example, the adding equipment can include equipment for transporting the substrate from a roll and packaging the formed unit dose articles by the traveling mask method.

[0072] Manufacturing method

[0073] A method for preparing a water-soluble product may first include preparing a substrate. The substrate can be fibrous, non-fibrous, or a combination thereof. The substrate can be continuous or discontinuous. A description of a method for preparing a water-soluble fibrous substrate can be found, for example, in U.S. Patent No. 10,683,618, which is incorporated herein by reference.

[0074] Once the substrate is formed, it can be provided to the method. A single substrate, multiple substrates, or even a parent substrate that is cut into multiple substrates during the manufacturing process can be provided. Examples of a single substrate forming multiple substrates can be seen in Figure 4 . Examples of a single substrate forming multiple substrates can be seen in Figure 4 wherein a parent continuous substrate 59 can be formed on a die block assembly 40 and then cut in the machine direction MD by a knife 70, such as a rotary cutting knife cutting in the longitudinal MD, to form a first continuous substrate 60 and a second continuous substrate 65. Cutting the second substrate from the parent continuous laminate substrate 59 is practical for providing better manufacturing quality control.

[0075] According to the apparatus described above, a method for manufacturing a unit dose product, such as a water-soluble product, may include providing one or more substrates (such as a first water-soluble fibrous substrate or a water-soluble non-fibrous substrate) to a traveling mask system in a continuous or discontinuous manner. Illustrations of exemplary methods utilizing both continuous and discrete substrates can be seen in Figure 1 and Figure 2 . The substrate can be provided in the form of a roll or any other suitable known method. The substrate can be fed into the traveling mask system to receive particles on the substrate (such as on a first side of the substrate). A roller, belt, conveyor, or any combination thereof can be used to feed the substrate into the traveling mask system to receive particles. Additionally, the substrate can be fed into the system and / or passed through the system under tension. The tension can be set, for example, by using a vacuum conveyor.

[0076] The substrate fed into the traveling mask system can move continuously, discontinuously, or a combination thereof. The substrate can move in a first direction, such as in the longitudinal direction. The substrate can also move in the transverse direction. The substrate can move at a rate of, for example, about 5 m / min to about 100 m / min. The direction of movement of the substrate can be determined based on, for example, the coverage area of the space in which the manufacturing method will operate and / or the conditions required to most efficiently operate the method.

[0077] The substrate can enter a traveling mask system adjacent to, for example, a feed system, a discretization unit, or a combination thereof. Particles are delivered to the feed system, such as a hopper. Generally, the particles are fed into the feed system through, for example, a belt, a chute, etc. The particles generally enter a feeder in the feed system. The particles move from the feeder inlet, where the feeder receives the particles, to the feeder outlet, where the particles leave the feeder. This movement of the particles in the feeder can be passive (e.g., by using gravity) or active (by using mechanisms and / or motion (e.g., vibration)). Once the particles move to the outlet of the feeder, they can be directly dispensed into the discretization unit for application to the substrate, or they can be dispensed onto another part of the feed system, such as a conveying device. The feeder can control (i.e., meter) the rate at which the particles leave the feeder and / or the rate at which they are delivered to the next stage (e.g., the discretization unit or the conveying device). One way to control this rate is by using a weir-like structure as discussed above.

[0078] In the case of using a conveying device, it also moves the particles from one part of it that receives the particles to another part that dispenses the particles. The conveying device can control the rate at which the particles move from one part to another. It can also control the rate at which the particles are dispensed from it into the discretization unit. In addition, the feeder and intermediate structures (such as the conveying device) can work together to control the rate at which the particles are transferred into the discretization unit. The dispensing of the particles from the feeder and from the intermediate structure can be done at a consistent rate or a variable rate as needed to meet the requirements of the manufacturing method. This control can be passive or active. The particles can leave the conveying device and enter the discretization unit. The particle flow from the feeder system 300 to the discretization unit can be continuous or discontinuous.

[0079] In one example, the feeder system 300 includes a vibratory feeder (i.e., the feeder) and a trough (i.e., the conveying device). The particles are fed into the vibratory feeder, which deposits the particles into the trough. The vibratory motion of the feeder causes the particles to move along the trough until they reach the end of the trough. At this point, the particles proceed towards the discretization unit. For example, this can be done by gravity, where the particles spill over the end of the trough and fall into the discretization unit.

[0080] The discretization unit can receive the particles and deliver them to the substrate. This delivery can be continuous, intermittent, or a combination thereof. The discretization unit can include, for example, pockets and tracks. The tracks can be arranged such that at least a portion of one or more pockets travels over at least a portion of the substrate. In one example, the tracks are configured in a loop, such as circular or elliptical (e.g., Figure 10 ). In this loop configuration, one or more pockets can be in a row and / or side by side. During all or part of the particle receiving and / or delivery method, the pockets can be nested with adjacent pockets (see, for example,Figure 8 ) When the pocket travels along a path (e.g., via a track), the pocket passes through a feeding system where it receives particles. When receiving particles, one or more pockets can move at a constant or variable speed. One or more pockets can move longitudinally, transversely, or any combination thereof. The particles received from the feeding system can be in a continuous stream. The ability to utilize a continuous stream of particles simplifies the delivery to the discretization unit as it does not require precise alignment of timing between the feeder and the discretization unit to get the correct amount of particles into the pockets of the unit.

[0081] By nesting of the pockets, the use of a continuous stream of particles from the feeder can be facilitated. Pocket nesting allows separation of the continuous stream of particles into unit doses in one or more pockets. The nesting forces the particles into the pockets while minimizing any particle spillage that might be caused by the gaps between the pockets. Thus, the nesting of the pockets includes minimizing the gaps between adjacent pockets during particle reception. Such nesting can be achieved, for example, by having a predefined distance between adjacent pockets during particle reception. This gap can be maintained during multiple stages of the particle application method, or the adjacent pockets can be moved to positions with a predefined gap at any point before particle reception. This gap can be defined based on the particles received by the pockets (e.g., particle size, shape, and / or flowability). Two adjacent pockets can also have no effective gap between them where their adjacent sides are in contact.

[0082] Another way to nest adjacent pockets during particle reception is to utilize features of adjacent pockets such as flanges and / or cover flaps. Such flanges and / or cover flaps can be positioned to effectively eliminate the gap between the products during pocket particle reception. The flange and / or cover flap can overlap at least a portion of the entrance of the adjacent pocket, or be positioned to align with the edge of the adjacent pocket without overlapping.

[0083] Particles can enter the pocket through the pocket entrance and leave through the pocket exit. The height between the substrate and the pocket exit can be any desired height. Additionally, this height can be adjustable (see Figures 6 to 7 and Figure 9 ). For example, the substrate can start at a height H1, rise towards the pocket such that it is at a height H2 during particle application. Additionally, the pocket and / or at least a portion of the pocket (such as a guard) can start at a height H P1 and descend towards the substrate to a height H P2 . At least one of the one or more pockets can move downward towards the substrate to deposit particles, the substrate can move upward towards the one or more pockets to receive particles, or a combination thereof. The substrate can be maintained at a constant distance from the one or more pockets and / or the discretization unit while being below them. The movement of the substrate and / or the pocket can be accomplished, for example, by cam and / or roller positioning.

[0084] Ideally, during particle application, at least one pocket of the discretization unit may travel synchronously with the substrate at least during deposition of the particles onto the substrate, although it may also travel synchronously with the substrate before and / or after particle application. It is also desirable that, when applying particles to the substrate, at least the portion of the substrate where the particles are to be deposited and the portion of the discretization unit that delivers the particles (e.g., the outlet of the pocket) are close to each other. In fact, a portion of the pocket (e.g., the pocket outlet) and / or the guard may contact the substrate during any part of particle application, before particle application, after particle application, or any combination thereof. Such contact may even cause the substrate to dent. The contact of the pocket and / or the guard with the substrate may contribute to particle deposition on the substrate by restricting the initial portion of the substrate for delivery to a specific area of the substrate defined by the portion of the pocket and / or the guard that contacts the substrate. However, the contact also requires coordination of the movement of the independently moving pocket (and / or guard) and the substrate; otherwise, the contact between the pocket (and / or guard) and the substrate may damage the substrate.

[0085] The substrate may have a target area for particle application and / or deposition. The target area is the portion of the substrate where particles are desired to be applied. The configuration of the traveling mask may affect the ability of the delivered particles to be applied to and remain within the target area. The traveling mask may allow deposition of about 75% or more, about 80% or more, about 85% or more, about 90% or more, about 95% or more, or most preferably about 97% or more of the particles delivered from the pocket to remain within the target area after leaving the discretization unit (e.g., the pocket outlet) or until the substrate containing the particles is covered and / or sealed. Multiple pockets may deliver particles to the same target area of the substrate.

[0086] The discretization unit or a portion of the discretization unit may deliver particles to an area of the substrate of about 20 mm 2 to about 10,000 mm 2 to form a single dose. Once the particles are deposited on the substrate, the side of the substrate containing the particles may be at least partially covered. Such covering may be achieved, for example, by folding a portion of the substrate onto itself, and / or another substrate may be placed on at least a portion of the substrate having the particles. The substrate may then be sealed around the particles, thereby entrapping at least a portion of the particles between the substrate and the covering to form a water-soluble product. The sealed pockets of the particles may then be cut to separate them from each other and / or from the external substrate material and packaging for transportation and / or use.

[0087] Water-soluble product

[0088] As described above, the water-soluble product may include a water-soluble fibrous substrate, a water-soluble non-fibrous substrate, or a combination thereof. The water-soluble substrate may be continuous or discrete, as Figure 1 and Figure 2 shown. The water-soluble substrate can be used to form a water-soluble product, which will be discussed in more detail below.

[0089] The water-soluble product may include one or more layers. These layers may be stacked on top of each other. These layers may be placed directly on top of each other, with particles between these layers, or a combination thereof. For example, as Figure 5 can be seen, a substrate layer 500 is located at the bottom, particles 510 are on top of it, a second substrate layer 520 is above the particles 510, a second set of particles 530 is on top of the second layer 520, and a third substrate layer 540 is stacked on top of the second set of particles 530 and the second layer 520 to form a water-soluble product. In Figure 5 it can be seen that the edges of these layers appear to be pressed together because they have been pressed together and sealed to keep the particles inside.

[0090] The water-soluble unit dose article may contain 50% or more of bio-based materials, such as, for example, 50% to 95% of bio-based materials. Some of the individual components of the water-soluble unit dose article may be fully bio-based to produce an article with a total bio-based content greater than 50%.

[0091] These water-soluble unit dose articles can dissolve under various washing conditions, such as low temperature, low water, and / or one or more short wash cycles, where the consumer has overloaded the machine, especially for items with high water absorption capacity, while providing sufficient surfactant delivery to achieve the desired effect on the target consumer substrate (having performance similar to today's liquid products).

[0092] The surface of the water-soluble unit dose article may include a printed area. The printed area may cover from about 10% to about 100% of the article surface. The printed area may include inks, pigments, dyes, bluing agents, or mixtures thereof. The printed area may be opaque, translucent, or transparent. The printed area may include single-color or multi-color. The printed area may be on more than one side of the article and contain instructional text, graphics, etc. The surface of the water-soluble unit dose article may contain an aversion agent, such as a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octaacetate, quinine hydrochloride, denatonium benzoate, or mixtures thereof. Any suitable content of the aversion agent may be used. Suitable contents include, but are not limited to, 1 ppm to 5000 ppm, or even 100 ppm to 2500 ppm, or even 250 ppm to 2000 ppm.

[0093] Water-soluble unit dose products can exhibit a thickness, for example, greater than 0.01 mm and / or greater than 0.05 mm and / or greater than 0.1 mm and / or up to about 100 mm and / or up to about 50 mm and / or up to about 20 mm and / or up to about 10 mm and / or up to about 5 mm and / or up to about 2 mm and / or up to about 0.5 mm and / or up to about 0.3 mm.

[0094] Water-soluble unit dose products can have a basis weight of about 500 g / m 2 up to about 5,000 g / m 2 、or about 1,000 g / m 2 up to about 4,000 g / m 2 、or about 1,500 g / m 2 up to about 3,500 g / m 2 、or about 2,000 g / m 2 up to about 3,000 g / m 2 or a combination thereof.

[0095] Water-soluble unit dose products can exhibit different regions, such as different regions of basis weight, density, thickness, and / or wetting characteristics. The water-soluble unit dose product can be compressed at the edge seal. The water-soluble unit dose product can include a texture on one or more of its surfaces. The surface of the water-soluble unit dose product can include a pattern, such as a non-random repeating pattern. The water-soluble unit dose product can include pores. The water-soluble unit dose product can include a structure having discrete regions that are different from other regions of the structure. The water-soluble unit dose product can be used as is, or can be coated with one or more active agents.

[0096] Water-soluble unit dose products can include one or more laminae. Water-soluble unit dose products can include at least two and / or at least three and / or at least four and / or at least five laminae. Each lamina can include one or more layers, such as one or more substrate layers, one or more particle layers, and / or one or more substrate / particle mixture layers. The layer can be sealed. Specifically, the particle layer and the substrate / particle mixture layer can be sealed so that the particles do not leak. Water-soluble unit dose products can include a plurality of laminae, where each lamina includes two layers, one of which is a substrate layer and one of which is a substrate / particle mixture layer, and where the plurality of laminae are sealed (e.g., at the edge) together. The seal can inhibit the leakage of particles and help the unit dose product maintain its original structure. However, after the water-soluble unit dose product is added to water, the unit dose product dissolves and releases the particles into the wash liquid.

[0097] The water-soluble unit dose can be in the form of any three-dimensional structure. The water-soluble unit dose article can be open-celled. The article can also be cut or shaped into various sizes for different intended uses. For example, the water-soluble unit dose can be square, square with rounded corners, kite-shaped, rectangular, triangular, circular, oval, and mixtures thereof.

[0098] The water-soluble unit dose can contain fewer than 10 components. The water-soluble unit dose can contain from 3 to 9 components, such as 4 components, 5 components, 6 components, 7 components, or 8 components.

[0099] The water-soluble unit dose article disclosed herein can include a water-soluble fibrous structure and one or more particles. The fibrous water-soluble fibrous structure can include a plurality of fiber elements, such as a plurality of filaments. One or more particles, such as one or more active ingredient-containing particles, can be distributed throughout the structure. The fibrous water-soluble unit dose article can include a plurality of two or more and / or three or more fiber elements, the fiber elements being intertwined or otherwise associated with each other to form a fibrous structure and one or more particles, the particles being distributable throughout the fibrous structure.

[0100] The fibrous water-soluble unit dose article can include a water-soluble fibrous structure. The water-soluble fibrous structure can include two or more different fiber elements. Non-limiting examples of differences in fiber elements can be physical differences, such as differences in diameter, length, texture, shape, rigidity, elasticity, etc.; chemical differences such as crosslinking level, solubility, melting point, Tg, active ingredient, filament-forming material, color, active ingredient content, basis weight, filament-forming material content, whether there is any coating on the fiber element, whether it can be biodegradable, whether it is hydrophobic, contact angle, etc.; differences in whether the fiber element loses its physical structure when exposed to the intended use conditions; differences in whether the fiber element changes its morphology when exposed to the intended use conditions; and differences in the rate of release of one or more of its active ingredients when the fiber element is exposed to the intended use conditions. Two or more fiber elements in the fibrous structure can contain different active ingredients. This can be the case where different active ingredients may be incompatible with each other, such as anionic surfactants and cationic polymers. When different fiber elements are used, the resulting structure can exhibit different wetting, absorption, and dissolution characteristics.

[0101] Fiber structure

[0102] The fibrous structure includes one or more fiber elements. The fiber elements can be associated with each other to form a structure. The fibrous structure can include particles within and / or on the structure. The fibrous structure can be homogeneous, layered, integral, partitioned, or, if desired, have different active ingredients defining the various parts described above.

[0103] The fibrous structure may include one or more layers that together form a laminate.

[0104] Fiber element

[0105] The fibrous element may be water-soluble. The fibrous element may comprise one or more filament-forming materials and / or one or more active agents, such as surfactants. One or more active agents are capable of being released from the fibrous element, such as when the fibrous element and / or the fibrous structure including the fibrous element are exposed to the conditions of the intended use.

[0106] The fibrous element may be spun from a filament-forming composition (also referred to as a fibrous element-forming composition) via a suitable spinning process, such as meltblowing, spunbonding, electrospinning, and / or rotary spinning.

[0107] As used herein, "filament-forming composition" and / or "fibrous element-forming composition" means a composition suitable for preparing a fibrous element, such as by meltblowing and / or spunbonding. The filament-forming composition comprises one or more filament-forming materials that exhibit properties that render them suitable for being spun into a fibrous element. The filament-forming materials may comprise polymers. In addition to one or more filament-forming materials, the filament-forming composition may further comprise one or more active agents, such as surfactants. Further, the filament-forming composition may comprise one or more polar solvents (such as water) in which one or more (e.g., all) of the filament-forming materials and / or one or more (e.g., all) of the active agents in the filament-forming materials are dissolved and / or dispersed prior to spinning the fibrous element (such as filaments from the filament-forming composition).

[0108] The filament-forming composition may comprise two or more different filament-forming materials. Thus, the fibrous element may be single-component (one filament-forming material) and / or multi-component, such as bicomponent. Two or more different filament-forming materials are combined randomly to form the fibrous element. For the purposes of the present disclosure, two or more different filament-forming materials may be combined in an ordered manner to form a fibrous element such as a core-shell bicomponent fibrous element, which is not considered a random mixture of different filament-forming materials. The bicomponent fibrous element may be in any form, such as side-by-side, core-shell, sea-island, etc.

[0109] The fibrous element may be substantially free of alkyl alkoxylated sulfates. Each fibrous element may contain from about 0%, or about 0.1%, or about 5%, or about 10%, or about 15%, or about 20%, or about 25%, or about 30%, or about 35%, or about 40% to about 0.2%, or to about 1%, or to about 5%, or to about 10%, or to about 15%, or to about 20%, or to about 25%, or to about 30%, or to about 35%, or to about 40%, or to about 50% of alkyl alkoxylated sulfate, based on the weight of the dry fibrous element. The amount of alkyl alkoxylated sulfate in each fibrous element of the fibrous element is small enough so as not to affect its processing stability and film dissolution. Alkyl alkoxylated sulfates, when dissolved in water, can undergo a highly viscous hexagonal phase at a certain concentration range (e.g., 30 wt% to 60 wt%), resulting in a gel-like substance. Thus, if incorporated into the fibrous element in a significant amount, the alkyl alkoxylated sulfate can significantly slow down the dissolution of the water-soluble unit dose product in water, and worse, cause undissolved solids thereafter. Accordingly, most such surfactants are formulated into granules.

[0110] Each fibrous element may contain at least one filament-forming material and an active agent, preferably a surfactant. The surfactant may have a relatively low hydrophilicity because such a surfactant is less likely to form a viscous gel-like hexagonal phase upon dilution. By using such a surfactant in forming filaments, gel formation during washing can be effectively reduced, which in turn can lead to faster dissolution and low or no residue in washing. The surfactant may be selected from, for example, un-alkoxylated C6-C 20 linear or branched alkyl sulfates (AS), C6-C 20 linear alkylbenzene sulfonates (LAS), and combinations thereof. The surfactant may be C6-C 20 linear alkylbenzene sulfonate (LAS). LAS surfactants are well known in the art and can be readily obtained by sulfonating commercially available linear alkylbenzenes. Exemplary C6-C 20 linear alkylbenzene sulfonates include alkali metal, alkaline earth metal or ammonium salts of C6-C 20 linear alkylbenzene sulfonic acid, such as C 11 -C 18 linear alkylbenzene sulfonic acid or C 11 -C 14 linear alkylbenzene sulfonic acid sodium, potassium, magnesium and / or ammonium salts. The sodium or potassium salt of C 12 linear alkylbenzene sulfonic acid, for example the sodium salt of C 12 linear alkylbenzene sulfonic acid, namely sodium dodecylbenzenesulfonate, can be used as the first surfactant.

[0111] The fibrous element may comprise at least about 5 wt%, and / or at least about 10 wt%, and / or at least about 15 wt%, and / or at least about 20 wt%, and / or less than about 80 wt%, and / or less than about 75 wt%, and / or less than about 65 wt%, and / or less than about 60 wt%, and / or less than about 55 wt%, and / or less than about 50 wt%, and / or less than about 45 wt%, and / or less than about 40 wt%, and / or less than about 35 wt%, and / or less than about 30 wt%, and / or less than about 25 wt% of a filament-forming material based on the dry fibrous element and / or dry fibrous structure and greater than about 20 wt%, and / or at least about 35 wt%, and / or at least about 40 wt%, and / or at least about 45 wt%, and / or at least about 50 wt%, and / or at least about 55 wt%, and / or at least about 60 wt%, and / or at least about 65 wt%, and / or at least about 70 wt%, and / or less than about 95 wt%, and / or less than about 90 wt%, and / or less than about 85 wt%, and / or less than about 80 wt%, and / or less than about 75 wt% of an active agent, preferably a surfactant, based on the dry fibrous element and / or dry fibrous structure. The fibrous element may comprise greater than about 80% surfactant by weight based on the dry fibrous element and / or dry fibrous structure.

[0112] Preferably, each fibrous element may be characterized by a total surfactant content that is high enough, such as at least about 30%, or at least about 40%, or at least about 50%, or at least about 60%, or at least about 70% of a first surfactant by weight based on the dry fibrous element and / or dry fibrous structure.

[0113] The total content of the filament-forming material present in the fibrous element may be from about 5% to less than about 80% by weight based on the dry fibrous element and / or dry fibrous structure, and the total content of the surfactant present in the fibrous element may be from greater than about 20% to about 95% by weight based on the dry fibrous element and / or dry fibrous structure.

[0114] One or more fibrous elements may comprise at least one other surfactant selected from the group consisting of: other anionic surfactants (i.e., excluding AS and LAS), nonionic surfactants, zwitterionic surfactants, amphoteric surfactants, cationic surfactants, and combinations thereof.

[0115] Other suitable anionic surfactants include C6-C 20 linear alkyl sulfonates or branched alkyl sulfonates, C6-C 20 linear alkyl carboxylates or branched alkyl carboxylates, C6-C 20 linear alkyl phosphates or branched alkyl phosphates, C6-C 20Linear alkyl phosphonic acid or branched alkyl phosphonate, C6-C 20 alkyl N-methylglucamide, C6-C 20 methyl ester sulfonate (MES), and combinations thereof.

[0116] Suitable nonionic surfactants include alkoxylated fatty alcohols. The nonionic surfactant may be selected from ethoxylated alcohols and ethoxylated alkylphenols of the formula R(OC2H4) n OH, where R is selected from the group consisting of: aliphatic hydrocarbon groups containing from about 8 to about 15 carbon atoms and alkylphenyls in which the alkyl group contains from about 8 to about 12 carbon atoms, and the average value of n is from about 5 to about 15. Non-limiting examples of nonionic surfactants useful herein include: C8-C 18 alkyl ethoxylates, such as those from Shell nonionic surfactants; C6-C 12 alkylphenol alkoxylates, where the alkoxylate units may be ethyleneoxy units, propyleneoxy units, or mixtures thereof; C 12 -C 18 alcohols and C6-C 12 condensates of alkylphenols with ethylene oxide / propylene oxide block polymers, such as those from BASF C 14 -C 22 medium-chain branched alcohols, BA; C 14 -C 22 medium-chain branched alkyl alkoxylates, BAE x , where x is from 1 to 30; alkyl polysaccharides; specifically alkyl polyglycosides; polyhydroxy fatty acid amides; and ether-capped poly(alkoxylated) alcohol surfactants. Suitable nonionic detergent surfactants also include alkyl polyglucosides and alkyl alkoxylated alcohols. Suitable nonionic surfactants also include those sold by BASF under the trade name those sold.

[0117] Non-limiting examples of cationic surfactants include: quaternary ammonium surfactants, which may have up to 26 carbon atoms, including: alkoxylated quaternary ammonium (AQA) surfactants; dimethyl hydroxyethyl quaternary ammonium; dimethyl hydroxyethyl lauryl ammonium chloride; polyamine cationic surfactants; cationic ester surfactants; and amino surfactants, such as amide propyl dimethylamine (APA). Suitable cationic detergent surfactants also include alkylpyridinium compounds, alkyl quaternary ammonium compounds, alkyl quaternary phosphonium compounds, alkyl ternary sulfonium compounds, and mixtures thereof.

[0118] Suitable cationic detergent surfactants are quaternary ammonium compounds having the following general formula:

[0119] (R)(R1)(R2)(R3)N + X -

[0120] wherein R is a straight-chain or branched-chain, substituted or unsubstituted C 6-18 alkyl moiety or alkenyl moiety, R1 and R2 are independently selected from a methyl moiety or an ethyl moiety, R3 is a hydroxy moiety, hydroxymethyl moiety or hydroxyethyl moiety, X is an anion providing electrical neutrality, and suitable anions include: halide ions (such as chloride ions); sulfate; and sulfonate. Suitable cationic detergent surfactants are mono-C 6-18 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride. Highly suitable cationic detergent surfactants are mono-C 8-10 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride, mono-C 10-12 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride and mono-C 10 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride.

[0121] Suitable examples of zwitterionic surfactants include: derivatives of secondary and tertiary amines, including derivatives of heterocyclic secondary and tertiary amines; derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfonium compounds; betaines, including alkyl dimethyl betaines, coconut oil dimethylamidopropyl betaines, sulfobetaines and hydroxybetaines; C8 to C 18 (e.g., C 12 to C 18 ) amine oxides; N-alkyl-N,N-dimethylamino-1-propane sulfonates, wherein the alkyl group can be C8 to C 18 .

[0122] Suitable amphoteric surfactants include aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines, wherein the aliphatic group can be straight-chain or branched-chain, and wherein one of the aliphatic substituents contains at least about 8 carbon atoms, or about 8 to about 18 carbon atoms, and at least one of the aliphatic substituents contains an anionic water-solubilizing group, such as carboxyl, sulfonate, sulfate. Suitable amphoteric surfactants also include sarcosinates, glycinate, taurates and mixtures thereof.

[0123] The fibrous element may comprise a surfactant system containing only anionic surfactants, such as a single anionic surfactant or a combination of two or more different anionic surfactants. Alternatively, the fibrous element may comprise a complex surfactant system, such as a combination of one or more anionic surfactants with one or more nonionic surfactants, or a combination of one or more anionic surfactants with one or more zwitterionic surfactants, or a combination of one or more anionic surfactants with one or more amphoteric surfactants, or a combination of one or more anionic surfactants with one or more cationic surfactants, or a combination of all the above types of surfactants (i.e., anionic surfactants, nonionic surfactants, amphoteric surfactants, and cationic surfactants).

[0124] Typically, the fibrous element is an elongated particle whose length greatly exceeds the average diameter, for example, the ratio of length to average diameter is at least about 10. The fibrous element can be a filament or a fiber. A filament is relatively longer than a fiber. The filament can have a length greater than or equal to about 5.08 cm (2 inches), and / or greater than or equal to about 7.62 cm (3 inches), and / or greater than or equal to about 10.16 cm (4 inches), and / or greater than or equal to about 15.24 cm (6 inches). The fiber can have a length less than about 5.08 cm (2 inches), and / or less than about 3.81 cm (1.5 inches), and / or less than about 2.54 cm (1 inch).

[0125] One or more filament-forming materials and the active agent may be present in the fibrous element in an amount such that the weight ratio of the filament-forming material to the total content of the active agent is about 2.0 or less, and / or about 1.85 or less, and / or less than about 1.7, and / or less than about 1.6, and / or less than about 1.5, and / or less than about 1.3, and / or less than about 1.2, and / or less than about 1, and / or less than about 0.7, and / or less than about 0.5, and / or less than about 0.4, and / or less than about 0.3, and / or greater than about 0.1, and / or greater than about 0.15, and / or greater than about 0.2. One or more filament-forming materials and the active agent may be present in the fibrous element in an amount such that the weight ratio of the filament-forming material to the total content of the active agent is from about 0.2 to about 0.7.

[0126] The fibrous element may comprise from about 10% to less than about 80% by weight, based on the weight of the dry fibrous element and / or dry fibrous structure, of a filament-forming material such as a polyvinyl alcohol polymer, a starch polymer, and / or a carboxymethyl cellulose polymer, and from greater than about 20% to about 90% by weight, based on the weight of the dry fibrous element and / or dry fibrous structure, of an active agent such as a surfactant. The fibrous element may further comprise a plasticizer such as glycerol and / or an additional pH regulator such as citric acid. The fibrous element may have a weight ratio of filament-forming material to active agent of about 2.0 or less. The filament-forming material may be selected from the group consisting of polyvinyl alcohol, starch, carboxymethyl cellulose, polyethylene oxide, and other suitable polymers, particularly hydroxyl-containing polymers and their derivatives. The weight average molecular weight range of the filament-forming material may be from about 100,000 g / mol to about 3,000,000 g / mol. It is believed that within this range, the filament-forming material may provide extensional rheology without elasticity, thereby inhibiting fiber attenuation during fiber manufacturing.

[0127] When the fibrous element and / or the fibrous structure comprising the fibrous element is exposed to the conditions of its intended use, one or more of the active agents may be capable of being released and / or released. The one or more active agents in the fibrous element may be selected from the group consisting of surfactants, organic polymeric compounds, and mixtures thereof.

[0128] The fibrous element may exhibit a diameter of less than about 300 μm, and / or less than about 75 μm, and / or less than about 50 μm, and / or less than about 25 μm, and / or less than about 10 μm, and / or less than about 5 μm, and / or less than about 1 μm. The fibrous element may exhibit a diameter greater than about 1 μm. The diameter of the fibrous element may be used to control the release rate of one or more active agents present in the fibrous element and / or the rate of loss and / or rate of change of the physical structure of the fibrous element.

[0129] Non-fibrous substrate

[0130] The non-fibrous water-soluble unit dose articles disclosed herein include a water-soluble non-fibrous substrate and one or more particles. The non-fibrous substrate may be, for example, a water-soluble film, foam, nonwoven material, or a combination thereof.

[0131] The non-fibrous substrate can be a soluble foam sheet and can contain polyvinyl alcohol (PVA) polymers or copolymers thereof as film formers, structurants, and carriers for any other optional ingredients such as surfactants and other active ingredients (e.g., emulsifiers, builders, chelating agents, fragrances, colorants, etc.). Preferably, the PVA polymer or copolymer is present in the non-fibrous foam substrate in an amount in the range of about 5% to about 50%, preferably about 10% to about 40%, preferably about 15% to about 30%, more preferably about 20% to about 25%, by weight of the total weight of the non-fibrous foam substrate, and most preferably the total amount of PVA present in the non-fibrous substrate does not exceed 25% of the total weight of the substrate.

[0132] The PVA polymers or copolymers suitable for use herein are selected from those having a weight average molecular weight in the following ranges: about 50,000 Daltons to about 400,000 Daltons, preferably about 60,000 Daltons to about 300,000 Daltons, more preferably about 70,000 Daltons to about 200,000 Daltons, and most preferably about 80,000 Daltons to about 150,000 Daltons. The weight average molecular weight is calculated by summing the products of the average molecular weight of each polymer raw material and their respective weight percentage by weight of the total weight of the polymers present in the porous solid.

[0133] The non-fibrous foam substrate is preferably prepared by first forming a wet premix containing PVA, any surfactant, and other optional ingredients, then shaping the wet premix into a sheet, and then drying such wet premix sheet to form a cured non-fibrous substrate. Correspondingly, the weight average molecular weight of the PVA polymer or copolymer can affect the overall film-forming characteristics of the wet premix and its compatibility / incompatibility with any desired additional ingredients. In addition, the weight average molecular weight of the PVA polymer or copolymer used herein may affect the viscosity of the wet premix, which in turn may affect various physical properties of the resulting non-fibrous substrate so formed.

[0134] The PVA polymer or copolymer is also characterized by a degree of hydrolysis in the range of about 40% to about 100%, preferably about 50% to about 95%, more preferably about 70% to about 92%, and most preferably about 80% to about 90%.

[0135] The PVA copolymer can contain vinyl alcohol monomers and one or more monomers of any other type. Preferred PVA copolymers can contain, in addition to vinyl alcohol monomers, one or more anionic monomers represented by the following formula (I) and / or (II):

[0136]

[0137] wherein R1, R2, and R3 are each independently H or methyl, and n is independently an integer from 0 to 3. If present, the above anionic monomer units are preferably present in an amount in the range of about 0.5 mol% to about 5 mol%.

[0138] Commercially available polyvinyl alcohols include those obtained from Celanese Corporation (Texas, USA) under the trade name CELVOL, including but not limited to CELVOL 523, CELVOL 530, CELVOL 540, CELVOL 518, CELVOL513, CELVOL 508, CELVOL 504; those obtained from Kuraray Europe GmbH (Frankfurt, Germany) under the trade name and POVAL TM ; and PVA 1788 (also known as PVA BP17), which is commercially available from various suppliers including Lubon Vinylon Co. (Nanjing, China); and combinations thereof. In one example, the non-fibrous substrate comprises from about 10% to about 25%, more preferably from about 15% to about 23%, by total weight of the article, of polyvinyl alcohol having a weight average molecular weight in the range of 80,000 daltons to about 150,000 daltons and a degree of hydrolysis in the range of about 80% to about 90%.

[0139] In addition to the PVA described above, a single starch or a combination of starches can be used as a filler material in an amount that reduces the overall level of PVA required, provided that it contributes to providing a non-fibrous substrate having the necessary structural and physical / chemical characteristics as described herein. However, too much starch can compromise the solubility and structural integrity of the non-fibrous article. Thus, it is preferred that the non-fibrous substrate comprises no more than 20%, preferably 0% to 10%, more preferably 0% to 5%, and most preferably 0% to 1% starch by weight of the solid sheet article.

[0140] The non-fibrous substrate can be a film. Preferred film materials are polymeric materials. As is known in the art, film materials can be obtained, for example, by casting, blowing, extruding, or blow molding and extruding polymeric materials. Preferred polymers, copolymers, or their derivatives suitable for use herein can include polyvinyl alcohol, polyvinylpyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetate, polycarboxylic acids and polycarboxylates, polyamino acids or peptides, polyamides, polyacrylamides, maleic acid / acrylic acid copolymers, polysaccharides (including starch and gelatin), natural gums (such as xanthan gum and carrageenan). More preferred polymers are selected from polyacrylates and water-soluble acrylate copolymers, methylcellulose, sodium carboxymethylcellulose, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and most preferably from polyvinyl alcohol, polyvinyl alcohol copolymers, and hydroxypropylmethylcellulose (HPMC) or combinations thereof.

[0141] Preferably, the content of the polymer such as PVA polymer in the film is at least 60%. The polymer can have any weight average molecular weight, preferably from about 1000 to 1,000,000, more preferably from about 10,000 to 300,000, still more preferably from about 20,000 to 150,000. Mixtures of polymers can also be used as the film. This may be beneficial for controlling the mechanical properties and / or dissolution properties of the compartments or the film according to their applications and the required requirements. Suitable mixtures include, for example, mixtures in which one polymer has a higher water solubility than another polymer, and / or one polymer has a higher mechanical strength than another polymer. Also suitable are mixtures of polymers having different weight average molecular weights, for example

[0142] mixtures of PVA or its copolymers having a weight average molecular weight of from about 10,000 to 40,000, preferably about 20,000, and mixtures of PVA or its copolymers having a weight average molecular weight of from about 100,000 to 300,000, preferably about 150,000.

[0143] Also suitable for use herein are polymer blend compositions, such as those comprising a hydrolyzable and water-soluble polymer blend, such as polylactide and polyvinyl alcohol, which are obtained by mixing polylactide and polyvinyl alcohol and generally contain from about 1-35% by weight of polylactide and from about 65% to 99% by weight of polyvinyl alcohol. Preferably used herein are polymers hydrolyzed from about 60% to about 98%, preferably from about 80% to about 90% hydrolysis to improve the dissolution properties of the material.

[0144] Of course, different film materials and / or films of different thicknesses can be employed herein. The beneficial effect of selecting different films is that the resulting products and / or compartments can exhibit different solubility or release characteristics.

[0145] The most preferred membrane materials are PVA membranes named MonoSol Trade References M8630, M8900, H8779 and those described in US 6,166,117 and US 6,787,512, as well as PVA membranes having corresponding solubility and plasticity characteristics, which are incorporated herein by reference.

[0146] The membrane materials of the present invention may also include one or more additive components. For example, it may be advantageous to add plasticizers such as glycerol, ethylene glycol, diethylene glycol, propylene glycol, sorbitol and mixtures thereof. Other additives include functional detergent additives to be delivered to the wash water, such as organic polymer dispersants and the like.

[0147] Particle

[0148] Particles may be incorporated into the water-soluble products discussed above at levels such as from about 0.1 g to about 30 g. The type of particles used can be any type compatible with the manufacturing system. One parameter that can contribute to the successful deposition of particles according to this method is the flowability of the particles. The flowability (f p ) can be defined as the ratio of the consolidation stress (cs) to the unconfined yield strength (ys). f p The larger, the better the particle flow. Generally, f p <1 is considered non-flowing, f p >1 but less than 2 is very cohesive, f p from 2 to less than 4 is considered cohesive, f p from 4 to less than 10 is considered easy to flow, and f p 10 or greater is considered free-flowing. For the above method, particles with an f p value of about 4 or greater are preferred. The flowability level can be determined by the flowability methods listed below. The flowability of the particles can be, for example, about 1 or greater, about 2 or greater, about 3 or greater, about 4 or greater, about 5 or greater, about 5 or greater, about 6 or greater, about 7 or greater, about 8 or greater, about 9 or greater, about 10 or greater, up to about 1000 or less.

[0149] The particles can be powders, granules, agglomerates, encapsulates, microcapsules and / or pellets. Many well-known methods in the art can be used to prepare the particles, such as spray drying, agglomeration, extrusion, granulation, encapsulation, tableting, and combinations thereof. The shape of the particles can be in the form of: spherical, rod-shaped, plate-shaped, tubular, square, rectangular, disc-shaped, star-shaped, fibrous, or having regular or irregular random shapes. The particles can have a D50 particle size of about 100 μm to about 1600 μm.

[0150] The granules can include a mixture of chemically different granules such as: surfactant granules including surfactant agglomerates, surfactant extrudates, surfactant needles, surfactant prills, surfactant flakes; phosphate granules; zeolite granules; silicate granules, especially sodium silicate granules; carbonate granules, especially sodium carbonate granules; polymer granules such as carboxylate polymer granules, cellulose polymer granules, starch granules, polyester granules, polyamine granules, terephthalic acid polymer granules, polyethylene glycol granules; aesthetic granules such as colored prills, needles, layered granules and ring granules; enzyme granules such as protease granules, amylase granules, lipase granules, cellulase granules, mannanase granules, pectate lyase granules, xyloglucanase granules, bleaching enzyme granules and co-granules of any of these enzymes, which enzyme granules may contain sodium sulfate; bleaching agent granules such as percarbonate granules, especially coated percarbonate granules such as percarbonate coated with carbonate, sulfate, silicate, borosilicate, or any combination thereof, perborate granules, bleach activator granules such as tetraacetylethylenediamine granules and / or alkoxylated benzene sulfonate granules, bleach catalyst granules such as transition metal catalyst granules, and / or isoquinolinium bleach catalyst granules, preformed peracid granules, especially coated preformed peracid granules; filler granules such as sulfate granules and chloride granules; clay granules such as montmorillonite granules and clay and siloxane granules; flocculant granules such as polyethylene oxide granules; wax granules such as wax agglomerates; siloxane granules, optical brightener granules; dye transfer inhibitor granules; dye fixative granules; perfume granules such as perfume microcapsules and starch encapsulated perfume blend granules, and precursor perfume granules such as Schiff base reaction product granules; colorant dye granules; chelating agent granules such as chelating agent agglomerates; and any combination thereof.

[0151] Combination

[0152] 1. An apparatus for discretizing a dose of granules, the apparatus comprising: a. a feeder system including a feeder, wherein the feeder system provides a continuous granule stream to a discretizing unit; and b. the discretizing unit, wherein the discretizing unit converts the continuous granule stream from the feeder system into individual granule doses, receives the granule doses through an inlet, and delivers the individual doses to a moving substrate through individual outlets.

[0153] 2. The apparatus according to claim 1, wherein the feeder system controls the mass flow rate of the granules.

[0154] 3. The device according to any one of 1 or 2, wherein the discretization unit comprises one or more pockets, the one or more pockets comprise the inlet and the outlet, and at least one of the one or more pockets is movable in a vertical direction, a horizontal direction, or a combination thereof.

[0155] 4. The device according to 3, wherein the pocket inlet receives particles from the feeder system.

[0156] 5. The device according to any one of 3 or 4, wherein the one or more pockets divide the continuous particle stream into individual doses.

[0157] 6. The device according to any one of 1 to 5, wherein the feeder system comprises a hopper and conveying equipment.

[0158] 7. The device according to any one of 1 to 6, wherein at least a portion of the discretization unit is movable in a vertical direction, a horizontal direction, or a combination thereof.

[0159] 8. The device according to 7, wherein the linear motion is aligned with the moving substrate.

[0160] 9. The device according to any one of 3 to 8, wherein adjacent ones of the one or more pockets are separated by a gap during receipt of the particles.

[0161] 10. The device according to 9, wherein the gap is adjustable, preferably by moving two adjacent pockets closer to each other.

[0162] 11. The device according to any one of 1 to 10, the device further comprising a flange attached to one or more pockets, wherein preferably the flange at least partially covers any gap between the one or more pockets.

[0163] 12. The device according to any one of 3 to 11, wherein when depositing particles onto the moving substrate, at least one of the one or more pockets moves in at least a horizontal direction.

[0164] 13. The device according to any one of 1 to 12, wherein the discretization unit moves in a loop.

[0165] 14. The device according to any one of 3 to 13, wherein the one or more pockets move in a loop.

[0166] 15. The device according to any one of 3 to 14, wherein adjacent ones of the one or more pockets are nested during receipt of the particles.

[0167] 16. The device according to any one of 1 to 15, wherein the discretization unit delivers the particles to a target area on the substrate, and at least 75%, about 80% or more, about

[0168] 85% or more, about 90% or more, about 95% or more, or most preferably about 97%

[0169] or more of the first particles remain on the target area when leaving the discretization unit.

[0170] 17. The device according to any one of 1 to 16, wherein the water-soluble substrate comprises a fibrous water-soluble substrate, a non-fibrous water-soluble substrate, or a combination thereof; preferably a water-soluble fibrous substrate.

[0171] 18. A device for discretizing particles into a single dose, the device comprising: a) a feeding system, wherein the feeding system provides a continuous stream of particles to a discretization unit; and b)

[0172] a discretization unit comprising a track and one or more movable pockets, wherein the one or more pockets convert the continuous stream of particles from the feeding system into individual particle doses and deliver the individual doses to a substrate.

[0173] 19. The device according to 18, wherein the one or more movable pockets receiving the particles are nested during receiving the particles.

[0174] 20. The device according to any one of 18 or 19, wherein the particles are delivered to a target area on the substrate, and at least 75%, about 80% or more, about 85% or more, about 90% or more, about 95% or more, or most preferably about 97% or more of the first particles remain on the target area when leaving the discretization unit.

[0175] 21. The device according to any one of 18 to 20, wherein the substrate is a movable substrate.

[0176] 22. The device according to any one of 18 to 21, wherein the water-soluble substrate comprises a fibrous water-soluble substrate, a non-fibrous water-soluble substrate, or a combination thereof; preferably a water-soluble fibrous substrate.

[0177] 23. The device according to any one of 18 to 22, wherein the feeding system controls the mass flow rate of the particles.

[0178] 24. The device according to any one of claims 18 to 23, wherein the discretization unit comprises one or more pockets, the one or more pockets comprising the inlet and the outlet, and at least one of the one or more pockets is movable in a vertical direction, a horizontal direction, or a combination thereof.

[0179] 25. The device according to claim 24, wherein the pocket inlet receives the particles from the feeder system.

[0180] 26. The device according to any one of claims 24 or 25, wherein the one or more pockets divide the continuous particle stream into individual doses.

[0181] 27. The device according to any one of claims 18 to 26, wherein the feeder system comprises a hopper and a conveying device.

[0182] 28. The device according to any one of claims 18 to 27, wherein at least a portion of the discretization unit is movable in a vertical direction, a horizontal direction, or a combination thereof.

[0183] 29. The device according to claim 28, wherein the linear movement is aligned with the moving substrate.

[0184] 30. The device according to any one of claims 24 to 29, wherein adjacent ones of the one or more pockets are separated by a gap during receipt of the particles.

[0185] 31. The device according to claim 30, wherein the gap is adjustable, preferably by moving two adjacent pockets closer to each other.

[0186] 32. The device according to any one of claims 18 to 31, the device further comprising a flange attached to the one or more pockets, preferably the flange at least partially covers any gap between the one or more pockets.

[0187] 33. The device according to any one of claims 27 to 32, wherein when depositing the particles onto the moving substrate, at least one of the one or more pockets moves in at least a horizontal direction.

[0188] 34. The device according to any one of claims 18 to 33, wherein the discretization unit moves in a loop.

[0189] 35. The device according to any one of claims 24 to 34, wherein the one or more pockets move in a loop.

[0190] Flowability method

[0191] The following comparative tests are carried out to demonstrate the flowability of the particles at ambient temperature and humidity.

[0192] The device suitable for this test is a commercially available flowability test system, Flodex TM (Teledyne Hanson Research, Chatsworth, Calif., USA), which includes a flat-bottomed cylindrical hopper with a removable bottom and a set of interchangeable chassis, and these chassis contain orifices of different sizes. In addition, additional chassis with orifices of smaller sizes (diameter less than 4 mm) are manufactured to provide a more complete range of orifice diameters, including 3 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 12 mm, 14 mm, 16 mm, 18 mm up to 34 mm.

[0193] Flodex TM The device includes a funnel for loading a particulate test sample into a flat-bottomed stainless-steel cylindrical hopper with a diameter of approximately 5.7 cm. The hopper has a removable bottom defined by a removable chassis, and the removable chassis has an orifice of a specific size. As mentioned above, a plurality of removable chassis with orifices of different sizes are provided, and these multiple removable chassis can be interchangeably fitted at the bottom of the hopper in place of the disk, thereby defining bottom orifices of different sizes. A discharge gate is placed directly below the orifice and above the receiver. When the flowability measurement starts, the discharge gate moves to expose the bottom orifice and allows the particulate test sample to flow downward from the hopper through the bottom orifice into the receiver.

[0194] To test the flowability of a specific test sample, the following steps are followed:

[0195] a. Fill the hopper by pouring approximately 75 ml of the test sample through the funnel. This corresponds to an approximately 1" (25 mm) powder layer in the cylindrical hopper.

[0196] b. After the sample has settled for 30 seconds, open the spring-loaded discharge gate and allow the sample to flow through the orifice into the receiver.

[0197] c. Repeat steps (a) and (b) for the same test sample using different chassis with orifices of gradually increasing orifice sizes. At the beginning, when using a chassis with a relatively small orifice, the flow of the test sample usually stops due to blockage at a certain point, that is, it cannot pass through the orifice due to the small orifice size. Once the flow of the test sample stops, blockage is declared, and the specific chassis causing the blockage is removed and replaced with another chassis with a slightly larger orifice, and steps (a) and (b) are repeated again. When the test sample can continuously flow through an orifice of a specific size three (3) times without blockage, such an orifice size is recorded as the Flodex TM blockage parameter and B refers to the diameter of the orifice in the flow plate used in the test. Flodex TMThe smaller the blocking parameter, the better the flowability of the test sample (i.e., it can flow through smaller orifices without clogging).

[0198] Then the flowability is calculated according to the following formula:

[0199]

[0200] , where \(H( heta')=(130^{\circ}- heta') / 65^{\circ}\) is the hopper flow function proposed by Jenike, \( heta'\) is the internal flow channel angle in the powder, \(A\) is the cross-sectional area of the FloDex TM , \(U\) is the perimeter of the Flodex TM , \(K\) is the lateral stress ratio proposed by Janssen, \(\phi'\) is the wall friction coefficient between the powder and the side wall of the steel cylinder, \(B\) is the critical blocking diameter in the Flodex TM (in mm), and \(h\) is the powder filling height in the Flodex TM (in mm). After inserting the values of the FloDex TM geometry and reasonable values of the powder in the flat-bottom steel hopper (\(K = 0.4, heta' = 10^{\circ}, \phi' = 20^{\circ}\)), the formula simplifies to:

[0201]

[0202] The dimensions and values disclosed herein should not be construed as strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to represent the recited value and a range functionally equivalent around that value. For example, a dimension disclosed as "40 mm" is intended to represent "about 40 mm".

[0203] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-reference or related patent or patent application and any patent application or patent to which this application claims priority or the benefit of, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein, or an admission that it alone or in any combination with any one or more other references anticipates, suggests, or discloses any such invention. Further, when any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to the term in this invention shall govern.

[0204] Although specific embodiments of the invention have been illustrated and described, it will be apparent 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. Accordingly, it is intended that all such changes and modifications that fall within the scope of the invention be covered by the appended claims.

Claims

1. An apparatus for discretizing a dose of particles, the apparatus comprising: a. A feeder system 300, the feeder system including a feeder, wherein the feeder system provides a continuous stream of particles to a discretization unit; and b. The discretization unit, wherein the discretization unit converts the continuous stream of particles from the feeder system into individual doses, receives the particles through an inlet, and delivers the individual doses to a moving substrate through individual outlets.

2. The apparatus according to claim 1, wherein the feeder system controls the mass flow rate of the particles.

3. The apparatus according to any one of claims 1 or 2, wherein the discretization unit includes one or more pockets, the one or more pockets including the inlet and the outlet.

4. The apparatus according to claim 3, wherein at least one of the one or more pockets is movable in a vertical direction, a horizontal direction, or a combination thereof.

5. The apparatus according to any one of claims 3 or 4, wherein the one or more pockets divide the continuous stream of particles into individual doses.

6. The apparatus according to any one of claims 3 to 5, wherein at least one pocket travels synchronously with the substrate during deposition of the particles onto the substrate.

7. The apparatus according to any one of claims 3 to 6, wherein adjacent ones of the one or more pockets are separated by a gap, preferably an adjustable gap, during receipt of the particles.

8. The apparatus according to claim 8, the apparatus further including flanges attached to the one or more pockets, wherein the flanges at least partially cover the gap between the one or more pockets.

9. The apparatus according to any one of claims 3 to 8, wherein at least one of the one or more pockets moves downwardly towards a first water-soluble fibrous substrate to deposit first particles, the first water-soluble fibrous substrate moves upwardly towards the one or more pockets to receive the first particles, or a combination thereof.

10. The apparatus according to any one of claims 3 to 9, wherein the one or more pockets move in a loop.

11. The apparatus according to any one of claims 3 to 10, wherein adjacent ones of the one or more pockets are nested during receipt of the particles.

12. The apparatus according to any one of claims 3 to 11, wherein the first particles are intermittently delivered from the discretization unit, preferably from the one or more pockets.

13. The apparatus according to any one of claims 1 to 12, wherein the particles are delivered to a target area on the substrate, and at least 75%, preferably 80% or more, more preferably 85% or more, even more preferably 90% or more, even more preferably 95% or more, or most preferably 97% or more of the particles remain on the target area when leaving the discretization unit.

14. The apparatus according to any one of claims 1 to 12, wherein the particles are intermittently delivered from the discretization unit, preferably from the one or more pockets.

15. The apparatus according to any one of claims 1 to 14, wherein the feeder system includes a hopper and conveying means.

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