Method for preparing non-fibrous water-soluble products

Abstract

Included herein are methods of making water-soluble non-fibrous substrates having particles and apparatuses for placing the particles on the water-soluble non-fibrous substrates.

Description

Technical Field

[0001] Method for preparing non-fibrous water-soluble products using discretization elements. Background Art

[0002] Non-fibrous water-soluble products are highly desired by consumers. These non-fibrous water-soluble products allow for easy use as consumers can easily and simply dispense a desired amount of the product into their desired process. This is much easier than having to pour a liquid or powder into the process, which can be very difficult to accurately dispense the correct amount of active substance and can also be physically difficult for some consumers.

[0003] Methods for manufacturing non-fibrous water-soluble products are complex and require many steps to form the non-fibrous water-soluble product and to dispense the desired amount of ingredients, such as particles, into the non-fibrous water-soluble product in an effective and consistent manner.

[0004] Typically, a first non-fibrous water-soluble film is formed into a cavity, an overall particle, such as a detergent composition, is dispensed into the cavity, and the cavity is sealed by a second non-fibrous water-soluble film. The process of dispensing the particles into the cavity can be inefficient, and controlling the consistency of the chemicals dispensed into the cavity can be challenging. This is particularly problematic for ingredients that are typically present in detergent compositions only in very low amounts, such as enzymes.

[0005] Accordingly, there is a continuing unmet need for a method of preparing non-fibrous water-soluble unit dose products with particles in an effective manner. Summary of the Invention

[0006] This application includes a method for manufacturing a water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble non-fibrous substrate including a first side moving in a first direction; b) providing a discretization unit including one or more pockets, wherein the one or more pockets have an inlet and an outlet; c) providing a first feed of a first particle to the inlet of at least one of the one or more pockets; d) delivering the first particle from the outlet of the one or more pockets of the discretization unit to at least a portion of the first side of the first continuous water-soluble non-fibrous substrate; e) at least partially covering the first side of the first continuous water-soluble non-fibrous substrate with a cover.

[0007] The present application also includes a method of manufacturing a water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble non-fibrous substrate moving in a first direction; b) providing a discretization unit comprising one or more pockets, wherein the one or more pockets have an inlet and an outlet; c) providing a feed of a first type of particles to the inlet of at least one of the one or more pockets; d) delivering the first type of particles from the outlet of the one or more pockets of the discretization unit onto a portion of a first side of the first continuous water-soluble non-fibrous substrate; wherein at least one of the one or more pockets receiving the first type of particles nests with an adjacent pocket when receiving the first type of particles.

[0008] These and other iterations will be described more fully below. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a representation of an apparatus for depositing a discretized particulate dose on a substrate;

[0010] Figure 2 is a representation of an apparatus for depositing a discretized particulate dose on a continuous substrate;

[0011] Figure 3 is a schematic view of a weir system on a hopper;

[0012] Figure 4 is a schematic view of a method for forming a single substrate into multiple substrates;

[0013] Figure 5 is a schematic view of a method for preparing a non-fibrous water-soluble product, wherein the pocket travels towards and contacts the water-soluble non-fibrous substrate during application of the particles;

[0014] Figure 6 is a schematic view of a method for preparing a non-fibrous water-soluble product, wherein the water-soluble non-fibrous substrate contacts the pocket during application of the particles and then descends away from the pocket;

[0015] Figure 7 is a schematic view of a method for preparing a water-soluble product, wherein two adjacent pockets nest with each other during receipt of the particles;

[0016] Figure 8 is a schematic view of a method for preparing a non-fibrous water-soluble product, wherein at least a portion of the pocket (such as a shield) travels towards and contacts the water-soluble non-fibrous substrate during application of the particles;

[0017] Figure 9 is a top view of a schematic view of a method for preparing a non-fibrous water-soluble product, wherein the discretization unit operates in a loop configuration;

[0018] Figure 10A top view of a unit that deposits particles onto a substrate using multiple feed systems in an in-line configuration;

[0019] Figure 11 A top view of a unit that deposits particles onto a substrate using multiple feed systems in a radial configuration; and

[0020] Figure 12 A representation of adjacent pockets of flashing in a minimum spacing configuration and a maximum spacing configuration. DETAILED DESCRIPTION

[0021] Manufacturing non-fibrous 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 large-scale production. Previous methods for manufacturing non-fibrous water-soluble products with particles included directly incorporating a small amount of particles into the substrate, such as by incorporating particles into the substrate during the substrate preparation method, or spraying particles onto the finished substrate. However, these methods have several disadvantages. When particles are incorporated into the substrate during the manufacture of the substrate, the particles can interfere with the capture and entanglement methods of preparing the substrate. This can lead to insufficient 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 adhesiveness and cohesiveness), stability of the particles during the substrate preparation method, difficulty in separating incompatible particles, etc. This addition method also increases the cost of the manufacturing method because 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 when the particles reach the area of the substrate to be sealed, this creates sealing problems.

[0022] 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 non-fibrous 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: dosing 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 filler is typically limited to an operating frequency of 3.33 doses / second - about 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.

[0023] Another challenge in adding particles to a non-fibrous water-soluble product is the manufacture of the non-fibrous water-soluble product. For example, one way to prepare a non-fibrous 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.

[0024] Another challenge in controlling the delivery of particles to a substrate is observed when 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 non-fibrous 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 the formation of discrete units.

[0025] 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, the inability to control the coverage area of the particles deposited on the substrate can cause some particles to flow into the area used for sealing the substrate, resulting in a non-fibrous water-soluble product. While a small amount of particles in this area can be tolerated, too many particles in this area will interfere with sealing and will cause the product to fail or prevent the product from being formed. Ideally, these issues are controlled through manufacturing conditions without the need to add corrective steps such as vacuum treatment to remove loose particles, thus allowing for more cost-effective and faster production of the product.

[0026] 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 changes in manufacturing rate and product size. The method solution is referred to as a travelling mask.

[0027] Generally speaking, in a traveling mask method, a continuous particle feed is provided and separated into discretized doses by using discretization units with pockets (explained in more detail below). The main speed-limiting factor for a traveling mask is gravity, as it is the main force used to deposit particles onto a substrate, although other forces can also be used.

[0028] Specifically, the rate at which gravity can pull 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 particles to pass through the discretization unit pockets and reach 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 other parameters of the system. All that is needed is to increase the dwell time with the given pockets properly aligned with the substrate. In a linear production method, this costs a relatively small longitudinal distance.

[0029] Through the design of the feed system and discretization units, the traveling mask concept also allows for accommodation of a wider range of particles. By manipulating certain properties, the system can accommodate particles exhibiting 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 being performed in the system (discretization, controlling the particle stream, and controlling particle deposition).

[0030] 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., 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 non-fibrous product may have dimensions of approximately 76×76 mm, and if this form is compressed to a 60×60 mm area, 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.

[0031] 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 adhere to the substrate and / or minimize the rebound 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 assist in pulling the particles onto the substrate and / or holding them in place.

[0032] 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.

[0033] device

[0034] 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.

[0035] 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, as well as 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.

[0036] 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 the 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.

[0037] feeding system

[0038] 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 the addition of particles to the same pocket or different pockets in the discretization unit (e.g., Figure 10 ). 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 11 ). 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.

[0039] When utilized, the conveying equipment 400 conveys the 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.

[0040] An example of a feeder in the feed system is a hopper. The hopper 500 can hold the particles to be applied 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 is inclined towards the front wall 520. The rear wall can be inclined at an angle, for example, of about 60 degrees or greater with respect to the horizontal plane. The presence of an inclined surface in the rear wall helps to prevent the particles from rolling back in the hopper and helps to prevent clogging.

[0041] 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 optimal particle and manufacturing options.

[0042] The slot can be of any suitable shape. The most common shape is rectangular. The horizontal slot can 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.

[0043] 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.

[0044] 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.

[0045] The feeder can supply the particles onto the conveying device 400 or directly into the discretization unit. The outflow of 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 can include, for example, a gate 550 that can be adjusted up and down by a mechanism.

[0046] The hopper 500 can 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.

[0047] 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 a 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.

[0048] 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 a belt 600 or a similar device, it can form a continuous loop that picks up the particles from the hopper 500 and delivers the particles to the discretization unit 700.

[0049] In the case of not using a conveying device, the particles leave the feeder and enter the discretization unit.

[0050] discretization unit

[0051] The discretization unit 700 receives a particle stream from the feeder and / or the conveying device and separates the particle stream into discrete particle loads. When looking at single-use 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.

[0052] 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.

[0053] 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 bring one or more pockets closer to the feeder or the conveying device when picking up particles and then lower to bring one or more pockets closer to the target substrate for particle application.

[0054] 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.

[0055] The discretization unit may include a guard. The guard 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 guard may contact the feeder, the conveying device, the substrate, the pocket, or any combination thereof. The guard may be attached to any part of the discretization unit, such as to the pocket. The guard may be attached to the pocket. The guard may be movably attached to the pocket. For example, when the pocket receives particles, the guard may be in one position, and when the pocket deposits particles onto the substrate, the guard may be in another position. The guard may be made of a flexible material, a rigid material, or a combination thereof. For example, a part of the guard that contacts the feeder, the conveying device, and / or the substrate may be flexible while the rest may be rigid.

[0056] 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.

[0057] One or more pockets may be in motion. The pockets may move vertically and / or horizontally. One or more pockets may move in the longitudinal 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 pocket and away from the target substrate.

[0058] 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 part of one or more sides. This close fitting (kissing) of at least a part of two or more pockets prevents particle loss between the pockets, especially when the particles are loaded into one or more pockets.

[0059] 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 the 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.

[0060] In cases where the pockets are rigid and they contact during the receipt of 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 allow minimization of particle spillage between two adjacent pockets, cover sheets can be used. In Figure 12 an example of a cover sheet 750 on a pocket and how it can be used to help adjust the spacing is visible.

[0061] It can also be used to force the 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 a higher specificity of particle deposition onto the target substrate. This can even allow for particle printing, where, with an appropriate design of the outlets of the pockets on the discretization unit (e.g., adding a screen), patterns are made on the target substrate with the particles.

[0062] 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 visible, multiple pockets 710 in the discretization unit travel under a conveying device (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 the 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 the 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.

[0063] 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 facilitate 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 pocket 710 can have any acceptable shape for delivering the particles to the substrate 800. For example, one or more pockets 710 can be funnel-shaped, as Figure 1 visible.

[0064] 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 keep the particles flowing through the pocket. The outlet size is also helpful. An outlet size that is at least 3X the maximum particle size of the particles deposited on the target substrate can help minimize bridging and / or clogging.

[0065] Additionally, the interior of the pocket can include design features such as baffles. These design features can be used, for example, to direct the particles to the outlet, control the energy of the particles between the inlet and the outlet, minimize clogging, etc.

[0066] The particles pass through at least one of the one or more pockets 710 to the outlet 730, where they leave the one or more pockets 710 and are deposited onto the substrate 800. The distance from the outlet of the pocket to the substrate can be, for example, from 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 be below the substrate plane to reach a negative value. Additionally, a negative value indicates a situation where the outlet of the pocket may extend into a cavity formed in the substrate and is also below the substrate plane.

[0067] Once the particles are deposited on the substrate, the substrate can be folded onto itself to create a covering. A second substrate or multiple substrates can be placed on the particle-containing substrate to form a covering. The second substrate or multiple substrates used as the covering can be introduced, for example, via their own rollers and unwind mechanisms. The second substrate or multiple substrates can travel with the substrate on which the particles are deposited and be stacked on the particle-containing substrate through, for example, folding plates, idler wheels, etc.

[0068] Once the covering is in place, the covering 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.

[0069] 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.

[0070] manufacturing method

[0071] A method for preparing a non-fibrous water-soluble product may first include preparing a non-fibrous water-soluble substrate. The substrate may be continuous or discontinuous. Once the substrate is formed, it can be provided to the method. A single substrate, multiple substrates, or even a mother substrate that is cut into multiple substrates during the manufacturing method can be provided. In Figure 4 an example of a single substrate forming multiple substrates can be seen. In Figure 4 , a mother continuous substrate 59 can be formed on a die block assembly 40 and then cut in the longitudinal MD by a knife 70 (e.g., a rotary cutting knife cut in the longitudinal MD) to form a first continuous substrate 60 and a second continuous substrate 65. Cutting the second substrate from the mother continuous laminate substrate 59 is practical for providing better manufacturing quality control.

[0072] According to the apparatus described above, a method for manufacturing a unit dose product (such as a water-soluble non-fibrous product) may include providing one or more substrates (e.g., a first water-soluble non-fibrous substrate) to a traveling mask system in a continuous or discontinuous manner. In Figure 1 and Figure 2 an illustration of an exemplary method utilizing both continuous and discrete substrates can be seen. The substrate (e.g., a water-soluble non-fibrous substrate) can be provided in the form of a roll or any other suitable known method. The substrate (e.g., a first water-soluble non-fibrous substrate) can be fed into the traveling mask system to receive particles on the substrate (e.g., on the first side of the substrate (e.g., a water-soluble non-fibrous substrate)). The substrate can be fed into the traveling mask system to receive particles using rollers, belts, conveyors, or any combination thereof. 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.

[0073] The substrate fed into the traveling mask system can move continuously, discontinuously, or a combination thereof. The substrate can move in a first direction, e.g., longitudinally. The substrate can also move transversely. 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.

[0074] The substrate can enter a traveling mask system adjacent to, for example, a feeding system, a discretization unit, or a combination thereof. Particles are delivered to the feeding system, such as a hopper. Generally, the particles are fed into the feeding system through, for example, a belt, a chute, etc. The particles generally enter a feeder in the feeding 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 feeding 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.

[0075] 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 flow of particles from the feeder system to the discretization unit can be continuous or discontinuous.

[0076] In one example, the feeder system includes a vibrating feeder (i.e., the feeder) and a chute (i.e., the conveying device). The particles are fed into the vibrating feeder, which deposits the particles into the chute. The vibrating motion of the feeder causes the particles to move along the chute until they reach the end of the chute. At this point, the particles proceed towards the discretization unit. For example, this can be done by gravity, where the particles cascade over the end of the chute and fall into the discretization unit.

[0077] 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 (such as a water-soluble non-fibrous substrate). In one example, the tracks are configured in a loop, such as circular or elliptical (e.g., Figure 9 ). 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 7 ) When the pocket travels along a path (e.g., via an orbit), the pocket passes through the 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, laterally, or any combination thereof. The particles received from the feeding system can be in a continuous stream. The ability to utilize a continuous particle stream simplifies the delivery to the discretization unit because it does not require precise alignment timing between the feeder and the discretization unit to get the correct amount of particles into the pockets of the unit.

[0078] By nesting of the pockets, the use of a continuous particle stream from the feeder can be facilitated. Pocket nesting allows separation of the continuous particle stream 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.

[0079] 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.

[0080] 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 5 to 6 and Figure 8 ). For example, the substrate can start at height H1, rise towards the pocket such that it is at 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 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.

[0081] Ideally, during particle application, at least one pocket of the discretization unit can travel synchronously with the substrate at least during deposition of the particles onto the substrate, although it can also travel synchronously with the substrate before and / or after particle application. It is also desirable that, when applying the 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 can 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 can contribute to the deposition of the particles 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.

[0082] The substrate can 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 can affect the ability of the delivered particles to be applied to and remain within the target area. The traveling mask can 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 can deliver particles to the same target area of the substrate.

[0083] The discretization unit or a portion of the discretization unit can 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 can be at least partially covered. Such covering can be achieved, for example, by folding a portion of the substrate onto itself, and / or by placing another substrate on at least a portion of the substrate having the particles. The substrate can then be sealed around the particles, thereby entrapping at least a portion of the particles between the substrate and the covering to form a non-fibrous water-soluble product. The sealed pockets of the particles can then be cut to separate them from each other and / or from the external substrate material and packaging for transportation and / or use.

[0084] non-fibrous water-soluble product

[0085] The non-fibrous water-soluble product can comprise a water-soluble non-fibrous substrate. The substrate can be continuous or discrete, as Figure 1and Figure 2 as shown. Non-fibrous water-soluble substrates can be used to form non-fibrous water-soluble products, which will be discussed in more detail below.

[0086] Non-fibrous water-soluble products can include one or more layers. These layers can be stacked on top of each other. These layers can be placed directly on top of each other, with particles between these layers, or a combination thereof. The layers of the non-fibrous water-soluble product can comprise a non-fibrous water-soluble substrate, particles, or a combination thereof.

[0087] Non-fibrous water-soluble unit dose articles can comprise 50% or more bio-based materials, such as, for example, bio-based materials between 50% and 95%. Some of the individual components of the non-fibrous water-soluble unit dose articles can be fully bio-based to produce an article with a total bio-based content greater than 50%.

[0088] These non-fibrous 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).

[0089] The surface of the non-fibrous water-soluble unit dose article can include a printed area. The printed area can cover from about 10% to about 100% of the article surface. The printed area can include inks, pigments, dyes, blueing agents, or mixtures thereof. The printed area can be opaque, translucent, or transparent. The printed area can include single-color or multi-color. The printed area can be on more than one side of the article and contain instructional text, graphics, etc. The surface of the water-soluble unit dose article can contain an aversive 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 aversive agent can 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.

[0090] The non-fibrous water-soluble unit dose article can exhibit a thickness of, 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.

[0091] The non-fibrous water-soluble unit dose article can have a basis weight of about 500 g / m 2 up to about 5,000 g / m 2 、or about 1,000 g / m2 to about 4,000 g / m 2 、or about 1,500 g / m 2 to about 3,500 g / m 2 、or about 2,000 g / m 2 to about 3,000 g / m 2 or a basis weight of a combination thereof.

[0092] Non-fibrous water-soluble unit dose articles can exhibit different regions, such as different regions of basis weight, density, thickness, and / or wetting characteristics. Non-fibrous water-soluble unit dose articles can be compressed at the edge seal. Non-fibrous water-soluble unit dose articles can include texture on one or more surfaces of their surface. The surface of the non-fibrous water-soluble unit dose article can include patterns, such as non-random repeating patterns. Non-fibrous water-soluble unit dose articles can include pores. Non-fibrous water-soluble unit dose articles can include a non-fibrous structure having discrete regions of non-fibrous elements that are different from other regions of the non-fibrous elements in the structure. Non-fibrous water-soluble unit dose articles can be used as is, or can be coated with one or more active agents.

[0093] Non-fibrous water-soluble unit dose articles can include one or more laminae. Non-fibrous water-soluble unit dose articles can include at least two and / or at least three and / or at least four and / or at least five laminae. The non-fibrous laminae can be non-fibrous structures. Each lamina can include one or more layers, such as one or more non-fibrous element layers, one or more particle layers, and / or one or more non-fibrous element / particle mixture layers. The layer can be sealed. Specifically, the particle layer and the non-fibrous element / particle mixture layer can be sealed so that the particles do not leak. The water-soluble unit dose article can include a plurality of laminae, where each lamina includes two layers, one of which is a non-fibrous element layer and one of which is a non-fibrous element / particle mixture layer, and the plurality of laminae are sealed (e.g., at the edge) together. Sealing can inhibit the leakage of particles and help the unit dose article maintain its original structure. However, after the water-soluble unit dose article is added to water, the unit dose article dissolves and releases the particles into the washing liquid.

[0094] Non-fibrous water-soluble unit doses can be in the form of any three-dimensional structure. Non-fibrous water-soluble unit dose articles can be open-celled. The article can also be cut or formed 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.

[0095] The non-fibrous water-soluble unit dose may contain fewer than 10 components. The water-soluble unit dose may contain from 3 to 9 components, such as 4 components, 5 components, 6 components, 7 components, or 8 components.

[0096] 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 can be, for example, a water-soluble film, foam, non-woven material, or a combination thereof.

[0097] The non-fibrous substrate can be a soluble foam sheet and can contain a polyvinyl alcohol (PVA) polymer or copolymer thereof as a film-forming agent, a structuring agent, and a carrier for any other optional components 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 based on the total weight of the non-fibrous foam substrate. Most preferably, the total amount of PVA present in the non-fibrous substrate does not exceed 25% of the total weight of the substrate.

[0098] 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, 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 corresponding weight percentage by weight based on the total weight of the polymer present in the porous solid.

[0099] The non-fibrous foam substrate is preferably prepared by first forming a wet premix containing PVA, any surfactant, and other optional components, then shaping the wet premix into a sheet, and then drying such a 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 components. 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.

[0100] 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%, most preferably about 80% to about 90%.

[0101] The PVA copolymer may comprise vinyl alcohol monomers and one or more monomers of any other type. Preferred PVA copolymers may comprise, in addition to vinyl alcohol monomers, one or more anionic monomers represented by the following formula (I) and / or (II):

[0102]

[0103]

[0104] 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%.

[0105] 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 and POVAL TM under the trade name from Kuraray Europe GmbH (Frankfurt, Germany); and PVA 1788 (also known as PVA BP17), which is commercially available from various suppliers including Lubon VinylonCo. (Nanjing, China); and combinations thereof. In one example, the non-fibrous substrate comprises about 10% to about 25%, more preferably 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%.

[0106] In addition to the PVA as described above, a single starch or a combination of starches may be used as a filler material in an amount that reduces the overall level of PVA required, provided that it helps to provide a non-fibrous substrate having the necessary structural and physical / chemical characteristics as described herein. However, too much starch may comprise the solubility and structural integrity of the non-fibrous article. Therefore, preferably the non-fibrous substrate comprises no more than 20%, preferably 0% to 10%, more preferably 0% to 5%, most preferably 0% to 1% starch by weight of the solid sheet article.

[0107] 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, extrusion, or blown extrusion of 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 selected from polyvinyl alcohol, polyvinyl alcohol copolymers, and hydroxypropylmethylcellulose (HPMC) or combinations thereof.

[0108] 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 about 1,000 to 1,000,000, more preferably about 10,000 to 300,000, still more preferably about 20,000 to 150,000. Mixtures of polymers can also be used as films. This can be beneficial for controlling the mechanical properties and / or dissolution properties of the compartments or films according to their applications and 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, such as

[0109] mixtures of PVA or its copolymers having a weight average molecular weight of about 10,000 to 40,000, preferably about 20,000, and mixtures of PVA or its copolymers having a weight average molecular weight of about 100,000 to 300,000, preferably about 150,000.

[0110] Also suitable for use herein are polymer blend compositions, such as those comprising a hydrolyzable degradable and water-soluble polymer blend, such as polylactide and polyvinyl alcohol, which is obtained by mixing polylactide and polyvinyl alcohol and typically comprises about 1-35% by weight of polylactide and about 65% to 99% by weight of polyvinyl alcohol. Preferably used herein are polymers that are hydrolyzed about 60% to about 98%, preferably about 80% to about 90% hydrolysis to improve the dissolution properties of the material.

[0111] 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.

[0112] 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.

[0113] 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, etc.

[0114] granule

[0115] Particles can be incorporated into the fibrous water-soluble products discussed above at levels, for example, of 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 ) of the particles can be defined as the ratio of the consolidation stress (cs) to the unconfined yield strength (ys). The larger the f p , 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 from 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. 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, tabulation, and combinations thereof. The shape of the particles can be in the following forms: 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.

[0116] The particles can include a mixture of chemically different particles, such as: surfactant particles, including surfactant agglomerates, surfactant extrudates, surfactant needles, surfactant pellets, surfactant flakes; phosphate particles; zeolite particles; silicate particles, especially sodium silicate particles; carbonate particles, especially sodium carbonate particles; polymer particles, such as carboxylate polymer particles, cellulose polymer particles, starch particles, polyester particles, polyamine particles, terephthalic acid polymer particles, polyethylene glycol particles; aesthetic particles, such as colored pellets, needles, layered particles and ring particles; enzyme particles, such as protease particles, amylase particles, lipase particles, cellulase particles, mannanase particles, pectate lyase particles, xyloglucanase particles, bleaching enzyme particles and co-particles of any one of these enzymes, and these enzyme particles may contain sodium sulfate; bleaching agent particles, such as percarbonate particles, especially coated percarbonate particles, such as percarbonate coated with carbonate, sulfate, silicate, borosilicate, or any combination thereof, perborate particles, bleach activator particles such as tetraacetylethylenediamine particles and / or alkyloxysulfonate particles, bleach catalyst particles such as transition metal catalyst particles, and / or isoquinolinium bleach catalyst particles, preformed peracid particles, especially coated preformed peracid particles; filler particles, such as sulfate particles and chloride particles; clay particles, such as montmorillonite particles and clay and siloxane particles; flocculant particles, such as polyethylene oxide particles; wax particles, such as wax agglomerates; siloxane particles, optical brightener particles; dye transfer inhibitor particles; dye fixative particles; fragrance particles, such as fragrance microcapsules and starch-encapsulated fragrance blend particles, and pre-fragrance particles, such as Schiff base reaction product particles; colorant dye particles; chelating agent particles, such as chelating agent agglomerates; and any combination thereof.

[0117] combination

[0118] 1. A method of manufacturing a water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble non-fibrous substrate moving in a first direction and including a first side; b) providing a discretization unit including one or more pockets, wherein the one or more pockets have an inlet and an outlet; c) providing a first feed of first particles to the inlet of at least one of the one or more pockets; d) delivering the first particles from the outlet of the one or more pockets of the discretization unit to at least a portion of the first side of the first continuous water-soluble non-fibrous substrate; e) at least partially covering the first side of the first continuous water-soluble non-fibrous substrate with a cover.

[0119] 2. A method of manufacturing a water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble non-fibrous substrate moving in a first direction; b) providing a discretization unit comprising one or more pockets, wherein the one or more pockets have an inlet and an outlet; c) providing a feed of a first particulate to the inlet of at least one of the one or more pockets; d) delivering the first particulate from the outlet of the one or more pockets of the discretization unit onto a portion of a first side of the first continuous water-soluble non-fibrous substrate; wherein at least one of the one or more pockets receiving the first particulate nests with an adjacent pocket when receiving the first particulate.

[0120] 2a. The method according to claim 2, further comprising at least partially covering the first side of the first continuous water-soluble non-fibrous substrate with a cover.

[0121] 3. The method according to any one of 1 or 2a, further comprising sealing the first continuous water-soluble non-fibrous substrate and the cover, thereby entrapping at least a portion of the first particulate between the first water-soluble substrate and the cover, wherein the cover comprises a second non-fibrous water-soluble substrate.

[0122] 4. The method according to any one of 1 to 3, wherein the first particulate is delivered to a target area on the first side of the first continuous water-soluble 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 particulate remains on the target area when leaving the discretization unit.

[0123] 5. The method according to 4, wherein a plurality of pockets supply particulates to the target area.

[0124] 6. The method according to any one of 1 to 5, further comprising providing a second particulate feed, wherein the second particulate feed can be the same or different in composition from the first particulate, and the second particulate feed can be delivered to the same one or more pockets as the first particulate feed or to one or more pockets different from the first particulate feed.

[0125] 7. The method according to any one of 1 to 6, wherein the discretization unit discretizes a continuous stream of the first particulate into one or more individual doses, preferably the one or more pockets of the discretization unit.

[0126] 8. The method according to any one of 1 to 7, wherein the outlet has a smaller surface area than the inlet.

[0127] 9. The method according to any one of 1 to 8, wherein during deposition of the particles onto the first continuous water-soluble non-fibrous substrate, at least one pocket of the discretization unit travels synchronously with the first continuous water-soluble non-fibrous substrate.

[0128] 10. The method according to any one of 1 to 9, wherein the first continuous water-soluble non-fibrous substrate moves in the first direction at about 5 m / min to about 100 m / min.

[0129] 11. The method according to any one of 1 to 10, wherein the first particles are intermittently delivered from the discretization unit, preferably from the one or more pockets of the discretization unit.

[0130] 12. The method according to any one of 1 to 11, wherein the particles have a flowability of 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.

[0131] 13. The method according to any one of 1 to 12, wherein the particles are delivered from the discretization unit to an area of about 20 mm 2 to about 10,000 mm 2 of the first continuous substrate to form a unit dose.

[0132] 14. The method according to any one of 1 to 13, wherein the distance from the pocket exit to the first water-soluble non-fibrous substrate during the delivery of the first particles is 0 mm to about 50 mm.

[0133] 15. The method according to any one of 1 to 14, wherein at least two adjacent pockets are nested when receiving the first particles.

[0134] 16. The method according to 15, wherein at least one of the adjacent pockets includes a cover flap on the side of the pocket closest to the adjacent pocket, and the cover flap overlaps a part of the entrance of the adjacent pocket.

[0135] 17. The method according to any one of 1 to 16, wherein the one or more pockets move in the first direction at a constant speed, or a combination thereof, when receiving particles.

[0136] 18. The method according to any one of 1 to 17, wherein the first water-soluble non-fibrous substrate is maintained at a constant distance from the discretization unit while being below the discretization unit.

[0137] 19. The method according to any one of 1 to 17, wherein at least one of the one or more pockets moves downwardly towards the first water-soluble non-fibrous substrate to deposit the first particles, the first water-soluble non-fibrous substrate moves upwardly towards the one or more pockets to receive the first particles, or a combination thereof.

[0138] 20. The method according to any one of 1 to 19, wherein the one or more pockets move in a loop.

[0139] 21. The method according to any one of claims 1 to 20, wherein the water-soluble non-fibrous web comprises a foam, a film, a nonwoven fabric, or a combination thereof.

[0140] fluidity method

[0141] The following comparative tests were conducted to demonstrate the flowability of the particles at ambient temperature and humidity.

[0142] The apparatus suitable for this test is the commercially available flowability test system Flodex TM (Teledyne HansonResearch, Chatsworth, Calif., USA), which comprises a flat-bottomed cylindrical hopper with a removable bottom and a set of interchangeable chassis, which contain orifices of different sizes. In addition, additional chassis with orifices of smaller sizes (diameter less than 4 mm) were fabricated in order 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.

[0143] Flodex TM The equipment includes a funnel for loading a particulate test sample into a flat-bottomed cylindrical stainless steel hopper having a diameter of about 5.7 cm. The hopper has a removable bottom defined by a removable chassis, which has an orifice of a specific size. As mentioned above, a plurality of removable chassis with orifices of different sizes are provided, and the plurality of removable chassis are interchangeably fitted at the bottom of the hopper in place of the disc, thereby defining bottom orifices of different sizes. A discharge gate is placed directly below the orifice and above the receiver. When the flowability measurement begins, the discharge gate moves so as to expose the bottom orifice and allow the particulate test sample to flow downward from the hopper through the bottom orifice into the receiver.

[0144] To test the flowability of a specific test sample, the following steps are followed:

[0145] 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.

[0146] b. After the sample has settled for 30 seconds, open the spring-loaded discharge door and allow the sample to flow through the orifice into the receiver.

[0147] c. Repeat steps (a) and (b) for the same test sample using different trays with orifices of gradually increasing size. At the beginning, when using a tray with a relatively small orifice, the flow of the test sample will usually stop due to blockage at a certain point, i.e., it cannot pass through the orifice because of the small orifice size. Once the flow of the test sample stops, blockage is declared, and the specific tray causing the blockage is removed and replaced with another tray with a slightly larger orifice, and steps (a) and (b) are repeated again. When the test sample can flow continuously and completely through an orifice of a specific size three (3) times without blockage, such an orifice size is recorded as the Flodex TM Blocking parameter and B refers to the diameter of the orifice in the flow tray used in the test. Flodex TM The smaller the blocking parameter, the better the flowability of the test sample (i.e., it can flow through a smaller orifice without blockage).

[0148] Then calculate the flowability according to the following formula:

[0149]

[0150] , where H(θ′) = (130° - θ′) / 65° is the hopper flow function proposed by Jenike, θ′ is the internal flow channel angle in the powder, A is the cross-sectional area of the Flodex TM of, U is the perimeter of the Flodex TM of, K is the lateral stress ratio proposed by Janssen, φ′ 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 (in mm), and h is the powder filling height in the Flodex TM in (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, θ′ = 10°, φ′ = 20°), the formula simplifies to:

[0151]

[0152] The dimensions and values disclosed herein should not be construed as strictly limited to the exact numerical values cited. 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".

[0153] Each document cited in this application, including any cross-referenced 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, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein, or 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 application 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 application shall govern.

[0154] 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. A method of manufacturing a water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble non-fibrous substrate moving in a first direction and including a first side; b) providing a discretization unit including one or more pockets, wherein the one or more pockets have an inlet and an outlet; c) providing a first feed of first particles to the inlet of at least one of the one or more pockets; d) delivering the first particles from the outlet of the one or more pockets of the discretization unit to at least a portion of the first side of the first continuous water-soluble non-fibrous substrate; e) at least partially covering the first side of the first continuous water-soluble non-fibrous substrate with a covering.

2. The method according to claim 1, further comprising sealing the first continuous water-soluble non-fibrous substrate and the covering, thereby entrapping at least a portion of the first particles between the first water-soluble substrate and the covering, wherein the covering comprises a second non-fibrous water-soluble substrate.

3. The method according to any one of claims 1 or 2, wherein the first particles are delivered to a target area on the first side of the first continuous water-soluble 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 first particles remain on the target area when leaving the discretization unit.

4. The method according to any one of claims 1 to 3, further comprising providing a second particle feed, wherein the second particle feed can be the same or different in composition from the first particles, and the second particle feed can be delivered to the same one or more pockets as the first particle feed or to one or more pockets different from the first particle feed.

5. The method according to any one of claims 1 to 4, wherein the discretization unit discretizes a continuous stream of the first particles into one or more individual doses.

6. The method according to any one of claims 1 to 5, wherein the outlet has a smaller surface area than the inlet.

7. The method according to any one of claims 1 to 6, wherein during deposition of the particles onto the first continuous water-soluble non-fibrous substrate, at least one pocket of the discretization unit travels synchronously with the first continuous water-soluble non-fibrous substrate.

8. The method according to any one of claims 1 to 7, wherein the first particles are intermittently delivered from the discretization unit, preferably from the one or more pockets.

9. The method according to any one of claims 1 to 8, wherein preferably when measured according to the flowability method, the particles have a flowability of about 1 or greater.

10. The method according to any one of claims 1 to 9, wherein the particles are delivered from the discretization unit to an area of from about 20 mm 2 to about 10,000 mm 2 to form a unit dose.

11. The method according to any one of claims 1 to 10, wherein the distance from the pocket outlet to the first water-soluble non-fibrous substrate during delivery of the first particles is from 0 mm to 50 mm.

12. The method according to any one of claims 1 to 11, wherein at least two adjacent pockets are nested when receiving the first particles.

13. The method according to any one of claims 1 to 12, wherein at least one of the adjacent pockets includes a flap on the side of the pocket closest to the adjacent pocket, and the flap overlaps a part of the entrance of the adjacent pocket.

14. The method according to any one of claims 1 to 13, wherein the one or more pockets move in the first direction when receiving the particles, move at a constant speed, or a combination thereof.

15. The method according to any one of claims 1 to 14, wherein at least one of the one or more pockets moves downward towards the first water-soluble non-fibrous substrate to deposit the first particles, the first water-soluble non-fibrous substrate moves upward towards the one or more pockets to receive the first particles, or a combination thereof.

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