Method for preparing fibrous water-soluble products

Abstract

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

Description

Technical Field

[0001] A method for preparing a fibrous water-soluble product using discrete units. Background Art

[0002] Fibrous 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 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] Fibrous substrates have historically been used in consumer products, including 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 manipulate 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. The surface texture of some fibrous substrates can be perceived by some consumers as unpleasant to the touch.

[0005] The manufacture of multi-layer sheet products from fibrous substrates can be challenging because the individual layers of the product need to be bonded to each other to form a cohesive product. Bonding and cutting multi-layer sheet products can be difficult if the thickness of the individual products varies across the surface of the product. This can easily occur when the product is loaded with particles. In addition, loading fibrous 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 a method of preparing a fibrous water-soluble unit dose product having particles that can be manufactured economically, has consumer-preferred operability, and maintains acceptable solubility. Summary of the invention

[0007] The present application includes a method for making a water-soluble product containing particles, the method comprising: a) providing a first continuous water-soluble fiber substrate moving in a first direction 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 fiber substrate; e) at least partially covering the first side of the first continuous water-soluble fiber substrate with a cover.

[0008] 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 fiber 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 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 onto a portion of a first side of the first continuous water-soluble fiber substrate; wherein at least one of the one or more pockets receiving the first particle nests with an adjacent pocket when receiving the first particle.

[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 a discretized particulate dose on a discontinuous substrate;

[0011] Figure 2 is a representation of an apparatus for depositing a discretized particulate dose 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 having particles

[0015] Figure 6 is a schematic view of a method for preparing a fibrous water-soluble product, wherein the pocket travels towards and contacts the water-soluble fiber 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 fibrous 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 fibrous water-soluble product, wherein at least a portion of the pocket (such as a shield) travels towards and contacts the water-soluble fiber substrate during application of the particles;

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

[0020] Figure 11 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 Top view of a unit for depositing particles onto a substrate using a plurality of feed systems in a radial configuration; and

[0022] Figure 13 Representation of adjacent pockets of flashing with minimum and maximum spacing configurations. Detailed Description

[0023] Manufacturing a fibrous water-soluble product 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 fibrous water-soluble products with particles included directly incorporating a small amount of particles into the substrate, such as by incorporating the particles during the substrate preparation method or spraying the particles onto the finished substrate. However, these methods have some drawbacks. When incorporating particles 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 adhesiveness and cohesiveness), particle stability during the substrate preparation method, difficulty in separating incompatible particles, etc. This method of addition also increases the cost of the manufacturing method because it may require dissolving solid components to add them to the substrate. Another drawback 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 numerous difficulties associated with known manufacturing methods, there remains a desire to load larger quantities of particles, different types of particles, control the location of the particles within the fibrous water-soluble product, and achieve these objectives 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 limitations. For example, the application of a screw auger-based intermittent particle filler is typically limited to an operating frequency of 3.33 doses per second – half of the target starting rate of nearly 6 doses per second. Utilizing this technology would require a significant capital investment to "add" units in series in an attempt to reach the 6-dose-per-second target starting rate.

[0025] Another challenge in adding particles to a fibrous water-soluble product is the manufacture of the fibrous water-soluble product. For example, one way to prepare a 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 remain 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 due to particles being in areas required for sealing.

[0026] Another challenge in controlling the delivery of particles to the 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 on the substrate where the fibrous substrate product is to be cut to form discrete units. Therefore, it is necessary to coordinate the timing of particle dose delivery and substrate movement to allow for the formation of discrete units.

[0027] In addition, movement of the substrate during and after particle application can make attempts to deliver particles to the desired portions of the substrate worse, as the particles may roll and / or splash as they land on the moving substrate or as they continue to move with the substrate to complete the manufacturing method. Additionally, lack of control over the coverage area of the particles deposited on the substrate can cause some particles to flow into the area used to seal the substrate, resulting in a 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 the seal and can cause product failure or inability to form a product. Ideally, these issues are controlled by 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.

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

[0029] Generally speaking, in the travelling mask method, a continuous particle feed is provided and the continuous particle feed is separated into discretized doses by using a discretization unit having pockets (explained in more detail below). The main speed-limiting factor of the travelling mask is gravity, as 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 reach the substrate is relatively fixed. When attempting to speed up the manufacturing method, this time can become a system-limiting factor due to the physical properties of the particle flow. However, the travelling mask concept allows for this fixed time component to be considered without fundamentally affecting the other parameters of the system. All that is needed is to increase the dwell time for proper alignment of a given pocket with the substrate. In a linear manufacturing method, this costs a relatively small longitudinal distance.

[0031] Through the design of the feed system and the discretization unit, the travelling 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 flow, and controlling the particle deposition).

[0032] Considering that the exit design of the pocket can be independently controlled by the pocket itself (e.g., shape, exit arrangement, baffle, etc.) and system design (e.g., the height from the pocket exit to the top of the substrate), it can be designed substantially quickly to meet the changing finished product requirements. For example, currently, a water-soluble fiber product may have a size of about 76×76 mm. If this form is compressed to an area of 60×60 mm, it is necessary to apply the particles 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 quite 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 according to the properties of the substrate. However, the traveling mask system can be optimized to offset these types of properties 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 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., defoamers), 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] Therefore, what the present 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 the substrate.

[0035] equipment

[0036] The equipment used in conjunction with the traveling mask method can include, for example, a feed system and a discretization unit. Generally speaking, 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 in the lateral direction ("CD"). On the other hand, the discretization unit receives the particle feed and converts it into individual particle doses.

[0037] The feeding system 300 may include, for example, a feeder 505, a conveying device 400, or a combination thereof. The discretization unit may include a conveyor system, one or more pockets, guards, or any combination thereof. The apparatus may include multiple feeding systems and / or multiple components of a single feeding system, as well as multiple discretization units and / or multiple components of a single discretization unit. The distance from the particle outlet of the feeding system (such as from the conveying device or the particle feeder) to the inlet of the discretization unit may 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 may be provided, for example, in the form of a roll. The substrate may be fed into the traveling mask system to receive particles and / or to form water-soluble unit doses containing particles. For example, a roll of the substrate may be fed into the system using rollers, belts, conveyors, or any combination thereof to deliver particles. Additionally, the substrate may be fed into the system and / or passed through the system under tension. The tension may be set, for example, by using a vacuum conveyor.

[0039] feeding system

[0040] The feeding system may include a feeder and / or a conveying device (see Figure 1 ). The feeding system 300 may include one or more feeders 505 and one or more conveying devices 400. The feeder and the conveying device may have the same or different configurations. For example, the feeder and / or the conveying device may be arranged in-line to allow addition of particles to the same or different pockets in the discretization unit (such as Figure 11 ). Additionally, multiple feeders and / or conveying devices may provide the same particles or different particles. The feeder and / or the conveying device may also be arranged in a radial configuration, where they may deliver the same or different particles (such as Figure 12 ). The feeding system may 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 may be deposited on the same or different substrates. Additionally, the first particle feed and the second particle feed may lead to the same or different pockets. The first particle feed and the second particle feed may be the same or different in composition.

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

[0042] An example of a feeder in a feeding system is a hopper. Hopper 500 can hold particles to be applied to a substrate. 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 hopper 500 slopes towards the front wall 520. The rear wall can slope at an angle, for example, of about 60 degrees or more with respect to the horizontal plane. Having a sloped surface in the rear wall helps prevent particles from rolling back in the hopper and helps prevent clogging.

[0043] The front wall 520 of hopper 500 can include an opening. The opening can be, for example, a vertical slot 530 or a horizontal slot (not shown). The vertical slot and the horizontal slot can have dimensions that are suitable for 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. Thus, the height and width of the slot can be adjusted to obtain optimal particle and manufacturing options.

[0044] 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 CD, or about 25 mm in CD, 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-end 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-end 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-end feeder can distribute 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 segmented / split 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 provide the particles onto a conveying device 400, or directly into a discretization unit. The outflow of particles from the opening of 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 3As 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 the leakage and / or spillage of particles. 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 the hopper 500), the particles may contact the conveying device. If the conveying device is the belt 600, it will generally be moving, preferably longitudinally. However, the direction of the conveying device can be adjusted as needed to a position, for example, between longitudinal and perpendicular to longitudinal, to help deliver the particles to the discretization unit most efficiently. The speed of the conveying device can also be adjusted.

[0050] The particles may travel along the conveying device (such as the belt 600) and spill onto the discretization unit 700 at the edge of the conveying device. In the case where the conveying device is the 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.

[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 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.

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

[0055] The conveyor system may include, for example, a track. One or more pockets may be movably or statically attached to the track. 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 guard. The guard may be used, for example, to help guide particles into and / or out of the pocket 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 attached 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 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), e.g., 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 and 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 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. Figure 13 An example of a cover sheet 750 on a pocket and how it can be used to help adjust the spacing is visible 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 in depositing particles 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 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 visible, 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 because 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 pocket 710 can have any acceptable shape for delivering particles to the substrate 800. For example, one or more pockets 710 can be in a funnel shape, as Figure 1 visible.

[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 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.

[0067] 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.

[0068] The particles pass through at least one of the one or more pockets 710 to reach the outlet 730, where they exit 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 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.

[0069] 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 unwinders. 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.

[0070] 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.

[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] The method for preparing a fibrous water-soluble product can first include preparing a fibrous water-soluble substrate. The substrate can be continuous or discontinuous. A description of the 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 mother substrate that is cut into multiple substrates during the manufacturing method can be provided. An example of a single substrate that forms multiple substrates is visible in Figure 4 In Figure 4 a mother continuous substrate 59 can be formed on the 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.

[0075] According to the apparatus described above, a method for manufacturing a unit dose product (such as a water-soluble fiber product) can include providing one or more substrates (e.g., a first water-soluble fiber substrate) to the traveling mask system in a continuous or discontinuous manner. An illustration of an exemplary method utilizing both continuous and discrete substrates is visible in Figure 1 and Figure 2 The substrate (e.g., the water-soluble fiber substrate) can be provided in the form of a roll or any other suitable known method. The substrate (e.g., the first water-soluble fiber 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., the water-soluble fiber 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.

[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, 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.

[0077] 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.

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

[0079] In one example, the feeder system 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 (such as a water-soluble fibrous substrate). In one example, the track is configured as 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 the feeding system where it receives the particles. When receiving the particles, one or more pockets may move at a constant or variable speed. One or more pockets may move longitudinally, laterally, or any combination thereof. The particles received from the feeding system may be in a continuous stream. The ability to utilize a continuous stream of particles 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.

[0081] By nesting of the pockets, the use of a continuous stream of particles from the feeder can be facilitated. Pocket nesting allows the separation of the continuous stream of particles into unit doses in one or more pockets. Nesting forces the particles into the pockets while minimizing any particle spillage that may be caused by the gaps between the pockets. Thus, the nesting of the pockets includes minimizing the gap 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 receiving the particles. This gap can be defined based on the particles received by the pockets (e.g., particle size, shape, and / or flowability). Two adjacent pockets may also have no effective gap 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 flaps. Such flanges and / or flaps can be positioned to effectively eliminate the gap between the products during pocket particle reception. The flange and / or flap may 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] The 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 may 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) may 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 may move downward towards the substrate to deposit the particles, the substrate may move upward towards the one or more pockets to receive the particles, or a combination thereof. The substrate may 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 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 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 indentation of the substrate. The contact of the pocket and / or the guard with the substrate can 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 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.

[0086] 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 trapping at least a portion of the particles between the substrate and the covering to form a 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.

[0087] fibrous water-soluble product

[0088] As discussed above, the substrate can be a fibrous water-soluble substrate. The fibrous water-soluble substrate can be continuous or discrete, such asFigure 1 and Figure 2 as shown. The fibrous water-soluble substrate can be used to form fibrous water-soluble products, which will be discussed in more detail below.

[0089] The 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. 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 on top of 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 fibrous water-soluble product. In Figure 5 , 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 fibrous water-soluble unit dose articles can 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 fibrous water-soluble unit dose articles can be fully bio-based to produce an article with a total bio-based content greater than 50%.

[0091] These 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 consumers have overloaded the machine, especially 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 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, bluing agents, or mixtures thereof. The printed area can be opaque, translucent, or transparent. The printed area can include single color or multiple colors. 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.

[0093] Fibrous water-soluble unit dose articles 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.

[0094] Fibrous water-soluble unit dose articles 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] Fibrous water-soluble unit dose articles can exhibit different regions, such as different regions of basis weight, density, thickness, and / or wetting characteristics. Fibrous water-soluble unit dose articles can be compressed at the edge seals. Fibrous water-soluble unit dose articles can include texture on one or more of their surfaces. The surface of the fibrous water-soluble unit dose article can include patterns, such as non-random repeating patterns. Fibrous water-soluble unit dose articles can include pores. Fibrous water-soluble unit dose articles can include a fibrous structure having discrete regions of fibrous elements that are different from other regions of the fibrous elements in the structure. Fibrous water-soluble unit dose articles can be used as is or coated with one or more active agents.

[0096] Fibrous water-soluble unit dose articles can include one or more laminae. 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 fiber laminae can be fibrous structures. Each lamina can include one or more layers, such as one or more fibrous element layers, one or more particle layers, and / or one or more fibrous element / particle mixture layers. The layer can be sealed. Specifically, the particle layer and the fibrous element / particle mixture layer can be sealed so that the particles do not leak. Water-soluble unit dose articles can include a plurality of laminae, where each lamina includes two layers, one of which is a fibrous element layer and one of which is a 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 adding the water-soluble unit dose article to water, the unit dose article dissolves and releases the particles into the wash liquid.

[0097] The fibrous water-soluble unit dose can be in the form of any three-dimensional structure. The fibrous 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 fibrous 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 fibrous water-soluble unit dose article disclosed herein comprises 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 that are intertwined or otherwise associated with each other to form a fibrous structure and one or more particles, which can be distributed 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 the 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, monolithic, 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 formed by spinning 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" mean 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 material may comprise a polymer. 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 material 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, subsequently result in undissolved solids. Accordingly, most such surfactants are formulated into granules.

[0110] The fibrous elements may each contain at least one filament-forming material and an active agent, preferably a surfactant. The surfactant may have a relatively low hydrophilicity since 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 dodecylbenzene sulfonate, 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 alkylphosphonic acids or branched alkylphosphonates, C6-C 20 alkyl N-methylglucamides, C6-C 20 methyl ester sulfonates (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 alkylphenyl groups 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 alkylphenols condensed 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 and those.

[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 hydroxyl 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. A suitable cationic detergent surfactant is a mono-C 6-18 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride. A highly suitable cationic detergent surfactant is a 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, for example, a combination containing one or more anionic surfactants and one or more nonionic surfactants, or a combination of one or more anionic surfactants and one or more zwitterionic surfactants, or a combination of one or more anionic surfactants and one or more amphoteric surfactants, or a combination of one or more anionic surfactants and 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 may be a filament or a fiber. A filament is relatively longer than a fiber. The filament may 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 may 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 active agents 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 active agents 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 also 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, especially 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 can 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 the intended use, one or more 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 can be used to control the release rate of one or more active agents present in the fibrous element and / or the loss rate and / or change rate of the physical structure of the fibrous element.

[0129] particle

[0130] Particles can be incorporated into the fibrous water-soluble product as discussed above at a level, for example, of about 0.1 g to about 30 g. The type of particles used can be any type that is 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 greater the f p , the better the particles 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 easily flowing, and fp being 10 or greater is considered free-flowing. For the above method, f p Particles with an f value of about 4 or greater are preferred. The level of flowability 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.

[0131] 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 spheres, rods, plates, tubes, squares, rectangles, discs, stars, fibers, or have regular or irregular random shapes. The particles can have a D50 particle size of about 100 μm to about 1600 μm.

[0132] The particles can include a mixture of chemically different particles such as: surfactant particles including surfactant agglomerates, surfactant extrudates, surfactant needles, surfactant prills, 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 prills, 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, which enzyme particles can 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 alkoxylated benzene sulfonate particles, bleach catalyst particles such as transition metal catalyst particles, and / or isoquinolinium bleach catalyst particles, pre - formed peracid particles, especially coated pre - formed 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; color - toning dye particles; chelating agent particles such as chelating agent agglomerates; and any combination thereof.

[0133] combination

[0134] 1. A method of manufacturing a water - soluble product comprising particles, the method comprising: a) providing a first continuous water - soluble 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 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 fibrous substrate; e) at least partially covering the first side of the first continuous water - soluble fibrous substrate with a cover.

[0135] 2. A method of manufacturing a water-soluble product comprising particles, the method comprising: a) providing a first continuous water-soluble 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;

[0136] c) feeding a first particulate matter to the inlet of at least one of the one or more pockets; d) delivering the first particulate matter from the outlet of the one or more pockets of the discretization unit onto a portion of the first side of the first continuous water-soluble fibrous substrate; wherein at least one of the one or more pockets receiving the first particulate matter nests with an adjacent pocket when receiving the first particulate matter.

[0137] 2a. The method according to claim 2, further comprising at least partially covering the first side of the first continuous water-soluble fibrous substrate with a covering.

[0138] 3. The method according to any one of 1 or 2a, further comprising sealing the first continuous water-soluble fibrous substrate and the covering, thereby entrapping at least a portion of the first particulate matter between the first water-soluble substrate and the covering, wherein the covering comprises a second fibrous water-soluble substrate.

[0139] 4. The method according to any one of 1 to 3, wherein the first particulate matter 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 matter remains on the target area when leaving the discretization unit.

[0140] 5. The method according to 4, wherein a plurality of pockets supply particulate matter to the target area.

[0141] 6. The method according to any one of 1 to 5, further comprising providing a second particulate matter feed, wherein the second particulate matter feed can be the same or different in composition from the first particulate matter, and the second particulate matter feed can be delivered to the same one or more pockets as the first particulate matter feed or to one or more pockets different from the first particulate matter feed.

[0142] 7. The method according to any one of 1 to 6, wherein the discretization unit discretizes a continuous stream of the first particulate matter into one or more individual doses, preferably the one or more pockets of the discretization unit.

[0143] 8. The method according to any one of 1 to 7, wherein the outlet has a smaller surface area than the inlet.

[0144] 9. The method according to any one of 1 to 8, wherein during deposition of the particles onto the first continuous water-soluble fiber substrate, at least one pocket of the discretization unit travels synchronously with the first continuous water-soluble fiber substrate.

[0145] 10. The method according to any one of 1 to 9, wherein the first continuous water-soluble fiber substrate moves in the first direction at about 5 m / min to about 100 m / min.

[0146] 11. The method according to any one of 1 to 10, wherein the first particles are delivered intermittently from the discretization unit, preferably from one or more pockets of the discretization unit.

[0147] 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.

[0148] 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.

[0149] 14. The method according to any one of 1 to 13, wherein the distance from the pocket outlet to the first water-soluble fiber substrate during delivery of the first particles is from 0 mm to about 50 mm.

[0150] 15. The method according to any one of 1 to 14, wherein at least two adjacent pockets are nested when receiving the first particles.

[0151] 16. The method according to 15, wherein at least one of the adjacent pockets includes a cover sheet on the side of the pocket closest to the adjacent pocket, and the cover sheet overlaps a part of the entrance of the adjacent pocket.

[0152] 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.

[0153] 18. The method according to any one of 1 to 17, wherein the first water-soluble fiber substrate is maintained at a constant distance from the discretization unit while being below the discretization unit.

[0154] 19. The method according to any one of 1 to 17, wherein at least one of the one or more pockets moves downward towards the first water-soluble fiber substrate to deposit the first particles, the first water-soluble fiber substrate moves upward towards the one or more pockets to receive the first particles, or a combination thereof.

[0155] 20. The method according to any one of 1 to 19, wherein the one or more pockets move in a loop.

[0156] fluidity method

[0157] The following comparative tests were conducted to demonstrate the flowability of the particles at ambient temperature and humidity.

[0158] 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 manufactured 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.

[0159] Flodex TM The apparatus includes a funnel for loading a particulate test sample into a flat-bottomed stainless steel cylindrical 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, which 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 is started, the discharge gate is moved 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.

[0160] To test the flowability of a specific test sample, the following steps are followed:

[0161] a. The hopper is filled 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.

[0162] b. After the sample has settled for 30 seconds, the spring-loaded discharge gate is opened and the sample is allowed to flow through the orifice into the receiver.

[0163] c. Repeat steps (a) and (b) for the same test sample using different chassis with orifices having gradually increasing orifice sizes. At the beginning, when using a chassis with a relatively small orifice, the flow of the test sample will typically stop due to blockage at some point, i.e., 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 having a slightly larger orifice, and steps (a) and (b) are repeated again. When the test sample can flow continuously three (3) times completely through an orifice of a specific size without blockage, such an orifice size is recorded as Flodex TM The blocking parameter and B refers to the diameter of the orifice in the flow plate 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).

[0164] Then calculate the flowability according to the following formula:

[0165] , where H(θ′) = (130 o - θ′) / 65 o 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 FloDex TM , U is the perimeter of FloDex TM , 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 Flodex TM (in mm), and h is the powder filling height in 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, θ′ = 10 o , φ′ = 20 o ), the formula simplifies to:

[0166]

[0167] 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".

[0168] Each document cited in this application, including any cross-referenced or related patent or patent application and any patent application or patent from 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 in this application or 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.

[0169] While the 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 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 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 fibrous substrate; e) at least partially covering the first side of the first continuous water-soluble fibrous substrate with a cover.

2. The method according to claim 1, further comprising sealing the first continuous water-soluble fibrous substrate and the cover, thereby trapping at least a portion of the first particle between the first water-soluble substrate and the cover, wherein the cover includes a second fibrous water-soluble substrate.

3. The method according to any one of claims 1 or 2, wherein the first particle is 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 particle, 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 particle 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 particle onto the first continuous water-soluble fibrous substrate, at least one pocket of the discretization unit travels synchronously with the first continuous water-soluble fibrous substrate.

8. The method according to any one of claims 1 to 7, wherein the first particle is 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 particle has a flowability of 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 20 mm of the first continuous substrate. 2 Up to 10,000mm 2 area 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 fibrous substrate during delivery of the first particle 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 particle.

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 fiber substrate to deposit the first particles, the first water-soluble fiber substrate moves upward towards the one or more pockets to receive the first particles, or a combination thereof.

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