Paper box

Abstract

A carton comprising: a) a base; b) a lid having a top side and a bottom side; c) a first side; d) a front side wherein at least a portion of the front side is positioned adjacent to the first side and there is an arcuate transition between the first side and the front side; e) a second side wherein at least a portion of the second side is positioned adjacent to the front side and there is an arcuate transition between the second side and the front side; and f) a rear side wherein a portion of the rear side is positioned adjacent to the first side and a portion of the rear side is positioned adjacent to the second side and the rear side does not have an arcuate transition between itself, the first side or the second side.

Description

TECHNICAL FIELD

[0001] The present application relates to cartons for containing products. The products can include, for example, unit dose articles. BACKGROUND

[0002] A growing trend among consumers is to use single use products in pre-determined doses. Consumers desire these unit dose products because they provide a convenient, efficient, and clean way of dosing the desired product. However, one challenge for manufacturers is how to package such products so that they are aesthetically pleasing and maintain the convenience of use. This is especially true when trying to bundle a large number of such products together. Thus, there is a need for a package for a plurality of single use articles that is able to maintain the convenience of its use. SUMMARY

[0003] Included herein is a carton comprising: a) a base; b) a lid having a top side and a bottom side; c) a first side; d) a front side, wherein at least a portion of the front side is positioned adjacent to the first side; e) a second side, wherein at least a portion of the second side is positioned adjacent to the front side; and f) a back side, wherein a portion of the back side is positioned adjacent to the first side and a portion of the back side is positioned adjacent to the second side; wherein the carton comprises 2 right angle corners and 2 non-right angle corners.

[0004] Also included herein is a carton comprising: a) a base portion comprising: i) a first side; ii) a front side, wherein at least a portion of the front side is positioned adjacent to the first side and there is an arcuate transition between the first side and the front side; iii) a second side, wherein at least a portion of the second side is positioned adjacent to the front side and there is an arcuate transition between the second side and the front side; and iv) a back side, wherein a portion of the back side is positioned adjacent to the first side and a portion of the back side is positioned adjacent to the second side and the back side does not have an arcuate transition between itself, the first side, or the second side; and b) a lid having a top side and a bottom side; wherein the lid is integral with a portion of the carton.

[0005] This embodiment, as well as other embodiments, are more fully described below. BRIEF DESCRIPTION OF DRAWINGS

[0006] Figure 1 is a perspective view of a closed carton;

[0007] Figure 2 is a perspective view of an open carton with a tray and products

[0008] Figure 3 is a schematic view of an open carton without a tray

[0009] Figure 4 is a schematic view of an open carton with a tray;

[0010] Figure 5 is a schematic view of a flat carton before assembly;

[0011] Figure 6 is a micro-CT scan of a cross-section of a substantially flat unit dose;

[0012] Figure 7 is a perspective view of a closed carton with chamfers; and

[0013] Figure 8 is a schematic view of an open carton with chamfers on both the lid and base of the carton. DETAILED DESCRIPTION

[0014] Unit dose articles, such as those used in dish care and laundry, are popular with consumers for their ease of use. When these types of articles are sold in bulk, they are often packaged in a bucket style package where the unit doses are not arranged in a particular pattern and are removed from a random stack or pile at the time of use. While some of this can be attributed to the design of the unit dose product itself, it can lack aesthetic appeal and is not optimal for all unit dose article types.

[0015] Some unit dose types are more amenable to ordered packaging. These can include those that are flat or substantially flat. Substantially flat unit dose types are those where the major surfaces are substantially parallel. Substantially flat unit dose types can be stacked on top of one another without exceeding at least 3 heights. Depending on the unit dose, ordered packaging can allow more unit doses to be placed in the package than a bucket. It also allows for more efficient use of space. Ordered packaging can also protect the unit doses from damage by the seal or shear damage that occurs when unit doses rub against one another.

[0016] The first part of ordered packaging is the outer package. This is the package that encases the product and is visible to the consumer. One common outer product package is a carton. Cartons are generally square or rectangular in shape and often have a uniform shape. Here, the inventors wanted to design a carton with a unique shape. As shown in Figures 1 to 8 the inventors designed a carton with non-right angle corners and right angle corners. Right angle corners are those where the walls intersect to form approximately a 90° angle. Non-right angle corners can include, for example, rounded corners, chamfered corners, concave corners, star corners, beveled corners, or combinations thereof. Non-right angle corners can include any shape that gives the overall impression that the corner is not a right angle. Utilizing non-right angle corners on a portion of a carton can present some challenges. For example, in the case where the carton has a lid, the lid will need to have complementary shaped non-right angle corners. In addition, the lid will need to have proper clearance from the rest of the carton to properly open and close.

[0017] Most cartons with mixed corner shapes, such as non-right angle corners and right angle corners, have two different pieces formed separately as this simplifies assembly of the lid and base and allows for easy opening. However, the present design can be made from a single piece of carton board. This means that the lid is integral with at least a portion of the carton. This attachment of the lid to a portion of the carton provides a smaller gap for the lid and is a challenge to overcome. The present inventor has overcome this challenge.

[0018] For those embodiments with rounded corners, different curvatures can be used on the rounded corners on the base portion of the carton and the corresponding rounded corners on the lid to allow for sufficient gap between the lid and the base portion. For example, in the case where the lid overlaps the outside of the base portion, the curvature of any rounded corners on the lid will be greater than the curvature of the corresponding rounded corners on the base portion. In the closed configuration, where the lid is positioned to the inside of the base portion, the opposite is true. Curvature can be measured by the radius of curvature. For a curve, the radius of curvature is the radius of the circle that best fits the normal section of the curve. Thus, for a rounded corner, one would find the circle that best fits the normal section of the rounded corner and look at the radius. The radius of the circle can be measured according to any known standard. For sufficient gap between the lid and the base portion, a difference in curvature of at least 2%, 3%, 4%, 5%, 7%, 10%, 12%, 15% to about 50%, 70%, 80%, 90% or 100% or more can be utilized between the lid and the base portion.

[0019] For embodiments with non-right angle corners, where the lid overlaps the outside of the base portion and the lid is integral with at least a portion of the carton, some additional ways to help ensure a gap between the lid and the base portion can include having the lid protrude beyond the base portion and having the lid have a larger area than the base (not including any panel portions on the lid and base). For embodiments with non-right angle corners, where the lid is positioned to the inside of the base portion and the lid is integral with at least a portion of the carton, some additional ways to help ensure a gap between the lid and the base portion can include having the base portion protrude beyond the lid and having the base have a larger area than the lid (not including any panel portions on the lid and base).

[0020] Another challenge encountered with this design is consistency in the shape of the non-right angle corners in the finished carton. Maintaining the shape of non-right angle corners, such as rounded corners, helps to provide the proper gap for the lid, and thus consistency in these shapes is needed during the manufacturing process to achieve a uniform, finished carton. To maintain consistent non-right angle corner shapes during manufacturing, score marks can be added to a portion of the panels and / or tabs used to manufacture the non-right angle corners to indicate where the non-right angle shape begins and / or ends. For manual construction of the carton, these marks can be visible to the human eye and / or have sufficient contrast to guide automation on the manufacturing line. Preferably, these marks are not visible to the consumer in the finished carton.

[0021] When the carton is made from a single piece of paperboard, some changes to the manufacturing process also help to achieve a more uniform finished carton shape. Using a layflat and forming the carton in a sequential manner allows the carton to have non-right angle corners (e.g., rounded corners) without the need for hard folds or multi-piece assembly. A layflat is a collapsed parallelogram state in which the carton is partially assembled before being moved to another station and / or location for assembly with another. Sequential assembly can include first forming and gluing the bottom portion of the carton, and then forming and gluing the lid. For example, where the lid overlaps the outside of the bottom portion, the lid can be formed around the bottom portion to help ensure proper non-right angle corner shape (e.g., curvature is maintained). Where the lid is inside the bottom portion, sequential assembly can include first forming and gluing the lid, and then forming the bottom portion around the lid to help maintain proper shape of the non-right angle corners.

[0022] Once the lid gap with consistent corner shape (e.g., consistent curvature) has been established between the bottom portion and the lid during the manufacturing process, this gap needs to be maintained for filling and / or use. To maintain this gap, the carton needs to have sufficient rigidity so that it does not deform excessively when filled with product, shipped, or handled by the consumer. The rigidity of the carton can be increased by the material used to manufacture the carton and / or by structuring built into the carton. Here, where the material of the carton is bent to form the carton, the rigidity that can be achieved by the material itself is limited.

[0023] For paperboard, a minimum thickness is needed to allow for sufficient rigidity and a maximum thickness is needed to allow for bending to form the carton. The exact thickness needed can depend on whether the carton utilizes support structures that help the carton's rigidity. In such cases, a lower thickness material can be used. Also, a smaller overall package size can allow for a lower thickness material. The carton can be made from paperboard having a thickness of from about 0.008 inch to about 0.028 inch, from about 0.012 inch to about 0.028 inch, from about 0.016 inch to about 0.028 inch, most preferably from about 0.016 inch to about 0.024 inch. The paperboard can include, for example, clay-coated newsprint board, folding boxboard, solid bleached sulfate, natural kraft, coated unbleached kraft, and coated recycled paperboard.

[0024] As mentioned above, if sufficient rigidity cannot be achieved through the carton's material alone, structures can be used to supplement the carton's rigidity. If there is not enough structure in the carton, the shape of the carton can deform and the lid gap created by the effort to form the carton can be lost. Providing structure to the carton can be done in a number of ways. For example, one or more interior walls extending from a non-right angle corner (e.g., a rounded corner) can be provided and glued in place and / or structural supports can be included in the carton. Such structural supports can provide horizontal support, vertical support, or a combination thereof. The structural supports can also be provided in the form of internal packaging and / or internal structures, which will be described in more detail below.

[0025] Another portion of the organized packaging can include internal structures and / or internal packaging. The internal structures can include, for example, product guides and / or dividers that can help position the products during product filling and / or help maintain the products in the desired order in the packaging. The product guides and / or dividers can be integral portions of the carton or something added separately. Also, these structures can be designed in a way that provides additional structure to the carton itself. For example, these structures can be very close (or even touching) to the top side of the bottom portion and / or the bottom side of the lid to help minimize the amount that these two structures will deform when pressure is applied to one or both. The same can be true if these structures are placed in a horizontal manner that extends from the front side to the back side, where these structures will help minimize the deformation of those portions of the carton when pressure is applied. These structures in either configuration can also help provide structure to the carton such that twisting of the carton is minimized when, for example, the carton is being handled by a consumer.

[0026] One potential problem with packaging products directly into the outer package, however, is that if there is a problem with the packaging manufacturing process, the finished product has nowhere to go and can jam up on the manufacturing line, creating a host of problems. One solution to this problem is to utilize an inner package. The use of an inner package allows the finished product to be packaged within the inner package without interruption if there is a problem with the manufacturing of the outer package. The use of an inner package also allows the product to be stored and / or used in a modular configuration. This allows flexibility in the size of the outer package, the number of units included in the package, and how the inner packages are arranged in the outer package. For example, the product can be shipped in the outer package in one configuration, and rearranged by the consumer into a different configuration for use.

[0027] The inner package also has other potential uses. The inner package can capture any product leakage so that the product in the remainder of the outer package is not affected. The inner package can also help to maintain the product in a desired configuration and minimize the risk of the product shifting during shipping or shelf storage. The inner package can also help to prevent the product from being compressed during packaging, shipping, and / or storage.

[0028] The inner package can include, for example, a sleeve, a carton, a tray, a bag, or a combination thereof. The sleeve and bag can be made of different materials, such as a film, a paperboard, a paper, a wax paper, a foil, a cellophane, a plastic, or any combination thereof. The sleeve and bag can help to maintain the flavor life of the unit dose product by protecting the unit dose product from exposure to air. If desired, the sleeve and bag can also include an aperture to allow for controlled release of the flavor contained within the unit dose product. The sleeve and bag can also include a closure, such as a seal, a snap, a hook and loop fastener, an interlocking flange, or any combination thereof.

[0029] One example of an inner package is a tray. As noted above, in general, loading the product into a tray allows the finished product to be aggregated and transferred away from problem areas in the manufacturing process without having to be discarded. Another benefit of a tray or similar structure is that the tray can be made to fit different quantities, allowing flexibility in determining the size of the outer package to best meet the needs of the consumer. Loading the product into a tray also minimizes the amount of contact between individual unit doses and helps to prevent damage from such interaction. The tray can be oriented vertically or horizontally or a combination thereof to help control the way the size is displayed relative to each other on a shelf. It also imparts a more organized appearance to the product and a better consumer experience when the outer package is opened. The trays can be the same size and shape in a carton or a combination of sizes and shapes can be used in a carton.

[0030] Another advantage of using an inner package, such as a tray, is that the structure of the tray can be used to help provide additional support to the outer package. For example, a portion of the tray wall, such as a side wall, can be extended so that it provides internal vertical support from the base to the lid, making the overall package more robust. Packaging the inner structure in a way that substantially occupies most of the space in the outer package can also provide horizontal support to the carton. These can help provide support to avoid accidental distortion and / or bending of the carton. The inner package can also help prevent and / or minimize deformation of the lid or base portion when these components are under stress, such as when being carried or opened. The inner package also helps keep the weight of the product within the carton, such as unit doses, evenly distributed, helping to prevent the product from shifting during shipping, shelving, and use. The inner package also allows for modular use of the product. For example, a consumer can remove a tray of product from a larger package, such as a carton, and store the tray close to the location or use, while leaving the remainder of the product in the outer package at a different storage location.

[0031] When utilizing a carton having a non-uniform shape or a shape that does not match the shape of the product to be loaded into the carton, additional structures can be added to the carton to allow for more uniform loading of the product. For example, in a carton having 2 non-right angle corners, a structure can be added that makes the interior portion of the carton, for example, square or rectangular, to allow for better packaging of products that are primarily square and / or rectangular. The structure can be, for example, an internal wall or compartment.

[0032] Carton

[0033] Cartons are described herein with reference to the indicated figures. As Figure 1 and Figures 7 to 8 shown, carton 10 can have one or more non-right angle corners, such as rounded corners 20 and chamfered corners 180. The carton can have 1 to 4 non-right angle corners, preferably 1 to 3 non-right angle corners, more preferably 2 to 3 non-right angle corners, most preferably 2 non-right angle corners. The carton can have 1 to 4 rounded corners, preferably 1 to 3 rounded corners, more preferably 2 to 3 rounded corners, most preferably 2 rounded corners. The carton can have 1 to 4 chamfered corners, preferably 1 to 3 chamfered corners, more preferably 2 to 3 chamfered corners, most preferably 2 chamfered corners. Carton 10 can have one or more right angle corners 30. The carton can have 1 to 3 right angle corners, preferably 2 to 3 right angle corners, most preferably 2 right angle corners. The carton can have 2 rounded corners and 2 right angle corners. The carton can have 2 chamfered corners and 2 right angle corners. The carton can have any desired shape. Preferably, the carton has a generally rectangular shape.

[0034] The carton can have a base portion 40 and a lid 50, as Figures 2 to 5The bottom portion 40 can include a base 60, a front side 70, a back side 80, a first side 90, and a second side 100. The base 60 can help define the shape of the bottom of the carton 10. Thus, the base 60 can have 1 to 4 non-right angled corners, preferably 1 to 3 non-right angled corners, more preferably 2 to 3 non-right angled corners, most preferably 2 non-right angled corners. The base 60 can have 1 to 4 rounded corners 20, preferably 1 to 3 rounded corners, more preferably 2 to 3 rounded corners, most preferably 2 rounded corners. The base 60 can have one or more right angled corners 30. The base 60 can have 1 to 3 right angled corners, preferably 2 to 3 right angled corners, most preferably 2 right angled corners. The base 60 can have 1 to 4 beveled corners 180, preferably 1 to 3 beveled corners, more preferably 2 to 3 beveled corners, most preferably 2 beveled corners. The base 60 can have 2 rounded corners and 2 right angled corners. The base 60 can have 2 beveled corners and 2 right angled corners.

[0035] The base 60 can include one or more panels 110. The one or more panels can include a wall. The one or more panels can be the first side 90, the back side 80, the front side 70, and / or the second side 100. The first side 90, the back side 80, the front side 70, and / or the second side 100 can extend upwardly from the base 60 when in the folded configuration. The base 60 can include one or more guides. The guides can be used to help load products into the carton. For example, the guides can help properly place internal packaging, such as a removable tray. The guides can be panels that extend upwardly from the base 60. Score lines 120 can also be provided between the base 60, the first side 90, the back side 80, the front side 70, and / or the second side 100. The score lines 120 can be continuous or discontinuous. It can or can not penetrate the material. The score lines 120 can be used as fold lines to mark where the material is to be folded and / or to help provide a more uniform fold at a particular point.

[0036] The base 60 can include one or more structural shelves. The structural shelves can extend upwardly from the base 60 toward the bottom side of the lid 50. The structural shelves can extend to a height of at least 80% of the height between the base 60 and the bottom side of the lid 50. The structural shelves can extend to a height of about 80% to 100% of the height between the base 60 and the bottom side of the lid 50. The structural shelves can contact the base 60 and the bottom side of the lid 50.

[0037] Each of the panels 110 can also include additional panels. For example, the front side 70 can include a panel 110. For example, the panel can form a top portion 140A of a compartment 140 on the inside of the carton 10 (see Figure 3 and Figure 4 ). The panel that forms the top portion of the compartment 140 can also include one or more panels. The additional panels can, for example, form a wall 140B of the compartment 140 (see Figure 5). The wall 140B can act as a guide for placement of a removable tray or other internal packaging. The compartment 140 can create void space in the carton 10. This void space can be used to include, for example, a desiccant to help control humidity within the carton 10, product samples, supplemental products, etc. The flat surface of the compartment 140 can be used to provide information to a consumer, for example, interesting facts, coupons, instructions for use, etc.

[0038] The compartment 140 can also help the structural integrity of the carton by helping to keep the internal packaging aligned. When non-right angle corners are included in the packaging, this can create an asymmetrical shape on the interior of the packaging. This asymmetry can cause difficulties in the process of packaging the product. By including the compartment 140, the shape of the interior of the packaging can be symmetrical, which can be easier to fill.

[0039] Each panel 110 can also include one or more tabs 130 extending from the panel for connecting the panel to another portion of the carton. The tabs can, for example, adhesively connect portions of the carton. The panels can also interlock with another portion of the carton to connect the pieces together. Each panel can include from about 1 to about 10 tabs, from about 1 to about 8 tabs, from about 1 to about 6 tabs, from about 1 to about 4 tabs, from about 1 to about 3 tabs, from about 1 to about 2 tabs, or any combination thereof. For example, the back side 80 can include 1 or more tabs 130, preferably 2 tabs 130; the front side 70 can include 1 or more tabs 130, preferably 2 tabs 130; the panel forming the wall 140B of the compartment 140 can include 1 or more tabs 130, preferably 1 tab 130.

[0040] The tab 130 extending from the wall 140B can be attached to the base 60 of the carton 10. The tab 130 extending from the wall 140B can be attached to the base 60 such that it resides inside the compartment 140. Figure 3 However, it has been observed that there are benefits to attaching the tab 130 extending from the wall 140B to the base 60 such that it resides outside of the compartment 140. In the manufacturing process, when the base portion is formed, the carton is folded over on itself. When in this partially folded configuration, attaching the tab to the base inside the compartment results in an uneven number of layers of paperboard, which makes it more difficult to complete assembly and less efficient to transport the partially constructed carton to another location to complete assembly.

[0041] The lid 50 can have a top side and a bottom side. In the closed configuration, the top side will be visible, while the bottom side will be on the inside of the closed carton. The lid 50 can be integrally formed with the bottom portion 40 of the carton 10 or separate from the bottom portion 40. When the lid 50 is integral with the bottom portion 40, it can be attached to the first side 90, the back side 80, the front side 70, and / or the second side 100 in any configuration in which it will open to allow access to the contents of the carton 10. The lid 50 is preferably attached to one of the first side 90, the back side 80, the front side 70, or the second side 100 with a score line 120 disposed between the lid 50 and the side to which it is attached. Preferably, the lid 50 is attached to the back side 80 with the score line 120 disposed therebetween.

[0042] The lid 50 can help define the shape of the top of the carton 10. Accordingly, the lid 50 can have 1 to 4 non-right angled corners, preferably 1 to 3 non-right angled corners, more preferably 2 to 3 non-right angled corners, most preferably 2 non-right angled corners. The lid 50 can have 1 to 4 rounded corners 20, preferably 1 to 3 rounded corners, more preferably 2 to 3 rounded corners, most preferably 2 rounded corners. The lid 50 can have one or more right angled corners 30. The lid 50 can have 1 to 3 right angled corners, preferably 2 to 3 right angled corners, most preferably 2 right angled corners. The lid 50 can have 1 to 4 bevels 180, preferably 1 to 3 bevels, more preferably 2 to 3 bevels, most preferably 2 bevels. The lid 50 can have 2 rounded corners and 2 right angled corners. The lid 50 can have 2 bevels and 2 right angled corners. Where the base has a particular shape, the lid can mirror that shape. For example, the base 60 can have 2 rounded corners 20 and the corresponding lid 50 can have complementary rounded corners 20 (e.g., rounded corner 20a on the base 60 corresponds to rounded corner 20a on the lid 50). The lid 50 can have 2 rounded corners and 2 right angled corners. The lid 50 can have 2 bevels and 2 right angled corners. Figure 4 ).

[0043] The lid 50 can include one or more panels 110. The one or more panels 110 can include walls. The one or more panels 110 attached to the lid can have a score line 120 disposed between them and the lid 50. The one or more panels attached to the lid can be folded such that, when the carton 10 is in the closed configuration, the panels at least partially overlap one or more of the first side 90, the back side 80, the front side 70, or the second side 100 (see, e.g., FIG. 6). Figure 2 The one or more panels attached to the lid can be folded such that, when the carton 10 is in the closed configuration, the panels at least partially overlap one or more of the first side 90, the back side 80, the front side 70, or the second side 100 (see, e.g., FIG. 6).

[0044] The lid 50 can include one or more guides. The guides can be used to help load products into the carton 10. For example, the guides can help properly place internal packaging, such as a removable tray. The guides can be panels that extend downward from the lid 50.

[0045] The lid 50 can include one or more structural shelves. The structural shelves can extend downward from the lid 50 toward the base 60. The structural shelves can extend to a height of at least 80% of the height between the base 60 and the bottom side of the lid 50. The structural shelves can extend to a height of about 80% to 100% of the height between the base 60 and the bottom side of the lid 50. The structural shelves can contact the base 60 and the bottom side of the lid 50.

[0046] The lid 50 can include a cutout 150 (see Figure 2 ) or a closure tab 160. The cutout 150 or the closure tab 160 can be positioned on the lid and / or one of the lid panels 110. For example, the cutout 150 or the closure tab 160 can be positioned at least partially along the score line 120 between the lid 50 and the lid panel 110. The cutout 150 can be any shape. In instances where the lid 50 includes a cutout 150, the corresponding piece on the bottom portion 40 will include a closure tab 160. For example, in instances where the lid 50 includes a cutout 150 positioned at least partially along the score line 120 between the lid 150 and the panel 110, where the panel 110 will overlap at least a portion of the front side 70 when folded down and in the closed configuration, the closure tab 160 can be positioned on the panel 110 attached to the front side 70 along the score line 120 between the front side 70 and the panel 110. The closure tab 160 will engage the cutout 150 when the carton 10 is in the closed configuration to help retain the lid 50 in the closed position. The lid can also include multiple cutouts and / or multiple closure tabs.

[0047] An audible sound can be heard when the closure tab 160 engages the cutout 150. This sound, if present, can signal to the user of the carton 10 that the carton is indeed closed. The length of the closure tab can affect the size of the audible sound.

[0048] The interlock of the closure tab 160 and the cutout 150 also provides additional structure to the carton 10.

[0049] The lid can also include a closure that is not or in addition to a cutout. The closure can be reusable. The closure for the lid can include, for example, a snap, a hook and loop fastener, an interlocking flange, a tab and a thread, a press and seal, or any combination thereof.

[0050] The carton 10 can include a front side 70. The front side can be attached to the base 60 with a score line 120 between them. The front side 70 can be longer than the lid 50. At least a portion of the front side 70 can be positioned adjacent to the first side 90. An arcuate transition 170 can be present between the first side 90 and the front side 70. The arcuate transition can be formed when a portion of the front side 70 is curved toward the first side 90 and attached to the first side. The arcuate transition can also be formed when a portion of the first side 90 is curved toward the front side 70 and attached to the front side. The first side 90 and the front side 70 can be attached by tabs placed on the front side 70 and adhesive attached to the first side 90, or by tabs placed on the first side 90 and adhesive attached to the front side 70. The arcuate transition 170 can form a rounded corner 20 on the bottom portion 40 of the carton 10.

[0051] At least a portion of the front side 70 can be positioned adjacent to the second side 100. An arcuate transition 170 can be present between the front side 70 and the second side 100. The arcuate transition can be formed when a portion of the front side 70 is curved toward the second side 100 and attached to the second side. The arcuate transition can also be formed when a portion of the second side 100 is curved toward the front side 70 and attached to the front side. The second side 100 and the front side 70 can be attached by tabs placed on the front side 70 and adhesive attached to the second side 100, or by tabs placed on the second side 100 and adhesive attached to the front side 70. The arcuate transition 170 can form a rounded corner 20 on the bottom portion 40 of the carton 10.

[0052] The carton 10 can include a back side 80. The back side 80 can be generally parallel to the front side 70 when in the closed configuration. The back side 80 can be attached to the base 60. The back side can also be attached to the lid 50. It can be attached to the base 60 and / or the lid 50 with a score line 120 between them. The back side 80 can include one or more panels 110. In addition, the back side 80 can include one or more tabs 130. For example, the back side 80 can include two tabs 130. The back side 80 can be attached to the one or more tabs 130 with a score line 120 between them. One of the tabs 130 can be folded along the score line 120 and attached to the first side 90. One of the tabs 130 can be folded along the score line 120 and attached to the second side 100. The tabs 130 can be attached to the first side 90 and / or the second side 100 with adhesive. The tabs 130 can be attached to the first side 90 and the second side 100 such that when the carton 10 is in the closed configuration, the tabs 130 are located inside the carton 10, outside the carton 10, or some combination thereof.

[0053] The carton 10 can include a first side 90. The first side 90 can be attached to the base 60 and / or the lid 50 with a score line 120 therebetween. The first side 90 can include one or more panels 110. Further, the first side 90 can include one or more tabs 130. In the closed configuration, the first side 90 can be a wall of the carton 10. Further, in the closed configuration, the first side 90 can be substantially parallel to the second side 100. The first side 90 can help form the non-right angle corners and / or the right angle corners of the carton 10. Preferably, the first side 90 helps both the right angle corners and the non-right angle corners on the carton 10.

[0054] The carton 10 can include a second side 100. The second side 100 can be attached to the base 60 and / or the lid 50 with a score line 120 therebetween. The second side 100 can include one or more panels 110. Further, the second side 100 can include one or more tabs 130. In the closed configuration, the second side 100 can be a wall of the carton 10. Further, in the closed configuration, the second side 100 can be substantially parallel to the first side 90. The second side 100 can help form the non-right angle corners and / or the right angle corners of the carton 10. Preferably, the second side 100 helps both the right angle corners and the non-right angle corners on the carton 10.

[0055] The carton can be coated or uncoated. Further, only a portion of the carton can be coated. The coating can include, for example, a UV coating or a water-based coating. The coating can be used, for example, to help protect the ink or pigments on the package, impart a particular sheen to the package (e.g., matte, glossy, etc.), and / or protect the package and / or the included product from moisture / humidity.

[0056] Portions of the carton can be adhered to one another. These adhesives can be, for example, thermoset adhesives. The carton can also be dyed and / or printed.

[0057] The carton can be any desired shape with corners. For example, the carton can be square, rectangular, triangular, polygonal, cruciform, etc. For example, the carton can be a rectangle with 2 non-right-angled corners and 2 right-angled corners; a rectangle with 2 rounded corners and 2 right-angled corners; a rectangle with 2 bevelled corners and 2 right-angled corners; the carton can be a square with 2 non-right-angled corners and 2 right-angled corners; a square with 2 rounded corners and 2 right-angled corners; or a square with 2 bevelled corners and 2 right-angled corners. For example, the carton can be a rectangle with 2 non-right-angled corners and 2 right-angled corners, wherein the 2 non-right-angled corners are adjacent to each other; a rectangle with 2 rounded corners and 2 right-angled corners, wherein the 2 rounded corners are adjacent to each other; a rectangle with 2 bevelled corners and 2 right-angled corners, wherein the 2 bevelled corners are adjacent to each other; the carton can be a square with 2 non-right-angled corners and 2 right-angled corners, wherein the 2 non-right-angled corners are adjacent to each other; a square with 2 rounded corners and 2 right-angled corners, wherein the 2 rounded corners are adjacent to each other; or a square with 2 bevelled corners and 2 right-angled corners, wherein the 2 bevelled corners are adjacent to each other.

[0058] The carton can be oriented to lie on the base, the first side or the second side. Preferably, the carton is oriented to lie like a book on the first side.

[0059] In the case where the carton is made of a foldable material, such as paperboard, the carton is assembled at least in part by folding and adhesively connecting portions of the carton. Adhesives for such use can include, for example, thermoset, thermoplastic, or combinations thereof. The adhesive can be of natural origin and / or biodegradable, which increases the environmental friendliness of the carton.

[0060] Unit dose product

[0061] The unit dose products can be packaged within the carton. The unit dose products can be, for example, foams, wafers, tablets, ampoules, sachets, etc. When the unit dose cannot be adapted to be stacked in the carton, the unit dose can be put into a package that will allow stacking in the carton. This can include, for example, a blister pack, an individual carton, a sleeve, etc.

[0062] Preferably, the unit dose product is a fibrous water-soluble unit dose. As used herein, the phrases "fibrous water-soluble unit dose article," "water-soluble fibrous unit dose article," "water-soluble fibrous unit dose," "water-soluble fibrous structure," and "water-soluble fibrous element" all mean that the unit dose article, fibrous structure, and fibrous element are capable of being miscible with water. In other words, the unit dose article, fibrous structure, or fibrous element is capable of forming a homogeneous solution with water under ambient conditions. As used herein, "ambient conditions" means 23 °C + 1.0 °C and a relative humidity of 50% + 2%. The fibrous water-soluble unit dose article can contain insoluble material that is capable of being dispersed into a suspension, having an average particle size of less than about 20 microns, or less than about 50 microns, under aqueous washing conditions.

[0063] The fibrous water-soluble unit dose article can include any of the disclosure present in U.S. Patent Application Publication No. 2018 / 0216052, filed January 26, 2018, U.S. Patent Application Publication No. 2018 / 0216050, filed January 26, 2018, and U.S. Patent Application Publication No. 2018 / 0216053, filed January 26, 2018, all incorporated by reference in their entirety.

[0064] These fibrous water-soluble unit dose articles can dissolve under a variety of wash conditions, such as low temperature, low water, and / or short wash cycles, where the consumer has overloaded the machine, while providing sufficient active delivery to achieve the intended effect on the target consumer substrate (with similar performance to today's liquid products). In addition, the fibrous water-soluble unit dose articles described herein can be produced in an economical manner by spinning the fibers.

[0065] The surface of the fibrous water-soluble unit dose article can include a printed region. The printed region can cover from about 10% to about 100% of the surface of the article. The printed region can include an ink, a pigment, a dye, a bluing agent, or a mixture thereof. The printed region can be opaque, translucent, or transparent. The printed region can include a single color or multiple colors. The printed region can be on more than one side of the article and contain instructional text and / or graphics. The surface of the fibrous 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 a mixture thereof. Any suitable level of aversive agent can be used. Suitable levels 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.

[0066] The fibrous water-soluble unit dose article can exhibit a thickness of 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.

[0067] The fibrous water-soluble unit dose article can have a basis weight of from about 500 g / m2 2 to about 5,000 g / m2 2 , or from about 1,000 g / m2 2 to about 4,000 g / m2 2 , or from about 1,500 g / m2 2 to about 3,500 g / m2 2 , or from about 2,000 g / m2 2 to about 3,000 g / m2 2 .

[0068] The fibrous water-soluble unit dose article can exhibit different regions, such as different regions of basis weight, density, thickness, and / or wetting characteristics. The fibrous water-soluble unit dose article can be compressed at the edge seal. The fibrous water-soluble unit dose article can comprise a texture on one or more surfaces of its surface. The surface of the fibrous water-soluble unit dose article can comprise a pattern, such as a non-random repeating pattern. The fibrous water-soluble unit dose article can comprise a hole. The fibrous water-soluble unit dose article can comprise a fibrous structure having discrete regions of fibrous elements that are different from other regions of fibrous elements in the structure. The fibrous water-soluble unit dose article can be used as is, or can be coated with one or more active agents.

[0069] 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 fibrous water-soluble unit dose can be square, rounded square, kite, rectangular, triangular, circular, oval, and mixtures thereof. The fibrous water-soluble unit dose article can have a width of from about 1 cm to about 11 cm; a length of from about 1 cm to about 20 cm; and a height of from about 0.01 mm to about 50 mm, preferably about 3.8 cm x about 3.2 cm. The fibrous water-soluble unit dose can be stackable.

[0070] The fibrous water-soluble unit dose can comprise less than 10 ingredients. The fibrous water-soluble unit dose can comprise from 3 to 9 ingredients, for example 4 ingredients, 5 ingredients, 6 ingredients, 7 ingredients, or 8 ingredients.

[0071] Fibrous structure

[0072] The fibrous water-soluble unit dose product comprises one or more fibrous elements. The fibrous elements can be associated with one another to form a structure. The fibrous structure can include particles within and / or on the structure. The fibrous structure can be uniform, layered, monolithic, zoned, or, if desired, have different active agents defining various portions as described above.

[0073] The fibrous structure can comprise one or more layers, the layers together forming a laminate.

[0074] Fibrous element

[0075] The fibrous elements can be water-soluble. The fibrous elements can comprise one or more filament-forming materials and / or one or more active agents, such as surfactants. The one or more active agents can be capable of being released from the fibrous elements, such as when the fibrous elements and / or the fibrous structure comprising the fibrous elements are exposed to the conditions of intended use.

[0076] The fibrous elements can be spun from a filament-forming composition (also referred to as a fibrous element-forming composition) via a suitable spinning process operation, such as meltblowing, spunbonding, electrospinning, and / or rotary spinning.

[0077] As used herein, "filament-forming composition" and / or "fibrous element-forming composition" means a composition suitable for making 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 make them suitable for spinning into a fibrous element. The filament-forming materials can comprise polymers. In addition to the one or more filament-forming materials, the filament-forming composition can comprise one or more active agents, for example, surfactants. Further, the filament-forming composition can 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 are dissolved and / or dispersed prior to spinning the fibrous elements, such as filaments from the filament-forming composition.

[0078] The filament-forming composition can comprise two or more different filament-forming materials. Thus, the fibrous elements can be mono-component (one filament-forming material) and / or multi-component, such as bi-component. The two or more different filament-forming materials are combined in a random combination to form the fibrous elements. For the purposes of the present disclosure, the two or more different filament-forming materials can be combined in an ordered combination to form a fibrous element, such as a core-shell bi-component fibrous element, which is considered not to be a random mixture of the different filament-forming materials. The bi-component fibrous elements can be in any form, such as side-by-side, core-shell, island-in-the-sea, and the like.

[0079] The fibrous elements can each comprise at least one filament-forming material and an active agent, preferably a surfactant. The fibrous elements can 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% 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% active agent, preferably surfactant, based on the dry fibrous element and / or dry fibrous structure. The fibrous elements can comprise greater than about 80 wt% active agent (e.g., surfactant) based on the dry fibrous element and / or dry fibrous structure.

[0080] Generally, the fibrous elements are elongated particles having a length substantially greater than the average diameter, for example, a length to average diameter ratio of at least about 10. The fibrous elements can be filaments or fibers. Filaments are relatively longer than fibers. Filaments can have a length greater than or equal to about 5.08 cm (2 inches), and / or greater than or equal to about 7.62 cm (3 inches), and / or greater than or equal to about 10.16 cm (4 inches, and / or greater than or equal to about 15.24 cm (6 inches). Fibers can have a length less than about 5.08 cm (2 inches), and / or less than about 3.81 cm (1.5 inches), and / or less than about 2.54 cm (1 inch).

[0081] The one or more filament-forming materials and active agent can be present in the fibrous element in an amount that is a weight ratio of the total content of filament-forming materials to active agent of 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. The one or more filament-forming materials and active agent can be present in the fibrous element in a weight ratio of the total content of filament-forming materials to active agent of about 0.2 to about 0.7.

[0082] The one or more active agents can be capable of release and / or released when the fibrous element and / or fibrous structure comprising the fibrous element is exposed to the conditions of intended use. The one or more active agents in the fibrous element can be selected from the group consisting of surfactants, organic polymeric compounds, and mixtures thereof.

[0083] The fibrous element can 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 as measured according to the Diameter Test Method described herein. The fibrous element can exhibit a diameter of greater than about 1 µm. The diameter of the fibrous element can be used to control the rate of release of the one or more active agents present in the fibrous element and / or the rate of loss and / or change of the physical structure of the fibrous element.

[0084] The fibrous element can comprise two or more different active agents that are compatible or incompatible with each other. The fibrous element can comprise an active agent within the fibrous element and an active agent on the outer surface of the fibrous element, such as an active agent coating on the fibrous element. The active agent on the outer surface of the fibrous element can be the same or different than the active agent present in the fibrous element. If different, the active agents can be compatible or incompatible with each other. The one or more active agents can be distributed uniformly or substantially uniformly throughout the fibrous element. The one or more active agents can be distributed as discrete regions within the fibrous element. Active agents are discussed in more detail below.

[0085] Granule

[0086] The fibrous water-soluble unit dose can further comprise one or more particles. The particles can be, for example, entangled with the fibrous element, added after the fibrous element is formed into a web, added between webs, added to the outer surface of the fibrous water-soluble unit dose, and the like.

[0087] The particles can have a particle size distribution such that the D50 is greater than about 150 microns to less than about 1700 microns. The particles can have a particle size distribution such that the D50 is greater than about 212 microns to less than about 1180 microns. The particles can have a particle size distribution such that the D50 is greater than about 300 microns to less than about 850 microns. The particles can have a particle size distribution such that the D50 is greater than about 350 microns to less than about 700 microns. The particles can have a particle size distribution such that the D20 is greater than about 150 microns and the D80 is less than about 1400 microns. The particles can have a particle size distribution such that the D20 is greater than about 200 microns and the D80 is less than about 1180 microns. The particles can have a particle size distribution such that the D20 is greater than about 250 microns and the D80 is less than about 1000 microns. The particles can have a particle size distribution such that the D10 is greater than about 150 microns and the D90 is less than about 1400 microns. The particles can have a particle size distribution such that the D10 is greater than about 200 microns and the D90 is less than about 1180 microns. The particles can have a particle size distribution such that the D10 is greater than about 250 microns and the D90 is less than about 1000 microns.

[0088] The particles can comprise a rheology modifier. For example, the particles can comprise an alkoxylated amine (preferably an alkoxylated polyamine, more preferably a quaternized alkoxylated polyethyleneimine or a non-quaternized alkoxylated polyethyleneimine, wherein the alkoxylated polyalkyleneimine has a polyalkyleneimine core with one or more alkoxyl side chains bonded to at least one nitrogen atom in the polyalkyleneimine core), an ethylene oxide-propylene oxide-ethylene oxide (EOx1POyEOx2) triblock copolymer (wherein each of x1 and x2 is in the range of about 2 to about 140 and y is in the range of about 15 to about 70), or a combination thereof.

[0089] The particles can comprise a filler. Exemplary fillers include sodium carbonate, silica, zeolite-A, or a combination thereof.

[0090] The particles can comprise an active agent, as described more fully below.

[0091] Active agent

[0092] The fibrous water-soluble unit dose articles described herein can contain one or more active agents. The active agent can be contained in the fibrous structure, fibrous element, particle, or any combination thereof. The active agent can be contained in the water-soluble unit dose at a level of about 1% to about 80%, about 2% to about 75%, about 5% to about 70%, about 5% to about 65%, about 5% to about 60%, about 5% to about 55%, about 5% to about 50%.

[0093] One active agent that can be used herein is a surfactant. One suitable surfactant is an alkyl alkoxylated sulfate. However, these types of surfactants tend to undergo a highly viscous hexagonal phase at higher concentration levels (e.g., about 15%). This hexagonal phase transition can cause problems when higher levels of alkyl alkoxylated surfactants are included in the fibrous element. For example, alkyl alkoxylated sulfates can significantly slow the dissolution of fibrous water-soluble unit doses in water if incorporated in large amounts into the fibrous element, and worse yet, result in undissolved solids thereafter. Thus, this particular surfactant is preferably included in the water-soluble fibrous unit dose in granules, or in an amount limited to less than 15% in the fibrous element. In one embodiment, the fibrous element can be substantially free or free of alkyl alkoxylated sulfates, or can include alkyl alkoxylated sulfates.

[0094] Other suitable surfactants can include those with relatively low hydrophilicity that are less likely to form a viscous hexagonal phase upon dilution. These surfactants can include unalkoxylated C6-C 20 linear or branched alkyl sulfates (AS), C6-C 20 linear alkylbenzene sulfonates (LAS), and combinations thereof. The surfactant can be a C6-C 20 linear alkylbenzene sulfonates (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, alkaline earth, or C6-C 20 ammonium salts of linear alkylbenzene sulfonic acids, such as C 11 -C 18 linear alkylbenzene sulfonic acids or C 11 -C 14 sodium, potassium, magnesium, and / or ammonium salts of linear alkylbenzene sulfonic acids. C 12 sodium or potassium salts of linear alkylbenzene sulfonic acids, for example C 12 sodium salts of linear alkylbenzene sulfonic acids, i.e., sodium dodecylbenzene sulfonate, can be used as the first surfactant.

[0095] Other suitable anionic surfactants include C6-C 20 linear or branched alkyl sulfonates, C6-C 20 linear or branched alkyl carboxylates, C6-C 20 linear or branched alkyl phosphates, C6-C 20 linear or branched alkyl phosphonates, C6-C 20 alkyl N-methyl glucamides, C6-C 20 methyl ester sulfonates (MES), and combinations thereof.

[0096] Suitable nonionic surfactants include alkoxylated fatty alcohols. The nonionic surfactant can be selected from the group consisting of ethoxylated alcohols and ethoxylated alkyl phenols of the formula R(OC2H4) n OH, wherein R is selected from the group consisting of an aliphatic hydrocarbon group containing from about 8 to about 15 carbon atoms and an alkyl phenyl group in which the alkyl group contains from about 8 to about 12 carbon atoms, and n has an average value of from about 5 to about 15. Non-limiting examples of nonionic surfactants useful herein include: C8-C 18 alkyl ethoxylates, such as NEODOL® from Shell ® nonionic surfactants; C6-C 12 alkyl phenol alkoxylates, wherein the alkoxylate units can be ethyleneoxy units, propyleneoxy units, or mixtures thereof; C 12 -C 18 alcohols and C6-C 12 condensates of an alkyl phenol with ethylene oxide / propylene oxide block polymers, such as Pluronic® from BASF ® ; C 14 -C 22 mid-chain branched alcohols, BA; C 14 -C 22 mid-chain branched alkyl alkoxylates, BAE x wherein x is 1 to 30; alkyl polysaccharides; in particular alkyl polyglycosides; polyhydroxy fatty acid amides; and ether capped poly(alkoxylated) alcohol surfactants. Suitable nonionic detersive surfactants also include alkyl polyglucosides and alkyl alkoxylated alcohols. Suitable nonionic surfactants also include those marketed under the trade name Lutensol® from BASF. ®

[0097] Non-limiting examples of cationic surfactants include: quaternary ammonium surfactants, which can 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, for example, amido propyl dimethyl amine (APA). Suitable cationic detersive surfactants also include alkyl pyridinium compounds, alkyl quaternary ammonium compounds, alkyl quaternary phosphium compounds, alkyl ternary sulfonium compounds, and mixtures thereof.

[0098] Suitable cationic detersive surfactants are quaternary ammonium compounds having the general formula:

[0099] (R)(R1)(R2)(R3)N + X - ​

[0100] wherein R is a linear or branched, substituted or unsubstituted C 6-18 alkyl or alkenyl moiety, R1and R2are independently selected from a methyl or ethyl moiety, R3is a hydroxyl moiety, a hydroxymethyl moiety, or a hydroxyethyl moiety, and X is an anion that provides charge neutrality, suitable anions include: halide ions (e.g., chloride); sulfate; and sulfonate. Suitable cationic soil release surfactants are mono-C 6-18 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride. Highly suitable cationic soil release surfactants are mono-C 8-10 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride, mono-C 10-12 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride, and mono-C 10 alkyl mono-hydroxyethyl dimethyl quaternary ammonium chloride.

[0101] 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, coco dimethyl amido propyl betaines, sulfobetaines, and hydroxybetaines; C8to 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 C8to C 18 .

[0102] Suitable amphoteric surfactants include aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines, wherein the aliphatic groups can be straight or branched chain, and wherein at least one of the aliphatic substituents contains an anionic water solubilizing group, such as carboxyl, sulfonate, sulfate. Suitable amphoteric surfactants also include sarcosinates, glycinates, taurinates, and mixtures thereof.

[0103] The active agent can be an acid. Examples of suitable acids for use include, but are not limited to, organic acids selected from the group consisting of: acetic acid, adipic acid, aspartic acid, carboxymethyloxy propanedioic acid, carboxymethyloxy butanedioic acid, citric acid, benzoic acid, formic acid, glutaric acid, gluconic acid, hydroxyethyl imino diacetic acid, imino diacetic acid, lactic acid, maleic acid, malic acid, malonic acid, oxydiacetic acid, oxydisuccinic acid, succinic acid, sulfamic acid, tartaric acid, tartrate disuccinic acid, tartrate monosuccinic acid, salts thereof, or mixtures thereof. Preferably, the acid is citric acid, lactic acid, acetic acid, and / or tartaric acid, and more preferably citric acid.

[0104] The acid can include a coating. The coating can help prevent premature dissolution of the active agent. A preferred acid is citric acid, and a preferred coating comprises maltodextrin, wax, citrate, sulfate, zeolite, an anti-caking agent such as silica or other desiccant. A preferred combination includes citric acid coated with maltodextrin (available under the tradename Citric Acid DC), citric acid coated with citrate (available under the tradename CITROCOAT ® Navailable under the tradename Citric Acid S40).

[0105] The fibrous water-soluble unit dose can comprise an active agent encapsulate. The encapsulate can comprise a core, a shell having an inner surface and an outer surface, the shell encapsulating the core. The core can comprise any laundry care adjunct, however the core can typically comprise a material selected from the group consisting of: a perfume; a brightener; a hueing dye; an insect repellent; a silicone; a wax; a flavor; a vitamin; a fabric softening agent; a skin care agent, in one aspect a paraffin; an enzyme; an antibacterial agent; a bleach; a sensate; and mixtures thereof; and the shell can comprise a material selected from the group consisting of: polyethylene; polyamide; polyvinyl alcohol, optionally comprising other comonomers; polystyrene; polyisoprene; polycarbonate; polyester; polyacrylate; an aminoplast, in one aspect the aminoplast can comprise a polyurea, a polyurethane, and / or a polyureaurethane, in one aspect the polyurea can comprise polyoxymethyleneurea and / or melamine formaldehyde; polyolefin; polysaccharide, in one aspect the polysaccharide can comprise alginate and / or chitosan; gelatin; shellac; epoxy; a vinyl polymer; a water-insoluble inorganic; a silicone; and mixtures thereof.

[0106] Preferred encapsulates comprise a perfume. Preferred encapsulates include a shell, which can comprise melamine formaldehyde and / or cross-linked melamine formaldehyde. Other preferred capsules comprise a polyacrylate-based shell. Preferred encapsulates include a core material and a shell, the shell is disclosed to at least partially surround the core material. At least 75%, 85% or even 90% of the encapsulates can have a burst strength of 0.2 MPa to 10 MPa, and a beneficial agent leakage of 0% to 20%, or even less than 10% or 5% based on the total initial encapsulated beneficial agent. Preferred are wherein at least 75%, 85% or even 90% of the encapsulates can have (i) a particle size of 1 micron to 80 microns, 5 microns to 60 microns, 10 microns to 50 microns, or even 15 microns to 40 microns and / or (ii) at least 75%, 85% or even 90% of the encapsulates can have a particle wall thickness of 30 nm to 250 nm, 80 nm to 180 nm or even 100 nm to 160 nm. Formaldehyde scavengers can be used with encapsulates, for example in a capsule slurry, and / or added to such compositions before, during or after the encapsulates are added to the compositions.

[0107] Suitable capsules can be prepared using known methods. Alternatively, suitable capsules can be purchased from Encapsys LLC, Appleton, Wisconsin USA. In a preferred aspect, the composition can comprise a deposition aid, preferably in addition to the encapsulates. Preferred deposition aids are selected from the group consisting of cationic polymers and nonionic polymers. Suitable polymers include cationic starch, cationic hydroxyethyl cellulose, polyvinyl formal, locust bean gum, mannan, xyloglucan, tamarind gum, polyethylene terephthalate, and polymers comprising dimethylaminoethyl methacrylate and optionally one or more monomers selected from the group consisting of acrylic acid and acrylamide.

[0108] Perfume

[0109] Fibrous water-soluble unit doses and / or particles can include a perfume. Non-limiting examples of perfumes and perfume ingredients include, but are not limited to, aldehydes, ketones, esters, and the like. Other examples include various natural extracts and essential oils, which can comprise complex mixtures of individual ingredients, such as orange oil, lemon oil, rose extract, lavender, musk, patchouli, balsam essential oils, sandalwood oil, pine oil, cedarwood, and the like. Finished perfumes can comprise extremely complex mixtures of such ingredients. Finished perfumes can be included at concentrations ranging from about 0.01 wt% to about 2 wt% of the detergent composition.

[0110] Dye transfer inhibitor

[0111] The fibrous water-soluble unit doses and / or particles can comprise a dye transfer inhibitor. Dye transfer inhibitors can be effective in inhibiting the transfer of dyes from one fabric to another during the cleaning process. Generally, such dye transfer inhibitors can include polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, manganese phthalocyanine, peroxidases, and mixtures thereof. If used, these agents can be used at concentrations of from about 0.0001 wt.% to about 10 wt.% of the composition, in some examples from about 0.01 wt.% to about 5 wt.% of the composition, and in other examples from about 0.05 wt.% to about 2 wt.% of the composition.

[0112] Suds suppressor

[0113] The fibrous water-soluble unit doses and / or particles can comprise a suds suppressor. The fibrous water-soluble unit doses can comprise from about 0.001 wt.% to about 4.0 wt.% of such suds suppressors of the composition. Foam inhibition can be especially important in so-called "high concentration cleaning processes" and in front-loading washing machines. Examples of suds suppressors include monocarboxylic fatty acids and soluble salts thereof, high molecular weight hydrocarbons such as paraffins, fatty acid esters (e.g., fatty acid triglycerides), fatty acid esters of monohydric alcohols, fatty acid esters of polyhydric alcohols, fatty amine surfactants, aliphatic C 18 -C 40 ketones (e.g., stearyl ketones), N-alkylated aminotriazines, waxy hydrocarbons preferably having a melting point below about 100°C, silicone suds suppressors, and secondary alcohols.

[0114] Other suitable suds suppressors are those derived from phenylpropylmethyl substituted polysiloxanes, organomodified silicone polymers having aryl or alkylaryl substituents, those in combination with silicone resins and a primary filler (modified silica).

[0115] The fibrous water-soluble unit doses can comprise a suds suppressor selected from the group consisting of: a) a mixture of from about 80% to about 92% ethylmethyl, methyl(2-phenylpropyl)siloxane; from about 5% to about 14% of an MQ resin in octyl stearate; and from about 3% to about 7% of a modified silica; b) a mixture of from about 78% to about 92% ethylmethyl(2-phenylpropyl)siloxane methyl ester; from about 3% to about 10% of an MQ resin in octyl stearate; from about 4% to about 12% of a modified silica; or c) mixtures thereof, wherein the percentages are by weight of the anti-foam.

[0116] Suds booster

[0117] If high sudsing is desired, suds boosters can be included in the fibrous water-soluble unit dose and / or the granules. They can be added at a level of from about 0.1% to about 2% by weight of the fibrous water-soluble unit dose. Some examples include C 10 - C 16 Alkanolamides and C 10 - C 14 Mono- and di-ethanol amides.

[0118] Modulator

[0119] Modulators can be included in the fibrous water-soluble unit dose and / or the granules. Suitable modulators include high melting point fatty compounds. High melting point fatty compounds useful herein have a melting point of 25°C or higher and are selected from the group consisting of fatty alcohols, fatty acids, fatty alcohol derivatives, fatty acid derivatives, and mixtures thereof. Suitable modulators also include non-ionic polymers and conditioning oils such as hydrocarbon oils, polyolefins, and fatty esters.

[0120] Suitable modulators include those typically characterized as silicones (e.g., silicone oils, polyoils, cationic silicones, silicone gums, high refractive silicones, and silicone resins), organic conditioning oils (e.g., hydrocarbon oils, polyolefins, and fatty esters), or combinations thereof, or those that otherwise form liquid dispersed particles in the aqueous surfactant matrix herein.

[0121] Miscellaneous

[0122] The fibrous water-soluble unit dose can include additional components such as structurants, builders, organic polymeric compounds, enzymes, enzyme stabilizers, bleach systems, whitening agents, hueing agents, chelating agents, humectants, fillers or carriers, alkalinity systems, pH control systems, buffers, alkanolamines, or combinations thereof. These materials can be present at a level of from about 0.1% to about 20%, but by weight of the fibrous water-soluble unit dose.

[0123] pH in wash liquor

[0124] The fibrous water-soluble unit dose articles described herein can be formulated such that during use in an aqueous cleaning operation, the wash water will have a pH of between about 2.0 and about 12, and in some examples, will have a pH of between about 3.0 and about 12, between about 7 and about 12, about 12 or less, about 11 or less, preferably about 10 or less. Techniques to control the pH at the recommended level of use include the use of buffers, bases or acids, etc., and these techniques are well known to those skilled in the art. These include, but are not limited to, the use of sodium carbonate, citric acid or sodium citrate, lactic acid or lactate salts, monoethanolamine or other amines, boric acid or borate salts, and other pH adjusting compounds well known in the art.

[0125] Method of making

[0126] A solution of a filament-forming composition is provided. The filament-forming composition can include one or more filament-forming materials and optionally one or more active agents. The filament-forming composition is passed through one or more module assemblies including a plurality of spinnerets to form a plurality of fibrous elements including one or more filament-forming materials and optionally one or more active agents. A plurality of module assemblies can be used to spin different layers of fibrous elements having different or the same composition from each other. Two or more module assemblies in series can be provided to form three, four, or any other integer number of layers in a given ply. The fibrous elements can be deposited on a belt moving in the machine direction (MD) to form a first ply.

[0127] Particles can be introduced into the stream of fibrous elements between the module assembly and the belt. The particles can be fed from a particle receiver onto a belt feeder or optionally a screw feeder. The belt feeder can be set and controlled to deliver the desired mass of particles into the process. The belt feeder can feed an air knife that suspends the particles in an air stream and directs them into the fibrous elements to form a particle-fiber layer of mixed fibrous elements and particles subsequently deposited on the belt.

[0128] To form a water-soluble product, a first ply can be provided. A second ply can be provided separately from the first ply. The first ply and the second ply are positioned on top of each other. By positioned on top of each other is meant that one is positioned above or below the other, with the proviso that additional plies or other materials, such as active agents and / or particles, can be located between the plies that are positioned on top of each other. A portion of the first ply can be connected to a portion of the second ply to form a water-soluble product. Each ply can include one or more layers.

[0129] The layers can be sealed at the ends using any type of known sealing, including but not limited to ultrasonic, pressurized, heated, use of water-soluble adhesive, and combinations thereof. The sealing is preferably performed, for example, using pressurized sealing.

[0130] Additional details regarding the method of making fibrous water-soluble unit doses can be found in U.S. Patent Publication No. 2018 / 0216050, incorporated herein by reference.

[0131] Combination

[0132] 1) A carton comprising: a) a base; b) a lid, the lid having a top side and a bottom side; c) a first side; d) a front side, wherein at least a portion of the front side is positioned adjacent to the first side; e) a second side, wherein at least a portion of the second side is positioned adjacent to the front side; and f) a back side, wherein a portion of the back side is positioned adjacent to the first side and a portion of the back side is positioned adjacent to the second side; wherein the carton comprises 2 right angle corners and 2 non-right angle corners.

[0133] 2) The carton of paragraph 1, wherein the non-right angle corners comprise rounded corners, chamfered corners, indented corners, star corners, beveled corners, or combinations thereof.

[0134] 3) The carton of paragraph 1 or 2, wherein the non-right angle corners comprise 2 rounded corners that are adjacent to each other.

[0135] 4) The carton of paragraphs 1-3, wherein the carton has a rectangular shape.

[0136] 5) The carton of paragraphs 1-4, further comprising a removable tray.

[0137] 6) The carton of paragraph 5, wherein the base further comprises a guide for placement of the removable tray.

[0138] 7) The carton of paragraph 6, wherein the guide comprises a panel extending upwardly from the base.

[0139] 8) The carton of paragraphs 1-7, wherein the carton is oriented upright on the first side and / or the second side.

[0140] 9) The carton of paragraphs 1-8, further comprising a structural shelf, wherein the structural shelf extends from the base or the bottom side of the lid to a height of at least 80% of a height between the base and the bottom side of the lid.

[0141] 10) The carton of paragraphs 1-9, wherein the lid further comprises a panel and a score line disposed between the lid and the panel.

[0142] 11) The carton of paragraph 10, wherein the panel comprises a slot.

[0143] 12) The carton of paragraph 11, wherein the front side further comprises a tab that extends outwardly from the front side and engages the slot in a closed configuration to retain the lid in a closed position.

[0144] 13) The carton of paragraph 12, wherein an audible sound is produced when the tab is engaged in the slot.

[0145] 14) The carton of paragraphs 1-13, wherein the carton is made of paperboard and has a thickness of about 16 points to about 24 points.

[0146] 15) The carton of paragraphs 1-14, wherein the front side further comprises a first panel having a score line disposed between at least a portion of the front side and the first panel.

[0147] 16) The carton of paragraph 15, wherein the front side further comprises a second panel adjacent to the first panel, and the second panel has a score line disposed between at least a portion of the second panel and the first panel.

[0148] 17) The carton of paragraph 16, wherein the first panel and the second panel are folded to form a hollow compartment within the carton.

[0149] 18) The carton of paragraphs 1-17, wherein the lid is attached to a portion of the carton.

[0150] 19) The carton of paragraphs 1-18, wherein the lid is attached to at least a portion of the back side.

[0151] 20) The carton of paragraphs 1-19, wherein the lid overlaps an exterior of the base.

[0152] 21) A carton comprising: a) a base portion comprising: i) a first side; ii) a front side, wherein at least a portion of the front side is positioned adjacent to the first side, and there is an arcuate transition between the first side and the front side; iii) a second side, wherein at least a portion of the second side is positioned adjacent to the front side, and there is an arcuate transition between the second side and the front side; and iv) a back side, wherein a portion of the back side is positioned adjacent to the first side, and a portion of the back side is positioned adjacent to the second side, and the back side does not have an arcuate transition between itself, the first side, or the second side; and b) a lid having a top side and a bottom side; wherein the lid is integral to a portion of the carton.

[0153] 22) The carton of paragraph 21, wherein the lid is attached to at least a portion of the back side.

[0154] 23) The carton of paragraphs 21-22, wherein the lid has 2 rounded corners that correspond to the 2 arcuate transitions on the base portion.

[0155] 24) The carton according to paragraphs 21-23, wherein the front side further comprises a first panel having a score line disposed between at least a portion of the front side and the first panel.

[0156] 25) The carton according to paragraph 24, wherein the front side further comprises a second panel adjacent to the first panel, and the second panel has a score line disposed between at least a portion of the second panel and the first panel.

[0157] 26) The carton according to paragraph 25, wherein the first panel and the second panel are folded to form a hollow compartment within the carton.

[0158] 27) The carton according to paragraphs 21-26, wherein the lid overlaps the exterior of the base portion.

[0159] 28) The carton according to paragraphs 21-27, wherein the carton has a rectangular shape.

[0160] 29) The carton according to paragraphs 21-28, further comprising a removable tray.

[0161] 30) The carton according to paragraph 29, wherein the base further comprises a guide for placement of the removable tray.

[0162] 31) The carton according to paragraph 30, wherein the guide comprises a panel extending upwardly from the base.

[0163] 32) The carton according to paragraphs 21-31, wherein the carton is oriented upright on the first side and / or the second side.

[0164] 33) The carton according to paragraphs 21-32, further comprising a structural shelf, wherein the structural shelf extends from the base or the bottom side of the lid to a height of at least 80% of a height between the base and the bottom side of the lid.

[0165] 34) The carton according to paragraphs 21-33, wherein the lid further comprises a panel and a score line disposed between the lid and the panel.

[0166] 35) The carton according to paragraph 34, wherein the panel comprises a slot.

[0167] 36) The carton according to paragraph 35, wherein the front side further comprises a tab extending outwardly from the front side and engaging the slot in a closed configuration to retain the lid in a closed position.

[0168] 37) The carton of paragraph 36, wherein an audible sound is produced when the tab is engaged in the slot.

[0169] 38) The carton of paragraphs 21-37, wherein the carton is made of paperboard and has a thickness of about 16 points to about 24 points.

[0170] 39) The carton of paragraphs 23-38, wherein the curvature of the 2 rounded corners on the lid is greater than the curvature of the 2 arcuate transitions on the base portion.

[0171] 40) The carton of paragraphs 23-38, wherein the curvature of the 2 rounded corners on the lid is less than the curvature of the 2 arcuate transitions on the base portion.

[0172] 41) The carton of paragraphs 1-40, wherein the carton comprises a plurality of fibrous water-soluble unit dose articles.

[0173] 42) The carton of paragraph 41, wherein at least a portion of the fibrous water-soluble unit dose articles are stacked in a row.

[0174] It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

[0175] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0176] Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or along with any other multiple documents, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall control.

[0177] While particular embodiments of the present application have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the application. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this application.

Claims

1. A cardboard box, the cardboard box comprising: a) a base portion, the base portion comprising: i) a first side; ii) a front side, wherein at least a portion of the front side is positioned adjacent to the first side and there is an arcuate transition between the first side and the front side; iii) a second side, wherein at least a portion of the second side is positioned adjacent to the front side and there is an arcuate transition between the second side and the front side; and iv) a rear side, wherein a portion of the rear side is positioned adjacent to the first side and a portion of the rear side is positioned adjacent to the second side, and the rear side does not have an arcuate transition between itself, the first side, or the second side; and b) a lid, the lid having a top side and a bottom side; wherein the lid is integral with a portion of the carton.

2. The cardboard box of claim 1, wherein the lid is attached to at least a portion of the rear side.

3. The paper box according to any one of claims 1 to 2, wherein the lid has two rounded corners, the rounded corners corresponding to two arcuate transitions on the base portion.

4. The paper box according to any one of claims 1 to 3, wherein the front side further includes a first panel having a groove line disposed between at least a portion of the front side and the first panel.

5. The cardboard box according to claim 4, wherein the front side further includes a second panel adjacent to the first panel, the second panel having a groove line disposed between at least a portion of the second panel and the first panel.

6. The cardboard box according to claim 5, wherein the first panel and the second panel are folded to form a hollow compartment within the cardboard box.

7. The paper box according to any one of claims 1 to 6, wherein the lid overlaps the exterior of the base portion.

8. The paper box according to any one of claims 1 to 7, wherein the paper box has a rectangular shape.

9. The cardboard box according to any one of claims 1 to 8, the cardboard box further comprising a removable tray, preferably comprising a removable tray and a guide for placing the removable tray.

10. The cardboard box of claim 9, wherein the guide includes a panel extending upward from the base.

11. The cardboard box according to any one of claims 1 to 10, wherein the cardboard box is oriented to stand upright on the first side and / or the second side, preferably on the first side.

12. The carton according to any one of claims 1 to 11, the carton further comprising a structural shelf, wherein the structural shelf extends from the base or the bottom side of the lid to at least 80% of the height between the base and the bottom side of the lid.

13. The paper box according to any one of claims 1 to 13, wherein the lid further comprises a panel and a serrated line disposed between the lid and the panel.

14. The paper box according to any one of claims 1 to 13, wherein the paper box is made of cardboard and has a thickness of about 16 points to about 24 points.

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