Method of packaging toilet cleaning blocks

Abstract

This invention describes a novel method for preparing an adhesive toilet cleaning block by using thermoforming technology to manufacture an in-cylinder toilet cleaning block encapsulated in a water-soluble film.

Description

Technical Field

[0001] The present invention generally relates to a method of packaging solid or semi-solid toilet cleaning blocks in a water-soluble or water-dispersible film. Background Technology

[0002] Adhesive hygiene agents for use in toilet bowls or tanks are also described in this art. At least one obstacle to using these agents is the direct application of these products to the side of the bowl or tank. Applying these agents requires the use of applicators, typically made of plastic, which is environmentally unfriendly. Furthermore, the applicator itself may come into contact with the inner wall of the toilet bowl, further contaminating the applicator and potentially causing the spread of toilet-related pathogens in and around the storage space when the applicator is stored in a bathroom environment.

[0003] U.S. Patent No. 6,667,286 discloses a gel-based hygiene composition for cleaning and / or disinfecting and / or releasing odorants, the composition comprising an adhesion promoter, water, anionic and / or nonionic and / or amphoteric surfactants. The disclosed hygiene formulation requires an applicator.

[0004] US 8,927,477 B2 describes a sanitary preparation for adhesion to the walls of a sanitary appliance, wherein the body of the preparation has an outer surface covered by a removable, water-soluble film. However, this document fails to provide any specific methods for manufacturing functional products. It also provides no guidance on how to encapsulate the sanitary composition with consistency and integrity for its intended use. Furthermore, the composition of such sanitary products may itself come into contact with the user's skin upon application, causing skin irritation and sensitivity.

[0005] Therefore, there is a need for new single-use hygiene products that are environmentally friendly, break the chain of transmission of toilet bowl pathogens outside the toilet bowl environment, and minimize the risk of chemical contact with the user's skin. This invention addresses these needs. Summary of the Invention

[0006] This invention relates to a method for manufacturing a single-use adhesive toilet bowl hygiene product that adheres directly to the inclined wall of a toilet bowl.

[0007] In a first aspect, the present invention describes a method of packaging a sanitary in-cylinder toilet cleaning block wrapped in a film, comprising the steps of: (a) providing a substrate (10) having at least one cavity (11) and an anvil profile (12) surrounding the perimeter of the cavity, wherein the cavity has an associated venting device; (b) placing a first flexible water-soluble film (20) with a thickness in the range of 10 to 75 micrometers, preferably 25 to 50 micrometers, over the substrate and covering the cavity; (c) placing an extruded semi-solid cleaning composition (30) comprising at least one surfactant over the cavity; (d) placing a second flexible polymer film (40) over the composition; (e) pressing the composition into the cavity with a pressure plate (50) at a force of an appropriate magnitude in the range of 150 to 700 Newtons (N), preferably 250 to 600 N, the force being applied from above the second flexible thermoformable film; and (f) applying heat to bond and seal the first and second flexible films, thereby providing a toilet cleaning block wrapped in a film. In some embodiments, the sealing force can be in the range of 0.5 to 4 N / mm², and the temperature can be in the range of 140 to 200°C, applied from the heating plate to the anvil contour. In some embodiments, the method further includes the step of cutting the enclosed toilet cleaning block along the cavity. In some embodiments, the method may further include the step of printing text, logos, or shapes on the surface of the membrane. In some embodiments, the substrate of step (a) can be a metallic material, such as aluminum, or a plastic, such as polyamide. In some embodiments, the anvil contour of the plate and the substrate can be two different materials. For example, the plate material can be metallic, while the anvil contour can be rubber or silicone.

[0008] The pressure plate can be made of any suitable material capable of withstanding the force. Such a plate can be metal, ceramic, plastic, etc. In some embodiments, the second polymer membrane is also a water-soluble membrane.

[0009] In some embodiments, the cavity on the metal plate is hexagonal in shape. In some embodiments, both the first and second films are flexible, water-soluble, and thermoformable, and are independently selected from the group consisting of: polyvinyl alcohol (PVOH), polyethylene terephthalate, polyethylene terephthalate-ethylene glycol, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinylpyrrolidone, polyalkylene oxide and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamide, polypeptides, polyamides, and any combination thereof, preferably wherein either the first or second film is a blown or cast PVOH film, and the film thickness is in the range of 25 micrometers to 75 micrometers.

[0010] In some embodiments, the sanitary composition is a semi-solid and malleable material, weighing from 5 to 25 grams, and comprises a surfactant selected from the group consisting of anionic surfactants, nonionic surfactants, cationic surfactants, and any combination thereof. In some embodiments, the sanitary composition is an extrudable semi-solid material with a hardness in the range of 5 to 20 N / mm and a density in the range of 1.0 to about 1.5 g / L.

[0011] In some embodiments, the punching force provided by the pressure plate (50) is applied for 1 to 20 seconds, preferably 2 to 10 seconds, and the sealing pressure is in the range of 1.0 to 3.00 N / mm², preferably 1.5 to 2.5 N / mm². In some embodiments, the sealing temperature is in the range of 125°C to 250°C, preferably 150°C to 180°C.

[0012] In some embodiments, the method of the present invention further includes the step of printing marks, shapes, designs, and text on the outer layer of the polymer film.

[0013] On the other hand, the present invention relates to a system for packaging toilet cleaning blocks encased in a water-soluble film, comprising: (a) a plurality of metal or plastic substrates, each substrate having a plurality of cavities and anvil profiles, wherein each of the cavities has an associated evacuation device; (b) a roller containing a flexible sheet of a first water-soluble film having a thickness in the range of 10 to 75, preferably 25 to 50 micrometers, the roller being configured to place the first water-soluble film over the cavities of the substrates; and (c) a vacuum assembly for each of the cavities, the vacuum assembly being configured to... (d) A first flexible water-soluble membrane is positioned in each cavity; (e) a loading assembly for placing an extruded semi-solid sanitary composition containing at least one surfactant above the cavity; (f) a second roller configured to place a flexible sheet of the second water-soluble membrane along a plate above the cavity containing the composition; (g) a stamping assembly having a pressure plate configured to stamp the composition into the cavity; and (h) a heating assembly for sealing the first and second membranes to provide a toilet cleaning block enclosed in the membranes.

[0014] According to this aspect, the hardness of the semi-solid composition is in the range of 5 to 20 N / mm², and the density is in the range of 1.0 to about 1.5 g / L. In some embodiments, the stamping pressure is applied for 1 to about 20 seconds, preferably 2 to 10 seconds. In other embodiments according to the second aspect of the invention, the sealing pressure is in the range of 1.0 to about 3.00 N / mm², preferably 1.5 to 2.5 N / mm². In some embodiments, the weight of the composition is in the range of 5 g to 25 g. In other embodiments, the system has a printing mechanism incorporated into the process, which is preferably used to print markings, shapes, and text on the outer layer of the polymer film before or after the first polymer sheet or the second polymer sheet is placed on the metal plate.

[0015] In a third aspect, the present invention relates to a method for manufacturing an adhesive toilet cleaning block having a three-dimensional shape having an upper surface and a lower surface, the method comprising: (a) providing a substrate having a plurality of cavities, wherein each cavity has an associated venting device and an anvil profile surrounding the perimeter of the cavity; (b) placing a first flexible film with a thickness in the range of 10 to 75 micrometers, preferably 25 to 50 micrometers, over the substrate; (c) covering the plurality of cavities with the first flexible film; and (d) applying a vacuum in each of the cavities to adhere the first flexible film. The membrane is placed into each cavity; (e) a semi-solid extruded detergent composition containing at least one surfactant is placed above each cavity; (f) a second flexible membrane is placed above the plate and covers the composition along the cavity; (g) the composition is pressed from above the second flexible form with a force in the range of 150 to 700 N, preferably 250 to 600 N, using a pressure plate; and (h) a heat seal is applied, whereby the first and second flexible membranes are joined and sealed around the toilet cleaning block, thereby encapsulating the toilet cleaning block within the membrane. In some embodiments, the sealing force may be in the range of 0.5 to 4 N / mm², and the temperature may be in the range of 140 to 200°C. In some embodiments, the adhesive toilet cleaning block according to the invention is a semi-solid extruded composition containing at least one surfactant, which is encapsulated within a water-soluble membrane. In other embodiments, the pressing of the sanitary composition pushes the composition into the cavity to form the upper or lower surface of the adhesive cleaning block. In some embodiments, at least one of the upper or lower surfaces is elliptical, circular, pentagonal, hexagonal, heptagonal, or octagonal in shape.

[0016] In some embodiments of the third aspect of the invention, the adhesive toilet cleaning block has at least one symmetrical edge, but no more than 20, preferably 16, and the adhesive toilet cleaning block has at least 3 to 20 side surfaces, preferably 16.

[0017] On the other hand, the present invention relates to all products manufactured according to the above-described process. Attached Figure Description

[0018] The accompanying drawings illustrate the process of the present invention and the products formed therefrom.

[0019] Figure 1 This is a perspective view of a plate (10) with a cavity according to the present invention and of a first polymer film placed on top of a metal plate.

[0020] Figure 2 The order of the components placed above the metal plate and the cavity is shown.

[0021] Figure 3 An embodiment and shape of a semi-solid composition according to the invention encapsulated in a polymer film are shown, along with different edges and surfaces of an adhesive toilet cleaning block. Detailed Implementation

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains, and should be understood to have the meanings set forth below. All publications and patents cited herein are incorporated herein by reference in their entirety. Unless otherwise stated, the following terms have the meanings set forth herein.

[0023] As used in this article, “about” means at most plus or minus 5% for a particular term.

[0024] As used in this article, “consistent with…” means excluding other active ingredients but including the listed optional excipients.

[0025] As used in this article, “sanitary fixtures” generally refers to toilet bowls, urinals, fixtures, and similar objects in washroom and bathroom environments.

[0026] The term "substantially free of" means that the final composition contains less than 2.5% of the total weight of the corresponding composition to a degree detectable by general quantitative methods known in the art for detecting such components in the final composition. For example, the phrase "substantially free of water" means that the corresponding composition contains less than 2.5% water. The term "free of" means that the final composition contains no trace amounts of the identified component to a degree that the component can be identified using the same assays as described above.

[0027] As used herein, the term "semi-solid" refers to a physical state that is between a solid and a liquid, capable of supporting its own weight and maintaining and conforming to a solid shape. However, when subjected to external pressure, it may be stretchable and compressible, and capable of changing shape from its original form. Examples of such products include clay-like consistency, pastes, hardening creams, and wax-like substances. Semi-solid does not refer to a gel or liquid state.

[0028] As used herein, the term "edge" refers to the outer boundary of an object, product, or surface; the location or portion furthest from the center of such an object or product, where at least two lines from different surfaces intersect. This can reflect the point where a side surface meets an upper or lower surface.

[0029] The terms “cavity” and “mold” are used interchangeably and are intended to refer to a hollow container for shaping a semi-solid composition according to the invention, the composition being an extrudable or wax-like composition containing at least one surfactant.

[0030] This invention relates primarily to a method for manufacturing semi-solid blocks, soaps, or detergent compositions, wherein the compositions are encapsulated in a polymer film for direct application to the inner wall of a toilet bowl. More specifically, in a first aspect, the present invention describes a method of packaging a hygienic in-cylinder toilet cleaning block wrapped in a film, comprising the steps of: (a) providing a substrate (10) having at least one cavity or mold (11), wherein the cavity or mold has an associated venting device and an anvil profile surrounding the perimeter of the cavity on the substrate; (b) placing a first flexible water-soluble film (20) with a thickness in the range of 10 to 75 micrometers, preferably 25 to 50 micrometers, over the substrate and covering the cavity; (c) placing an extruded semi-solid cleaning composition (30) comprising at least one surfactant over the cavity; (d) placing a second flexible polymer film (40) over the composition; (e) pressing the composition into the cavity with a pressure plate (50) at a force of an appropriate magnitude in the range of 150 to 700 N, preferably 250 to 600 N, applied from above the second polymer film; and (f) applying a heat seal, whereby the first and second polymer films are joined and sealed to provide a toilet cleaning block wrapped in a film. In some embodiments, the method further includes the step of cutting the encapsulated toilet cleaning block along the cavity boundary. In some embodiments, heat sealing is applied from a heating plate located directly above the substrate, and heating is applied to the anvil profile to connect the upper and lower films encapsulating the detergent semi-solid composition.

[0031] In some embodiments, the first or second membrane is flexible, biodegradable, water-soluble, and thermoformable. The biodegradable and water-soluble polymer membranes suitable for external wrapping of toilet cleaning block compositions according to the invention are generally those that can dissolve, disperse, or swell in the presence of water, preferably selected from the group consisting of polyethylene glycol, polyacrylamide, polyacrylic acid copolymers, and polyvinyl alcohol. The polymer membranes can be classified as natural (isolated from plant or animal sources), semi-synthetic, or synthetic polymers. Natural water-soluble polymers can be used as is or can be modified. Semi-synthetic water-soluble polymers are derived from chemical modifications of natural polymers or from microbial sources. Many natural and semi-synthetic water-soluble polymers are polysaccharides, which can vary considerably in their basic sugar units and linkages. Any combination of these polymer entities can be used to prepare the first or second membrane for wrapping toilet cleaning blocks according to the invention.

[0032] Suitable first or second polymer membranes are independently selected from the group consisting of: polyvinyl alcohol (PVOH), polyethylene terephthalate, polyethylene terephthalate-ethylene glycol, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinylpyrrolidone, polyalkylene oxides and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamide, polypeptides, polyamides, and any combination thereof, preferably wherein the first membrane or the second membrane is the same. In the most preferred embodiment, both the first membrane and the second membrane are PVOH.

[0033] In some embodiments, the cavity (11) or mold of the substrate (10) can be of any shape or form, such as elliptical, circular, pentagonal, hexagonal, heptagonal, or octagonal, preferably hexagonal. The width of the anvil profile surrounding the perimeter of the cavity is in the range of 0.5 to 2.5 mm, preferably 2 mm; the height is in the range of 0.5 to 2.5 mm, preferably 2 mm, and it is made of a material that is not thermally conductive or has a lower thermal conductivity compared to the material used to form the substrate. In some embodiments, the anvil profile is made of a material with a thermal conductivity of less than 0.1 W / m·K (watts per meter Kelvin) to facilitate proper heat sealing. In some embodiments, the anvil profile of the plate and the substrate can be two different materials. For example, the plate material can be metal, while the anvil profile can be rubber or silicone.

[0034] In some embodiments, the sanitary composition is semi-solid and malleable, weighing between 5 grams and 25 grams, and comprises a surfactant selected from the group consisting of: anionic surfactants, nonionic surfactants, cationic surfactants, and...

[0035] In other embodiments, the sealing pressure is in the range of 1.0 to about 3.00 N / mm², preferably 1.5 to 2.5 N / mm², and the sealing temperature is in the range of 125 to 250°C, preferably 150 to 180°C.

[0036] In some embodiments of the first aspect of the invention, the depth of the corresponding cavity and mold of the metal plate is in the range of about 1 to 40 mm, preferably 2 to 35 mm, and can be in the form of an ellipse, circle, pentagon, hexagon, heptagon, or octagon, preferably hexagon. Therefore, the final toilet cleaning block unit according to the invention can be formed in any shape, such as a pouch, sphere, cylinder, cube, cuboid, triangle, ellipse, circle, rectangle, pentagon, hexagon, heptagon, octagon, etc. The dimensions of the unit dose can vary, with a length of 0.25 to 15 cm, preferably 1.5 to 5.0 cm, a width of 0.5 to 7.0 cm, preferably 1.5 to 5.0 cm, and a height of 0.1 to 5 cm, preferably 0.5 to 2.5 cm. However, there are no theoretical limitations in size, quantity, or shape as long as it can be sealed and adhered to the wall of the sanitary appliance with a water-soluble film for a sufficient duration as intended herein.

[0037] In other embodiments of the first aspect of the invention, the in-cylinder toilet cleaning block is a sanitary composition comprising at least one surfactant selected from the group consisting of anionic surfactants, nonionic surfactants, cationic surfactants, and any combination thereof.

[0038] Figure 1 A substrate (10) according to the invention is shown, having at least one cavity (11) of suitable depth to receive an extruded composition for molding and / or embossing into a desired shape. The substrate may be a non-reactive metallic or plastic material to the extruded composition, such as aluminum or polyamide. In some embodiments, the substrate may comprise multiple cavities and is part of a machine designed to perform multiple functions in a series of steps to manufacture the hygienic adhesive cleaning block product of this article. In some embodiments, the substrate also includes at least one anvil profile (12) at the periphery of the cavity to facilitate heat transfer and sealing of the film for encapsulating the detergent composition therein. The substrate further includes multiple holes (13) to facilitate vacuum pressure, thereby retaining and maintaining the water-soluble film on the substrate throughout the process. In some embodiments, the water-soluble film (20) is preferably PVOH and may be placed on a top surface and over the substrate to cover the at least one cavity and anvil profile. The cavity is then purged to remove air and allow the PVOH membrane to enter and take shape accordingly, thus acting as a false bottom to form a semi-open bag. The open bag is then used as a container to receive the extruded sanitary composition.

[0039] In an alternative embodiment, a roller for thermoforming a water-soluble film is provided, and at the start of the process, the leading edge of the film roll is moved to a position above the substrate (10) and positioned in an overlay relationship relative to the cavity (11) and the anvil profile (12) to spread over the entire substrate to cover the cavity. Then an air evacuator is activated to remove air from each cavity (11), so that the film (20) is formed by being drawn into the cavity (11).

[0040] In some embodiments, the anvil profile (12) may be made of a different material having a lower thermal conductivity than the material used to manufacture the substrate. Therefore, in some embodiments, the substrate material may be metallic, such as aluminum, while the anvil profile may be rubber or silicone. In some embodiments, the anvil profile may be made of a non-thermally conductive material. In some embodiments, the width of the anvil profile is in the range of 0.5 to 2.5 mm; the height is in the range of 0.5 to 2.5 mm.

[0041] Those skilled in the art will understand that at least one distinguishing feature of the present invention is that the extruded composition is actually covered with a second polymer film and a suitable force is applied so as not to unduly crush the semi-solid composition, while avoiding such material from adhering to the pressure plate or the corresponding cavity.

[0042] In a preferred embodiment, the thickness of the membrane is in the range of 5 to 75 micrometers, preferably 10 to 50 micrometers, and more preferably 15 to 35 micrometers.

[0043] In some embodiments, the multiple cavities are preferably elliptical, circular, cylindrical, pentagonal, hexagonal, heptagonal, or octagonal in shape, with a depth ranging from 2 mm to 35 mm. In other embodiments, the cavities are configured to manufacture a toilet cleaning block composition having a three-dimensional shape having at least 3 symmetrical edges (60), but no more than 20, preferably 16, and at least 8 to 20 side surfaces (70), preferably 16.

[0044] A second aspect of the invention relates to machinery having multiple stages for performing the wrapping of a thermoformable film around an extruded sanitary toilet cleaning block composition. Therefore, the second aspect of the invention relates to a system for packaging a toilet cleaning block wrapped with a thermoformable film, comprising the steps of: (a) providing a plate (10) having a plurality of cavities, wherein each cavity (11) has an associated evacuation device, such as a vacuum suction device, and an anvil profile (12) having a width in the range of 0.5 to 2.5 mm and a height in the range of 0.5 to 2.5 mm; (b) placing a first flexible thermoformable film (20) with a thickness in the range of 10 to 75 micrometers above said plate; and (c) applying a vacuum in each cavity to enclose the first flexible thermoformable film (20). (d) An extruded solid or semi-solid detergent composition (30) containing at least one surfactant is placed above each cavity; (e) a second flexible thermoformable film (40) is placed above the detergent composition along a plate; (f) the extruded composition is pressed with a pressure plate (50) at a force of appropriate magnitude in the range of 150 to 700 N, preferably 250 to 600 N, applied from above the second flexible thermoformable film; and (g) a heat seal is applied, thereby sealing the first and second flexible thermoformable films to provide a toilet cleaning block encased in a thermoformable film. In some embodiments, the film may be preheated to achieve an appropriate degree of flexibility. In some embodiments, the heat seal is provided by a hot plate positioned on top of a substrate. In some embodiments, the heat seal is applied to the anvil profile to facilitate a proper seal.

[0045] In some embodiments, the cavity is a mold with a depth ranging from 1 mm to 40 mm, preferably from about 2 to 35 mm, and can be elliptical, circular, pentagonal, hexagonal, heptagonal, or octagonal in shape, preferably hexagonal. In other embodiments, the first or second thermoformable film is independently selected from the group consisting of: the first or second film is flexible, water-soluble, and thermoformable, and is independently selected from the group consisting of: polyvinyl alcohol (PVOH), polyethylene terephthalate, polyethylene terephthalate-ethylene glycol, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinylpyrrolidone, polyalkylene oxide and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamide, polypeptides, polyamides, and any combination thereof, preferably wherein both the first or second film are PVOH.

[0046] The sealing pressure is in the range of 1.0 to about 3.00 N / mm², preferably 1.5 to 2.5 N / mm², and the sealing temperature is in the range of 125 to 250°C, preferably 150 to 180°C. In some embodiments, the punching force is applied for about 1 second to about 20 seconds, preferably 2 to 10 seconds. In other embodiments, the final weight of the in-cylinder sanitary composition is in the range of 5 grams to 25 grams.

[0047] On the other hand, the present invention relates to a method for manufacturing an adhesive toilet cleaning block having a three-dimensional shape having an upper surface and a lower surface, the method comprising: (a) providing a plate having a plurality of cavities and a plurality of anvil contours in the perimeter of the cavities, wherein each cavity has an associated venting device; (b) placing a first flexible membrane with a thickness in the range of 10 to 50 micrometers above the plate; (c) covering the plurality of cavities with the first flexible membrane; (d) applying a vacuum in each cavity to place the first flexible membrane into each cavity; (e) placing at least one extruded solid or semi-solid detergent composition comprising at least one surfactant above each of the cavities; (f) placing a second flexible membrane above the plate and covering the composition along the plate; (g) pressing the detergent composition from above the second flexible form with a force in the range of 150 to 700 N, preferably 250 to 600 N, using a pressure plate; and (h) applying a heat seal, whereby the first and second flexible membranes are joined and sealed around the toilet cleaning block, thereby encapsulating the toilet cleaning block within the membrane. In some embodiments, the heat seal is provided by a hot plate positioned on top of the substrate. In some embodiments, the heat seal is applied to the anvil profile to facilitate a proper seal.

[0048] The preferred water-soluble polymer suitable for use in this invention is PVOH. PVOH is typically prepared by hydrolyzing polyvinyl acetate in ethanol in the presence of an alkali metal hydroxide, and depending on its thickness, it can coat around a toilet cleaning block, thereby further enhancing the adhesion of the product when applied directly to a hard surface.

[0049] On the other hand, the present invention relates to a method for manufacturing an adhesive toilet cleaning block having a three-dimensional shape having an upper surface and a lower surface, the method comprising: (a) providing a plate having a plurality of cavities and an anvil profile surrounding the perimeter of the cavities, wherein each cavity has an associated venting device; (b) placing a first flexible membrane with a thickness in the range of 10 to 50 micrometers above the plate; (c) covering the plurality of cavities with the first flexible membrane; (d) applying a vacuum in each cavity to place the first flexible membrane into each cavity; (e) placing at least one extruded solid or semi-solid detergent composition comprising at least one surfactant above each of the cavities; (f) placing a second flexible membrane above the plate and covering the composition along the plate; (g) pressing the detergent composition from above the second flexible form with a force in the range of 150 to 700 N, preferably 250 to 600 N, using a pressure plate; and (h) applying a heat seal, whereby the first and second flexible membranes are joined and sealed around the toilet cleaning block, thereby encapsulating the toilet cleaning block within the membrane. In some implementations, the heat seal is provided by a hot plate positioned on top of the substrate, and heat is applied to the anvil profile.

[0050] In some embodiments of the invention, the method of the invention includes the steps of: providing a plate having a plurality of cavities, each cavity having a venting device associated with the cavities; placing a flexible thermoformable film over and covering the cavities; and venting the cavities, thereby forcing the thermoformable film to be drawn into the cavities to form a plurality of bags ready to receive a sanitary composition comprising at least one surfactant.

[0051] Figure 2 The extruded cleaning block composition (30) is shown placed on top of a plate above a cavity that has been formed and a water-soluble film (21) is adapted to the shape of the cavity. In the next step, the plate (10) is moved to a section with a series of retainers positioned directly above the respective cavities, which, when activated, position the extruded cleaning composition on top of the cavities to fill them. In some embodiments, a second water-soluble film (40) is placed on top of the cleaning block composition and the plate to completely cover the entire plate (10) and the extruded cleaning block composition already placed inside the cavity (30).

[0052] In some embodiments, a pressure plate (50) positioned above the membrane moves downward to press the extruded composition (30) into the corresponding cavity to give the semi-solid cleaning block its final shape. Once the extruded composition (30) is pressed into the cavity, it adapts to the cavity's basic design, embossing, and shape, and has suitable parameters: a length of 0.25 to 10 cm, preferably 1.5 to 6.0 cm; a width of 0.5 to 7.0 cm, preferably 1.5 to 5.0 cm; and a height of 0.3 to 5 cm, preferably 0.5 to 2.5 cm. The membrane is then heated to seal it along the anvil boundary of the cavity to promote a heat seal, thereby forming a wrap-around cleaning block (see...). Figure 3 (80%). Then, the water-soluble film is cut along the plate and cavity boundaries to manufacture... Figure 3 The unique improved hexagonal design (80).

[0053] The cleaning block composition according to the invention can be prepared by combining cleaning ingredients, including but not limited to anionic surfactants, nonionic surfactants, cationic surfactants, adhesion promoters, chelating agents, antioxidants, and inorganic salts. In a preferred embodiment, the hygienic toilet cleaning block composition according to the invention is an extruded and stretchable bathroom cleaning composition comprising: (a) about 10% by weight to about 60% by weight of an inorganic sodium salt; (b) about 10% by weight to about 80% by weight, preferably about 15% by weight to about 75% by weight of anionic surfactant; (c) about 0.1% by weight to about 10% by weight of an adhesion promoter; (d) about 0.05% by weight to about 10% by weight of a chelating agent; and (e) about 0.05% by weight to about 1.0% by weight of an antioxidant; wherein the composition is encapsulated and sealed by a water-soluble film and is able to adhere to the sanitary object when applied directly against the wall of the sanitary fixture. In some embodiments, the extruded composition of the present invention optionally contains a nonionic surfactant in an amount of up to 5% by weight of the composition, preferably up to 2.5%, but most preferably less than 2% by weight of the composition. In some embodiments, the extruded composition is substantially free of any nonionic surfactant.

[0054] In some embodiments, the composition according to the invention is an extrusion combination of the following: (a) about 12.5% ​​by weight to about 45% by weight of an inorganic sodium salt; (b) about 25% by weight to about 75% by weight, preferably about 45% by weight to about 70% by weight of an anionic surfactant; (c) about 0.5% by weight to about 5% by weight, preferably about 0.5% by weight to about 3% by weight, more preferably about 1.0% by weight to about 2% by weight of an adhesion promoter; and / or (d) about 0.5% by weight to about 3% by weight of a chelating agent; and / or (e) about 0.1% by weight to about 1.0% by weight, preferably about 0.1% by weight to about 0.5% by weight, more preferably about 0.1% by weight to about 0.3% by weight of an antioxidant. In some embodiments, the total amount of all nonionic surfactants is less than 2.5% by weight of the composition. In some embodiments, the extruded composition does not contain any nonionic surfactants.

[0055] In some embodiments, the cleaning block composition is a stretchable semi-solid and consists essentially of a sodium salt, anionic surfactant, chelating agent, adhesion promoter, antioxidant, dye, and fragrance, which is extruded before being encapsulated in a water-soluble membrane. In some embodiments, the anionic surfactant is sodium dodecylbenzenesulfonate, sodium lauryl sulfate, or a combination thereof, and the adhesion promoter is N-methyl-alkylglucamide.

[0056] In some embodiments, the cleaning block composition prepared according to the process described herein has a length of 0.25 to 10 cm, preferably 1.5 to 6.0 cm, a width of 0.5 to 7.0 cm, preferably 1.5 to 5.0 cm, and a height of 0.3 to 5 cm, preferably 0.5 to 2.5 cm. In a preferred embodiment, the cleaning block composition has at least two parallel upper and lower surfaces. In some embodiments, the weight of the cleaning block composition is in the range of 5 to 25 grams, and the footprint is 30 to 45 mm, preferably 35 to 40 mm. In other embodiments, the cleaning block composition according to the invention is encapsulated in a transparent, water-soluble film with a thickness in the range of about 5 micrometers to about 75 micrometers, preferably 15 to 35 micrometers.

[0057] In some embodiments, the invention also includes a packaging system comprising a plurality of metal plates having at least one cavity, the system being configured to perform a process according to the first aspect of the invention. Such a system may further include executable software, stamping equipment, tracking and monitoring tools to identify movement of the metal plates, position of the cavities, weight of the extruded composition to be packaged, and the final manufactured product. The packaging system according to the invention further includes components such as computer hardware integrated with the executable software, a computer-based network, an access system, a web-based portal, a database, and processing units to provide the ability to modify the product itself in many ways. The system according to the invention is intended for use by those skilled in the art to modify manufacturing parameters and control process speed, heat-sealing temperature, substrate vacuum control, and adjust structural or thermal parameters involved in the process.

[0058] Those skilled in the art will understand that products manufactured according to the invention ideally have at least one upper or lower surface, which is elliptical, circular, pentagonal, hexagonal, heptagonal, or octagonal in shape, and has at least four symmetrical edges (60), but no more than 20, preferably 16, and at least eight to 20 surfaces (70), preferably 16. Regarding the shape of the cleaning block, it will be observed that the cleaning block according to the invention is preferably designed to have a substantially modified hexagonal shape. This modified hexagonal shape may include a flat hexagonal surface on one side, and flat surfaces of triangles (72) and / or rectangles (71), such as... Figure 3 As shown, this is to maximize the surface area exposed to the rinsing water.

[0059] Although specific embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Furthermore, although various aspects of the claimed subject matter have been described herein, these aspects need not be combined. Therefore, the appended claims are intended to cover all such changes and modifications within the scope of the claimed subject matter.

Claims

1. A method for packaging an in-tub toilet cleaning block wrapped in a film, the method comprising the following steps: a) Provides a plate having at least one cavity, wherein the cavity has a venting device associated with the cavity and an anvil profile surrounding the perimeter of the cavity. b) Place a first water-soluble polymer film with a thickness in the range of 10 to 75 micrometers above the at least one cavity. c) Place an extruded semi-solid cleaning composition containing at least one surfactant above the cavity. d) Place the second polymer film across the entire plate over the composition. e) The composition is pressed with a pressure plate using a suitable force in the range of 150 to 700 N, preferably 250 to 600 N, said force being applied from above the second membrane, and f) Apply heat sealing, thereby sealing the first and second membranes to provide a toilet cleaning block enclosed in the membranes.

2. The method according to claim 1, further comprising the step of cutting the enclosed toilet cleaning block along the shape of the cavity.

3. The method according to any one of the preceding claims, wherein, The second polymer membrane is a water-soluble membrane.

4. The method according to any one of the preceding claims, wherein, The cavity can be elliptical, circular, pentagonal, hexagonal, heptagonal, octagonal, or hexagonal in shape.

5. The method according to any one of the preceding claims, wherein, At least one of the first membrane or the second membrane is independently selected from the group consisting of: polyvinyl alcohol (PVOH), polyethylene terephthalate, polyethylene terephthalate-ethylene glycol, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinylpyrrolidone, polyalkylene oxide and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamide, polypeptides, polyamides and any combination thereof, preferably wherein... Both the first membrane and the second membrane are PVOH.

6. The method according to any one of the preceding claims, wherein, The surfactant is selected from the group consisting of anionic surfactants, nonionic surfactants, cationic surfactants, and any combination thereof.

7. The method according to any one of the preceding claims, wherein, The detergent composition has a hardness in the range of 5 to 20 N / mm and a density in the range of 1.0 to about 1.5 g / L.

8. The method according to any one of the preceding claims, wherein, The impact force is applied for 1 second to about 20 seconds, preferably 2 to 10 seconds.

9. The method according to any one of the preceding claims, wherein, The pressure of the seal is in the range of 1.0 to about 3.00 N / mm², preferably 1.5 to 2.5 N / mm².

10. The method according to any one of the preceding claims, wherein, The sealing temperature is in the range of 125°C to 250°C, preferably 150°C to 180°C.

11. The method according to any one of the preceding claims, wherein, The heat seal is applied to the anvil profile.

12. The method according to any one of the preceding claims, wherein, The detergent composition has a weight range of 5 to 25 grams.

13. The method according to any one of the preceding claims, further comprising the step of printing marks, shapes, designs, and text on the outer layer of the polymer film.

14. A wrap-around toilet cleaning block manufactured according to any one of claims 1 to 13.

15. A system for packaging toilet bowl cleaning blocks encapsulated in a water-soluble film, the system comprising: a) A plurality of metal plates, each plate having a plurality of cavities, wherein each of the cavities has a venting device associated with that cavity. b) A roller configured to place a flexible sheet of a first water-soluble film with a thickness in the range of 10 to 75 micrometers above the plate. c) A vacuum assembly for each of the cavities, the vacuum assembly being configured to position the first flexible water-soluble membrane into each cavity. d) A loading assembly that places an extruded semi-solid sanitary composition containing at least one surfactant above the cavity. e) A second roller, configured to place a flexible sheet of the second water-soluble film along the plate above the cavity containing the composition. f) A stamping plate, the stamping plate being configured to stamp the composition into the cavity, and g) A heating system for sealing the first membrane and the second membrane, the first membrane and the second membrane being sealed to provide a toilet cleaning block enclosed in the membrane.

16. The system according to claim 15, wherein, At least one of the first membrane or the second membrane is independently selected from the group consisting of: polyvinyl alcohol (PVOH), polyethylene terephthalate, polyethylene terephthalate-ethylene glycol, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinylpyrrolidone, polyalkylene oxide and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamide, polypeptides, polyamides and any combination thereof, preferably wherein... Both the first membrane and the second membrane are PVOH.

17. The system according to any one of claims 15 to 16, wherein, The surfactant is selected from the group consisting of anionic surfactants, nonionic surfactants, cationic surfactants, and any combination thereof.

18. The system according to any one of claims 15 to 17, wherein, The detergent composition has a hardness in the range of 5 to 20 N / mm and a density in the range of 1.0 to about 1.5 g / L.

19. The system according to any one of claims 15 to 18, wherein, The impact force is applied for 1 second to about 20 seconds, preferably 2 to 10 seconds.

20. The system according to any one of claims 15 to 19, wherein, The pressure of the seal is in the range of 1.0 to about 3.00 N / mm², preferably 1.5 to 2.5 N / mm².

21. The system according to any one of claims 15 to 20, wherein, The sealing temperature is in the range of 125°C to 250°C, preferably 150°C to 180°C.

22. The system according to any one of claims 15 to 21, wherein, The weight of the composition is in the range of 5 grams to 25 grams.

23. The system according to any one of claims 15 to 22, the system further comprising components for printing marks, shapes, and text on the outer layer of the polymer film.

24. A method for manufacturing an adhesive toilet cleaner block having a three-dimensional shape, said three-dimensional shape having an upper surface and a lower surface, the method comprising the steps of: a. A plate having multiple cavities, wherein each of the cavities has a venting device associated with that cavity. b. Place a first flexible film with a thickness in the range of 10 to 75 micrometers above the plate. c. Cover the plurality of cavities with the first flexible membrane. d. Apply a vacuum in each of the cavities to place the first flexible membrane into each cavity. e. Place over each of the cavities at least one extruded solid or semi-solid detergent composition containing at least one surfactant. f. Place the second flexible film over the plate and cover the composition along the plate. g. Pressing the detergent composition from above the second flexible form with a pressure plate using a force in the range of 150 to 700 N, preferably 250 to 600 N, and h. Apply a heat seal, thereby sealing the first flexible membrane and the second flexible membrane around the toilet cleaning block, thus enclosing the toilet cleaning block within the membrane.

25. The method according to claim 24, wherein, At least one of the upper surface or the lower surface is elliptical, circular, pentagonal, hexagonal, heptagonal or octagonal in shape.

26. The method according to claims 24 to 25, wherein, The adhesive toilet cleaning block has at least 4 symmetrical edges, but no more than 20, preferably 16.

27. The method according to claims 24 to 26, wherein, The adhesive toilet cleaning block has at least 8 to 20 side surfaces, preferably 16.

28. The method according to claims 24 to 27, wherein, The step of stamping the sanitary composition involves pushing the composition into the cavity to form the upper or lower surface of the adhesive cleaning block.

29. The method of claims 24 to 28, further comprising cutting the membrane along the edge of the toilet cleaning block enclosed within the membrane.

30. The method according to claims 24 to 29, wherein, The thickness of the membrane is in the range of 5 to 75 micrometers, preferably 10 to 35 micrometers.

31. The method according to claims 24 to 30, wherein, At least one of the first membrane or the second membrane is independently selected from the group consisting of: polyvinyl alcohol (PVOH), polyethylene terephthalate, polyethylene terephthalate-ethylene glycol, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinylpyrrolidone, polyalkylene oxide and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamide, polypeptides, polyamides and any combination thereof, preferably wherein... Both the first membrane and the second membrane are PVOH.

32. A product manufactured according to the process steps of any one of claims 24 to 31.

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