Method for thermoforming membranes used in the production of water-soluble dosing elements

Abstract

This disclosure provides a method for thermoforming membranes (2, 20, 20a, 20b, 320, 420, 422, 40, 435) for producing water-soluble dosing elements (475) and an apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465) for thermoforming membranes (2, 20, 20a, 20b, 320, 420, 422, 40, 435) for producing water-soluble dosing elements (475). The method includes: heating a film (2, 20, 20a, 20b, 320, 420, 422, 40, 435) and aligning the film with an array of cavities (4, 40, 40a, 340, 41, 440, 540); moving the array of films (2, 20, 20a, 20b, 320, 420, 422, 40, 435) and cavities (4, 40, 40a, 340, 41, 440, 540) through a stamping module (100, 200, 310, 410, 510, 120), the stamping module (100, 200, 310, 410, 510, 120) including cavities (4, 40, 40a, 20b, 320, 420, 422, 40, 435) movable in the array. At least one punch (120, 220, 330, 430) from the array (40, 41, 440, 540) moves through the punching module (100, 200, 310, 410, 510, 120) to push the membrane (2, 20, 20a, 20b, 320, 420, 422, 40, 435) into the cavity (4, 40, 40a, 340, 41, 440, 540) using the punch (120, 220, 330, 430). This disclosure also provides the use of the apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465) for performing methods, methods for manufacturing the apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465), and kits (500) used in the methods for manufacturing the apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465).

Description

Technical Field

[0001] This disclosure relates to a method for thermoforming a membrane for producing a water-soluble dosing element, and to an apparatus for thermoforming a membrane for producing a water-soluble dosing element. This disclosure also relates to the use of the apparatus to perform the method, methods for manufacturing the apparatus, and kits used in the methods of manufacturing the apparatus. Background Technology

[0002] Thermoforming is a well-known technique for preparing articles from polymers. It typically involves heating a polymer material to above its softening temperature and thermally deforming the composition within a mold.

[0003] It is also known to package chemical treatment agents into water-soluble dosing elements by thermoforming a water-soluble film and encapsulating the treatment agent therein. The water-soluble dosing element dissolves or ruptures in water to release the treatment agent. Dosing elements are commonly used as dishwasher or detergent tablets. Examples can be found in International Patent Application No. WO00 / 55045A1 and European Patent No. EP0507404B.

[0004] Water-soluble dosing elements can be prepared using a variety of devices and methods. Figure 1a and Figure 1b A specific device 1 is shown in the image. Figure 1a In this process, the water-soluble polymer film 2 is heated by the heating roller 6 and drawn onto the array of cavities 4 for stretching. For example... Figure 1b As shown, a vacuum is applied to the cavity using vacuum source 5 to draw the membrane 2 into the cavity, thereby shaping the cavity. The array of cavities 4 is then vertically withdrawn from the thermoformed membrane, and another length of membrane 2 is drawn onto the array of cavities 4. The array of cavities 4 returns to its initial position, and the other length of membrane is thermoformed. A treatment agent (not shown) can then be applied to the thermoformed membrane 2, and another membrane (not shown) is applied to seal the treatment agent inside, thereby forming a dosing element.

[0005] The object of this invention is to provide an overall improvement over existing methods and apparatus. Optionally, this invention may seek to provide one or more of the following advantages: i) Improve the quality of encapsulation through membranes; ii) Improve the visual appearance of the dosing element; iii) Improve the rupture resistance of the dosing element; iv) Provide equipment capable of delivering improved dosing elements in high quantities; v) Provide low-complexity equipment for producing dosing elements; vi) Provide equipment that can be added to existing equipment. Summary of the Invention

[0006] In a first aspect of this disclosure, there is a method for thermoforming a membrane for producing a water-soluble dosing element, the method comprising the following steps: i) Heating the membrane and aligning the membrane with the array of cavities in any order or simultaneously; ii) Moving the array of the membrane and the cavity through a stamping module, the stamping module including at least one punch movable into the cavity of the array; and iii) As each cavity from the array moves through the stamping module, the stamping module is operated to push the membrane into the cavity using the punch.

[0007] In a second aspect of this disclosure, there is an apparatus for thermoforming a membrane for producing a water-soluble dosing element, the apparatus comprising: i) An array of movable cavities; ii) A membrane feeding device for aligning a membrane with an array of cavities and moving the membrane along with the array of cavities; iii) A heat source for heating the membrane; and iv) A stamping module including a punch for pushing the membrane into the cavity as the cavity and the membrane move through the stamping module.

[0008] This disclosure provides a thermoformed dosing element with improved film thickness distribution throughout the dosing element. This results in more uniform tension throughout the dosing element, providing an improved visual appearance, among other improvements. This disclosure also allows for high-volume production of dosing elements using low-complexity equipment, among other benefits.

[0009] As used in this article regarding membranes, thermoforming is a process in which the membrane is heated to form (e.g., in a cavity), and then allowed to cool, so that the membrane retains its shape, such as the shape of the cavity.

[0010] membrane

[0011] In some embodiments, the membrane comprises a water-soluble polymer.

[0012] The water-soluble polymer may be selected from the group consisting of: polyvinyl alcohol, polyacrylamide, poly(acrylic acid), poly(methacrylic acid), polyvinylpyrrolidone, quaternary ammonium polymers, cellulose ethers, polyethylene oxide, starch, polyacrylamide, polyacrylonitrile, polyethylene methyl ether-maleic anhydride, polymaleic anhydride, styrene-maleic anhydride, hydroxyethyl cellulose, methyl cellulose, polyethylene glycol, carboxymethyl cellulose, polyacrylate, alginate, acrylamide copolymer, guar gum, casein, ethylene-maleic anhydride resin, polyethyleneimine, ethyl hydroxyethyl cellulose, ethyl methyl cellulose, hydroxyethyl methyl cellulose, and any mixture of the foregoing. In some embodiments, the membrane comprises a polyvinyl alcohol (PVOH) membrane. The polyvinyl alcohol may include modified or unmodified polyvinyl alcohol.

[0013] In some embodiments, the membrane has a thickness not exceeding 300 μm, or 260 μm, or 240 μm, or 220 μm, or 200 μm, or 180 μm, or 160 μm, or 140 μm, or 120 μm, or 100 μm, or 80 μm. In some embodiments, the membrane has a thickness greater than 40 μm, or 60 μm, or 80 μm, or 100 μm, or 120 μm, or 140 μm, or 160 μm, or 180 μm. Optionally, the membrane thickness is between 100 μm and 240 μm, or between 120 μm and 220 μm, or between 140 μm and 180 μm, or between 150 μm and 170 μm, or any range formed by any of the foregoing values. The membrane thickness can be measured before thermoforming. In some embodiments, the areal weight of the membrane is 80 g / m². 2 and 300g / m 2 Between, or at 100g / m 2 and 280g / m 2 Between, or at 120g / m 2 and 260g / m 2 Between, or at 140g / m 2 and 240g / m 2 Between, or at 160g / m 2 and 220g / m 2 Between, or at 180g / m 2 and 200g / m 2 Between, or any range formed by any of these endpoints.

[0014] Films can be formed by solvent casting, blow molding, extrusion, or blow molding extrusion. Solvent casting methods for films are well known in the art.

[0015] Some embodiments may use a first membrane and a second membrane. In such embodiments, the first membrane is a membrane pushed into the cavity. The first and second membranes may be formed from any membrane described herein.

[0016] heating

[0017] Heating the membrane may involve applying heat from a heat source to raise the membrane's temperature. The closer the membrane is to the stamping module, the higher its temperature. The term "heat source" may refer to a single heat source or multiple independent heat sources. Multiple heat sources may be distributed throughout the device. In some embodiments, the membrane is heated to a temperature range of 70°C to 220°C, or 85°C to 190°C, or 100°C to 170°C, or 115°C to 150°C, or 130°C to 135°C, or any range formed by any of these endpoints. Preferably, the membrane temperature is measured using an IR temperature sensor on the surface furthest from the cavity. Preferably, the membrane temperature is measured before and near the point where the membrane enters the stamping module. In this document, the term "before" may refer to the direction of travel of the membrane in the device, i.e., the machine direction. Thus, the term "before" in relation to a part of the device may refer to another part or other portion of the device that the membrane encounters while being processed through the device in the machine direction, before reaching the aforementioned portion. Conversely, "after" can refer to the subsequent or other parts of the equipment that the membrane encounters as it is processed in the machine direction.

[0018] A heat source can be configured to heat the membrane. In this document, "configured" can mean that the equipment is positioned, oriented, or otherwise arranged to direct sufficient heat energy to soften the membrane. The heat source may be located in contact with or adjacent to the membrane. The heat source may include one or more of the following: a hot air source, a radiant heater (optionally an infrared heater), a piezoelectric element, and / or a resistance heating element. The resistance heating element may optionally be incorporated into one or more rollers, one or more stationary plates, cavities, and / or punches. The membrane can be heated directly or indirectly, for example, by heating a surface or applying a hot article to the membrane.

[0019] In some embodiments, the membrane is heated before stamping. Therefore, in some embodiments, the heat source for heating the membrane may be located adjacent to and before the punch. When the heat source for heating the membrane is located adjacent to and before the stamping module, the heat source may be a radiant heater or a hot air source. The heat source, or a portion thereof, may be located before, as part of, and / or after the membrane supply device. Therefore, heating may occur before, during, or after membrane alignment with the cavity.

[0020] In some embodiments, the heat source includes a heating roller and a radiant heater. The heating roller may be all or part of the film feeding device and may be used to align the film while also heating it. The radiant heater may be positioned between the heating roller and the stamping module. The heating roller heats the film to an intermediate temperature between ambient temperature and thermoforming temperature. The radiant heater then heats the film from the intermediate temperature to the thermoforming temperature.

[0021] In some embodiments, the film is aligned with an array of one or more rollers and cavities preceding the stamping module, and at least one of the one or more rollers preceding the stamping module is heated. The one or more rollers can be heated to a temperature range of 50°C to 170°C, or 60°C to 160°C, or 70°C to 130°C, or 70°C to 90°C, or any temperature range formed by any of these endpoints. Optionally, the rollers can be heated using resistive elements within the rollers, or the rollers can be indirectly heated by an external heat source.

[0022] In some embodiments, the cavities of the array of cavities are heated to a temperature range of 50°C to 170°C, 60°C to 160°C, 70°C to 130°C, or 70°C to 90°C, or any range formed by any of these endpoints. In some embodiments, the device includes a heat source for heating the cavities. The heat source may be included inside the cavities or may be outside the cavities. The cavities may control the cooling rate of the film after thermoforming. After thermoforming, the cavities may partially heat the film to slow down the cooling rate of the film.

[0023] The membrane can be heated before alignment by the membrane feeding device. For example, the heat source can be located before the membrane feeding device. Alternatively, the membrane can be heated after alignment by the membrane feeding device. For example, the heat source can be located after the membrane feeding device and before the stamping module. The membrane can also be heated during alignment by a heat source that is part of the membrane feeding device. Embodiments can include any combination of heating before, after, or during alignment.

[0024] Array of cavities

[0025] An array of cavities may include multiple independent cavities connected together. The cavities may impart their shape to the thermoforming film. Thus, a cavity may optionally be considered a concave mold for thermoforming a heated film within that concave mold.

[0026] The cavity (in which the thermoformed membrane is placed) can have any shape, length, width, and depth, depending on the required size of the dosing element. The size and shape of the cavity can also be varied from one to another if needed.

[0027] In some embodiments, the array of cavities includes cavities arranged in annular rings. The annular rings may be arranged as a continuous belt or a circular wheel, the circular wheel including cavities on its outer radius. Adjacent cavities may be connected by flexible or articulated links or any other mechanical connection that allows cavities to move from a starting point, along a predetermined path, and back to the starting point. Alternatively, the cavities may be independently mounted to a chain, belt, or the like.

[0028] In embodiments including an annular ring, the cavity can move from a starting point in a first direction (e.g., the machine direction), reverse around an endpoint, and return to the starting point via a second direction, wherein the second direction is parallel to and opposite to the first direction. Such a device may include rollers, gears, or wheels to drive and guide the movement of the cavity.

[0029] The cavity may include a body having an inner surface and an outer surface. The inner surface may partially surround the internal volume. In some embodiments, the internal volume of the cavity is 5 cm³. 3 Up to 30cm 3 or 10cm 3 Up to 25cm 3 or 15cm 3 Up to 30cm 3 The internal volume can refer to the maximum volume of liquid that can be contained within the cavity. The shape of the internal volume can be the shape imparted to the dosing element during thermoforming. The body of the cavity can define the periphery of the opening. Therefore, the opening can be defined as the upper limit of the internal volume. The punch can move into the cavity perpendicular to the plane of the opening.

[0030] In some embodiments, the cavity has an internal depth ranging from 5 mm to 30 mm, or from 10 mm to 25 mm, or from 15 mm to 20 mm, or any range formed by any of these endpoints. The internal depth is measured internally in the depth direction from the opening to the deepest part of the cavity. The depth direction is perpendicular to the opening of the cavity. When the cavity is aligned with the opening in a horizontal plane, the depth direction will be aligned in the vertical direction.

[0031] The opening of the cavity can be surrounded by a flange. The flange can be a planar surface that extends parallel to the opening. In some embodiments, the membrane can be aligned such that it contacts the flange. The flange can improve the seal between the cavity and the membrane.

[0032] The cavity may have an inner radius of less than 10 mm, or 9 mm, or 8 mm, or 7.5 mm, or 7 mm, or 6.5 mm, or 6 mm, or 5.5 mm, or 5 mm, or 4.5 mm, or 4 mm, or 3.5 mm, or 3 mm. The cavity may have an inner radius greater than 0.1 mm, or 0.25 mm, or 0.5 mm, or 0.75 mm, or 1 mm, or 1.25 mm, or 1.5 mm, or 1.75 mm, or 2 mm, or 2.25 mm, or 2.5 mm.

[0033] The dosing element may include an outer radius corresponding to the inner radius of the cavity. The outer radius of the dosing element may be smaller than the inner radius of the cavity: the outer radius of the dosing element may be 10% to 0.01%, or 5% to 0.1%, or 2% to 0.05% smaller than the inner radius of the cavity, or any range formed by any of these endpoints. The dosing element may include an outer radius less than 10 mm, or 9 mm, or 8 mm, or 7.5 mm, or 7 mm, or 6.5 mm, or 6 mm, or 5.5 mm, or 5 mm, or 4.5 mm, or 4 mm, or 3.5 mm, or 3 mm. The dosing element may include an outer radius greater than 0.1 mm, or 0.25 mm, or 0.5 mm, or 0.75 mm, or 1 mm, or 1.25 mm, or 1.5 mm, or 1.75 mm, or 2 mm, or 2.25 mm, or 2.5 mm. This radius can be determined by applying a radius gauge to the radius to be measured.

[0034] In some embodiments, the cavity may include one, two, three, four or more compartments within each cavity. The compartments may be separate or distinct portions at the bottom of the cavity, resulting in separate cavities in the final dosing element.

[0035] The array of cavities may include at least 2 cavities, at least 10 cavities, at least 40 cavities, at least 100 cavities, at least 200 cavities, or at least 400 cavities. The array of cavities may include fewer than 100,000 cavities, 50,000 cavities, 10,000 cavities, 5,000 cavities, 1,000 cavities, or 500 cavities.

[0036] The cavities of the cavity array can also be arranged in parallel, meaning that multiple cavities can be aligned perpendicular to the direction of movement of the cavity array (i.e., perpendicular to the machine direction). For example, if the cavity array includes four cavities arranged perpendicular to the direction of movement, then as the array moves, the cavities will pass through the stamping module in sets of four, wherein each cavity in the set passes through the stamping module simultaneously. The cavity array may include at least one cavity aligned perpendicular to the direction of movement of the cavity array, at least two cavities, at least four cavities, at least eight cavities, at least twelve cavities, or at least twenty or forty cavities.

[0037] The array of cavities and the membrane can move perpendicular to the direction of movement of the punch entering and leaving the cavity. Therefore, if the punch moves vertically, the cavity and membrane can move horizontally, and vice versa. The direction of movement of the cavity and membrane can be called the machine direction; therefore, when the punch moves into and out of the cavity, it can move perpendicular to the machine direction.

[0038] alignment

[0039] In the context of this disclosure, "alignment" refers to bringing together an array of membranes and cavities such that the membrane is positioned so that it can be pushed into the cavity. In some embodiments, the membrane may be brought into contact with the cavity such that a seal is formed around the periphery of the opening between the membrane and the cavity, sufficient to allow a vacuum applied to the cavity to pull the membrane into the cavity. In cases where the cavity includes a flange, the membrane may be aligned to contact the flange. Once aligned, the membrane and the cavity move together at the same speed.

[0040] The apparatus includes a film feeding device for aligning the film. The film feeding device may include a web handling device for conveying the film. The film feeding device may include one or more rollers. Thus, in some embodiments, the film can be aligned with an array of cavities via one or more rollers. Rollers may include live and dead / idle rollers, or floating rollers. Rollers may be arranged in pairs, such as pinch rollers and S-shaped winding rollers. Alternatively, the film feeding device may include a single roller, or the film feeding device may include a mandrel housing the roller, and the film can be unfolded directly from the roller for alignment with the array of cavities. Thus, the film feeding device may include one or more additional rollers. Optionally, one or more additional rollers may align the film before the stamping module, and / or one or more additional rollers may align the film after the stamping module.

[0041] Prior to step ii), the membrane may be under tension. Optionally, tension may be applied during membrane-cavity alignment and maintained by contact between the membrane and the cavity. Tension may be applied by moving the array of cavities faster than the membrane feed device, such that the membrane is partially stretched before contact with the cavity. In some embodiments, the tension of the membrane prior to step ii) is greater than 1 N, or 5 N, or 10 N, or 15 N, or 20 N, or 25 N, and does not exceed 45 N, or 40 N, or 35 N, or 30 N, or 25 N, or 20 N, or 15 N. The tension may be within any range formed by any of these endpoints.

[0042] In some embodiments, the membrane and cavity move together at a speed of 4 m / min to 18 m / min, or 6 m / min to 16 m / min, or 8 m / min to 14 m / min, or 10 m / min to 12 m / min, or any range formed by any of these endpoints. Therefore, in some embodiments, the movable cavity array and membrane feeding device are configured to cause the membrane and cavity array to move together at a speed of 4 m / min to 18 m / min, or 6 m / min to 16 m / min, or 8 m / min to 14 m / min, or 10 m / min to 12 m / min, or any range formed by any of these endpoints. The speed of the cavity array can be continuous. Alternatively, the cavity array can pause as the cavity passes through the stamping module before the punch enters the cavity, and can resume movement once the punch has exited the cavity.

[0043] stamping module

[0044] A stamping module may include a housing and one or more actuators configured to move one or more punches into and out of a cavity via reciprocating motion. The actuators may be configured to move one or more punches as the cavity passes through the module.

[0045] Alternatively, the punches may move in the machine direction at the same or similar rate as the array of cavities. Thus, the punches can track the cavities as they move. For example, a stamping module may include multiple punches mounted on a rotating body. The rotation of the body may correspond to the speed of the array of cavities. Alternatively, the stamping module may include multiple actuated punches that track the movement of the cavities; for example, the punches may be mounted on an annular ring (e.g., a belt).

[0046] The method may include: a stamping module moving the punch at the same speed as the array of cavities while the punch enters and exits the cavity. The stamping module may move the punch parallel to the machine direction. Therefore, the stamping module may include one or more actuators for moving the punch parallel to the machine direction at the same speed as the array of cavities. From the time the punch is inserted into the cavity until it is withdrawn from the cavity, the stamping module may move the punch in the machine direction, tracking the cavity. After the punch has withdrawn from the cavity, the stamping module may move the punch in the opposite direction to the machine direction to return the punch to its starting position. The stamping module may then move the punch to the next cavity and restart the process. The stamping module may include multiple punches mounted on a rotating body. The rotation of the body may correspond to the speed of the array of cavities. Alternatively, the stamping module may include multiple actuated punches that track the movement of the cavities; for example, the punches may be mounted on an annular ring (e.g., a belt).

[0047] In some embodiments (where the stamping module moves the punch at the same speed as the cavity), a heat source may move adjacent to the punch. Optionally, a heat source may be mounted to the punch and / or the stamping module. Optionally, the heat source may move parallel to the machine direction.

[0048] The shape of the punch can be the same as the internal volume of the cavity, or its shape can be similar to the geometry of the cavity but smaller.

[0049] In some embodiments, the punch comprises a material with a coefficient of thermal expansion of less than 100 μm / mK, less than 75 μm / mK, less than 60 μm / mK, less than 50 μm / mK, less than 45 μm / mK, less than 40 μm / mK, less than 35 μm / mK, less than 30 μm / mK, or less than 25 μm / mK. The punch may also comprise a material with a coefficient of thermal expansion of greater than 10 μm / mK, or greater than 50 μm / mK, or greater than 100 μm / mK, or greater than 150 μm / mK, or greater than 200 μm / mK, or greater than 250 μm / mK, or greater than 30 μm / mK. In some embodiments, where the punch is heated and / or the punch comprises part of a heat source, the punch may comprise a material with a coefficient of thermal expansion of 15 W / m·K to 400 W / m·K, or 50 W / m·K to 300 W / m·K, or 100 W / m·K to 250 W / m·K, or any range of these endpoints. In some embodiments where the punch is not heated and / or the punch does not constitute part of a heat source, the punch may comprise a material with a coefficient of thermal expansion of 0.01 W / m·K to 20 W / m·K, or 0.1 W / m·K to 15 W / m·K, or 0.2 W / m·K to 10 W / m·K, or any range of these endpoints. The punch may be made of metal, including but not limited to aluminum, titanium, stainless steel and alloys thereof, or of polymer, including but not limited to thermosetting materials and thermoplastic polymers such as polyolefins, polyamides and polyesters. Optionally, the polymer may be a composite material comprising fillers, fibers or other reinforcing materials. The punch can be solid, hollow, or foamed, and in particular, can include synthetic foam. Alternatively, the punch can be made of ceramic or wood.

[0050] In some embodiments, the punch is heated to a surface temperature of 20°C to 170°C, or 50°C to 170°C, or 60°C to 120°C, or 70°C to 130°C, or 70°C to 90°C, or 80°C to 100°C, or any range formed by any of these endpoints. In some embodiments (where the heat source includes the heated punch), the punch may be configured to be heated to a surface temperature of 20°C to 170°C, or 50°C to 170°C, or 60°C to 120°C, or 70°C to 130°C, or 70°C to 90°C, or 80°C to 100°C. Heating the punch can help maintain the film at or above the softening temperature and can help improve film distribution.

[0051] In some embodiments, the punch moves into the cavity at a rate of 10 m / s to 500 m / s, or 50 m / s to 400 m / s, or 75 m / s to 300 m / s, or 100 m / s to 200 m / s, or 125 m / s to 175 m / s, or any range formed by any of these endpoints. Therefore, the stamping module can be configured to move the punch into the cavity at a rate of 10 m / s to 500 m / s, or 50 m / s to 400 m / s, or 75 m / s to 300 m / s, or 100 m / s to 200 m / s, or 125 m / s to 175 m / s, or any range formed by any of these endpoints.

[0052] In some embodiments, the average distance between the punch and the sidewall of the cavity is 0.1 mm to 6 mm, or 0.3 mm to 3 mm, or 0.35 mm to 1.5 mm, or 0.4 mm to 0.9 mm, or 0.5 mm to 0.75 mm, or any range formed by any of these endpoints. The average distance can be measured perpendicular to the machine direction when the punch is in the cavity. The sidewall of the cavity can be a surface adjacent to the opening of the cavity that defines the internal volume of the cavity.

[0053] In some embodiments, when the punch is at its maximum depth in the cavity, the average distance between the bottom of the punch and the bottom of the cavity does not exceed 10 mm, or 8 mm, or 6 mm, or 4 mm, or 2 mm, or 1 mm, or 0.75 mm, or 0.5 mm, or 0.25 mm, or 0.1 mm, or 0.05 mm. Optionally, when the punch is at its maximum depth in the cavity, the average distance between the bottom of the punch and the bottom of the cavity is greater than or equal to 0 μm, or 10 μm, or 50 μm, or 75 μm, or 0.1 mm, or 0.125 mm, or 0.15 mm, or 0.175 mm, or 0.2 mm, or 0.5 mm, or 1 mm, or 2 mm, or 5 mm. Optionally, when the punch is at its maximum depth in the cavity, the average distance between the bottom of the punch and the bottom of the cavity is the same as the thickness of the film. When the punch is at the deepest part of the cavity during the punching process, the average distance between the bottom of the punch and the bottom of the cavity can be measured parallel to the depth direction.

[0054] In some embodiments, the duration of the punch entering the cavity is between 0 and 4000 ms, or between 250 and 3500 ms, or between 500 and 3000 ms, or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500 ms, or any range formed by any of these endpoints. Therefore, in some embodiments, the punch is configured such that when the membrane is pushed into the cavity, the duration of its entry into the cavity is between 0 and 4000 ms, or between 250 and 3500 ms, or between 500 and 3000 ms, or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500 ms, or any range formed by any of these endpoints.

[0055] In some embodiments, the punch enters the cavity at most 100%, or 99.99%, or 99.75%, or 99.5%, or 99.25%, or 99%, or 97.5%, or 95% of the total depth of the cavity; and optionally greater than 50%, or 70%, or 80%, or 90%, or 95%, or 97.5%, or any range formed by any of these values.

[0056] The membrane feeding device and the stamping module can be separated by a distance of 0 to 400 cm, or 1 to 300 cm, or 60 cm to 240 cm, or 120 cm to 180 cm, or any range formed by any of these endpoints.

[0057] Dosing element

[0058] The dosing element may be water-soluble to release the treatment agent. The term "water-soluble" may optionally refer to a dosing element comprising a water-soluble membrane encapsulating the treatment agent. The water-soluble membrane may dissolve in the presence of water or otherwise degrade to release the treatment agent into the water.

[0059] A dosing element may include one, two, three, or more compartments. A compartment may be a void or region within the dosing element containing a treatment agent. In some embodiments, the dosing element may contain different treatment agents in adjacent compartments. Adjacent compartments may be separated by a membrane to prevent movement of the treatment agent between compartments. The compartments of a multi-compartment dosing article may have the same or different dimensions and / or volumes. In some embodiments, a second and / or third and / or subsequent compartment may be stacked on top of a first compartment.

[0060] The dosing element can have a length of less than 250 mm, 100 mm, 50 mm, 40 mm, or 35 mm. This length is the longest linear measurement of the outer surface of the dosing element, measured parallel to its edge. The dosing element can also have a length greater than 20 mm, 30 mm, 40 mm, or 50 mm.

[0061] The dosing element can have a depth of less than 50 mm, 40 mm, 30 mm, 25 mm, or 15 mm. The dosing element can also have a depth greater than 5 mm, 10 mm, 20 mm, 25 mm, or 30 mm. The depth can be measured perpendicular to the length and width of the dosing element and parallel to its outer edge.

[0062] The dosing element can have a width less than 50mm, 40mm, 30mm, 25mm, or 15mm. The dosing element can also have a width greater than 5mm, 10mm, 20mm, 25mm, or 30mm. The width can be perpendicular to the length and depth measurements of the dosing element and parallel to its outer edge. The width of the dosing element can be greater than its depth.

[0063] Treatment agent

[0064] Dosing elements may include single-dose treatment agents. Treatment agents may include any active chemical agents affected by water. In some embodiments, the treatment agent comprises a detergent, optionally a laundry detergent or dishwasher detergent. Such detergent compositions may include surfactants, bleach, enzymes, fragrances, rinsing aids, dyes or colorants, solvents, and combinations thereof. Alternatively, treatment agents may include, in particular: detergents for hand washing and / or machine washing; hard surface cleaning compositions; fabric strengtheners; detergent gels commonly used for clothing; bleach and laundry detergent additives; shaving creams; skin care products; hair care compositions (e.g., shampoos and conditioners); and bath products, etc. Treatment agents may be in the form of powders, gels, pastes, slurries, liquids, solids, tablets (e.g., compressed tablets), or any combination thereof.

[0065] The dosing element can be any size suitable for delivering a single dose. The size of a single dose can be determined to provide a single dose for a single treatment cycle for a household appliance, such as a washing machine or dishwasher. The size of a single unit dose will depend on the end application. In some embodiments, the volume of the treatment agent of the final dosing element can be from 1 ml to 200 ml, or from 5 ml to 100 ml, or from 10 ml to 50 ml, or any range formed by any combination of these endpoints.

[0066] filling

[0067] In some embodiments, the method may include filling the membrane in the cavity with one or more treatment agents. Therefore, in some embodiments, the device may include a filling device for filling the membrane in the cavity with one or more treatment agents.

[0068] Filling equipment may include nozzles for filling cavities with flowable materials, such as liquid gels and flowable powders. Filling equipment may include placement devices for placing tablets and other solid processing agent forms. These may be gravity-fed and may include valves for regulating the supply of processing agent into the cavity. The cavity can be filled by overflow metering. In this process, the cavity passes under a fixed metering unit that meters a given amount or volume of processing agent per unit time. Another well-known filling process is called continuous motion in-line filling. This process uses a dispensing unit with multiple nozzles located above the cavity. The dispensing unit rotates in a continuous motion manner. The nozzles move at the same speed as the cavity and in the same direction, such that each cavity is below the same one or more nozzles for the duration of the dispensing step. After the filling step, the nozzles rotate to begin another filling step. Another process for filling cavities is the reciprocating motion filling method. This process uses a moving filling station, which typically includes a series of nozzles. Each nozzle moves at the same speed as the cavity and in the same direction as dispensing the processing agent into the cavity. Then, when each cavity is filled, the nozzle stops moving with the bag, and when the process is repeated, the nozzle returns to its initial position above a new set of open bags.

[0069] In an alternative embodiment, the processing agent can be brought into contact with the film before the stamping module, and the punch of the stamping module is operated to push the processing agent into the cavity. Therefore, the shape and size of the punch and the cavity are configured to take into account the shape of the processing agent. This alternative embodiment is particularly valuable when the processing agent is a discrete solid (e.g., a tablet).

[0070] Cover and seal

[0071] In some embodiments, the method may include applying a membrane cap to a filled membrane in a cavity and sealing the membrane cap to the membrane to form a dosing element. Therefore, in some embodiments, the device may include: means for applying the membrane cap to the membrane in a cavity; and / or means for sealing the membrane cap to the membrane in a cavity to form a dosing element. The means for applying the membrane cap may include a second membrane feeding device. The second membrane feeding device may include any device defined for the membrane feeding device (i.e., the first membrane feeding device). The membrane cap may include the same or different material as the membrane. Therefore, the dosing element may include two different membranes or two identical membranes.

[0072] The membrane used to seal the cover into the cavity can be heat-sealed, solvent-welded, solvent-sealed, or wet-sealed, as well as combinations thereof. Typically, only the area to be sealed is treated with heat or solvent. Heat or solvent can be applied by any known method, typically applied to the sealing material, and typically only applied to the area to be sealed. Therefore, devices for sealing the cover can include heat-sealing devices, solvent-welding devices, or wet-sealing devices. Such devices include any applicable devices known in the art. A heat-sealing device can include a heat-sealing element that contacts a second cover to fuse the second cover into the first membrane in the cavity. The heat-sealing element can be any heating member suitably shaped for the desired sealing pattern.

[0073] A suitable heat-sealing device may include a heating roller having recesses corresponding to the cavities. The roller continuously rolls over an array of cavities. As a result, the heating roller only contacts predetermined sealing surfaces on the periphery of the cavity openings. Alternatively, a movable, reversible sealing device may be used to seal each surface for a period of time, after which it can be moved to a new position to seal a new set of bags.

[0074] Before pressing the cap and membrane together, one or both of the cap and membrane can be wetted to make them tacky, thereby improving the adhesion between the membrane and the cap. The membrane and cap can then be sealed together, for example by heat sealing on the flange of the cavity. Suitable heat sealing temperatures are, for example, 50°C to 300°C, depending on the membrane material and other characteristics of the sealing process. Suitable sealing pressures are, for example, 250 kPa to 800 kPa, which again depends on the membrane material and other characteristics of the sealing process. Other methods can be used to seal the membranes together, such as infrared, radio frequency, ultrasonic or laser solvent, vibration, electromagnetic, hot gas, hot plate, insert bonding, partial sealing or rotational welding. Adhesives, such as aqueous solutions of water or PVOH, can also be used. The adhesive can be applied to the membrane by spraying, transfer coating, roller coating or other methods, or the membrane / cap can be passed through a mist of adhesive. The adhesive can also be a solvent. Ideally, the seal is also water-soluble.

[0075] Remove from the cavity

[0076] In some embodiments, the method may include removing the dose element from the cavity. Therefore, in some embodiments, the device may include means for removing the dose element from the cavity. The means for removing the dose element from the cavity may include a lifting device for elevating the dose element from the cavity. Removal of the dose element may be facilitated by applying pressurized air to the cavity via a vacuum port, or the cavity may include a mechanical ejection device, such as a spring.

[0077] Cutting

[0078] In some embodiments, the method may include cutting or perforating the membrane between adjacent dosing elements. Therefore, in some embodiments, the apparatus may include a cutting device configured to cut or perforate the membrane between adjacent cavities to form individual dosing elements. Cutting or perforation can be accomplished using any known method. Preferably, the cutting is also performed continuously, preferably at a constant speed, and preferably while the membrane is aligned in a generally horizontal orientation. For example, the cutting device may include a sharp object, a hot object, or a laser, whereby, in the latter case, the hot object or laser “burns” through the membrane / sealing area. The cutting device may include a means for cutting or perforating in the machine direction and a second means for cutting in the transverse direction (perpendicular to the machine direction).

[0079] Stacked compartments

[0080] In some embodiments, the dosing element may include an internal membrane that divides the dose into multiple compartments. Therefore, the method may include: placing an additional membrane onto the cavity after a first treatment agent has been placed in the cavity; then heating the additional membrane; and a second stamping module pushing the additional membrane into the cavity and into contact with the first treatment agent; then placing a second treatment agent on top of the additional membrane; and applying a cap to the dosing element. Therefore, the device may additionally include an additional membrane feeding device, a second stamping module, and a second filling device.

[0081] Additional aids for thermoforming

[0082] In some embodiments, the method may include applying negative pressure to the cavities of the array before and / or after and / or during step iii) (i.e., pushing the membrane into the vanity with a punch). Therefore, in some embodiments, the device may include one or more vacuum sources for applying negative pressure to the respective cavities of the array of cavities. Negative pressure refers to a negative pressure relative to ambient pressure and may include partial or complete vacuum. The application of negative pressure may partially or completely draw the membrane into the cavity. Negative pressure may be applied before, after, or during the punch's entry into the cavity. Negative pressure may be applied after the punch has partially or completely entered the cavity. Negative pressure may facilitate thermoforming through the punch and may further improve the distribution of the membrane through the punch. When negative pressure is applied in this manner, it ideally should comprise a pressure difference from ambient pressure of no more than 0.9 bar, or no more than 0.6 bar, or no more than 0.3 bar, and optionally no less than 0.05 bar, 0.1 bar, or 0.2 bar. The cavity may include one or more vacuum ports in its bottom portion, which are fluidly connected to a vacuum source. Fluid connections to the vacuum source can occur when the array of cavities has been aligned with a nearby fluid source, or the cavities may include flexible connections to a static vacuum source. Alternatively, each individual cavity may include a vacuum source that moves with the array of cavities. To enable negative pressure to draw the membrane into the cavity, the membrane feeding device may align the membrane to contact the cavity such that the membrane surrounds the cavity opening, thereby forming a seal between them. A cavity including a flange surrounding the cavity opening can improve the contact between the membrane and the cavity.

[0083] In an alternative embodiment of the invention, the membrane is forced out of the cavity by blowing air onto it, i.e., by using positive pressure relative to the surrounding environment within the cavity. Typically, the pressure of the blown air will be less than 5 bar, preferably less than 3 bar. Blowing air may occur when the punch contacts the membrane or when the punch has partially moved into the cavity. The pressurized air can move through a vacuum port to elevate the membrane. In this configuration, the blown air can stretch the membrane in the region between the punch and the periphery of the cavity. The device may include clamps or other holding devices to hold the membrane on the cavity, particularly its flanges. After the membrane has been blown with positive pressure, a negative pressure may be applied to the cavity to pull the membrane from the punch into the cavity.

[0084] Plasticizing effect

[0085] In some embodiments, the wetting agent may be applied to the membrane prior to thermoforming (i.e., step iii) or prior to the stamping module. The wetting agent may be added to the membrane to make the membrane material softer, more flexible, and easier to process. As used herein, the term "wetting agent" includes aqueous and non-aqueous wetting agents that can plasticize the membrane. Optionally, the wetting agent may be partially or entirely water, a solution of the membrane composition, a plasticizer for the membrane composition, or any combination thereof. The wetting agent may be applied to the membrane prior to step iii), prior to heating the membrane, or prior to aligning the membrane with the array of cavities. In some embodiments, the apparatus may include a liquid application device for applying the wetting agent to the membrane, optionally located prior to the stamping module, and / or prior to aligning the membrane with the array of cavities, and / or prior to a heat source. The liquid application device may include a spraying device, optionally including one or more nozzles. The spraying device may be positioned to spray the wetting agent directly onto the membrane or indirectly onto a surface or object in contact with the membrane. Alternatively, liquid application may include a medium for transferring water via a non-jetting device, such as a wicking material or a gravure roller.

[0086] use

[0087] In a third aspect of this disclosure, there is an application of the apparatus according to the second aspect, or the method according to the first aspect, wherein the application is for the production of a dosing element. The dosing element can be any dosing element as described herein.

[0088] Add

[0089] In the fourth aspect, there is a method for manufacturing the device according to the second aspect, the method comprising: An apparatus is provided, the apparatus comprising: i) An array of movable cavities; and ii) A membrane feeding device for aligning the membrane with the array of the cavities; The following will be added to the device: iii) A heat source for heating the membrane; and iv) A stamping module including a punch for pushing the membrane into the cavity.

[0090] In this context, "addition" can refer to modifying the device to enable it to perform the methods of the first aspect. The device in the fourth aspect may not include a stamping module and / or a heat source prior to the methods of the fourth aspect. Specifically, it can include: integrating a heat source and a stamping module into a device comprising an array of movable cavities and a membrane feeding device. Integration may include connecting the heat source and the stamping module to the device, and may additionally include configuring the heat source and the stamping module to operate with the device. For example, the heat source may be configured to operate at a temperature suitable for thermoforming using the stamping module. Similarly, the stamping module is capable of operating at a stamping rate and depth suitable for the linear velocity and depth of the array of cavities. Addition may also include some configuration of the device, such as the speed of the array of cavities and the membrane feeding device. In some embodiments, the heat source is added after the membrane feeding device, and the stamping module is added after the heat source.

[0091] In the fifth aspect of this disclosure, there is a kit for the method according to the fourth aspect, the kit comprising: A heat source, used to heat the membrane; and A stamping module, the stamping module including a punch for pushing the membrane into the cavity; Of these, 1) and 2) can be installed on the following equipment, which includes: i) An array of movable cavities; and ii) A membrane feeding device for aligning a membrane with an array of cavities.

[0092] The fifth aspect of the equipment may not include a stamping module and / or a heat source. In this context, "can be added" can refer to the ability of the stamping module and heat source to be integrated with the equipment. Therefore, the heat source and stamping module can be configured to connect to the equipment. For example, the heat source and stamping module may include connectors such as bolt holes, bracket flanges, etc., which can facilitate mechanical connection with the equipment. Similarly, the heat source and stamping module can be configured to allow operation with the equipment. For example, the stamping module or heat source may include an accessible interface that allows configuration of operating temperature, stamping rate, and stamping depth.

[0093] This disclosure provides methods and apparatus for thermoforming films for producing dosing elements, as disclosed herein, uses of the apparatus, methods for manufacturing the apparatus, and kits used in the methods of manufacturing the apparatus. The apparatus, methods, uses thereof, and methods and kits for manufacturing the apparatus may implement any feature of any of the foregoing embodiments or another embodiment disclosed herein.

[0094] The foregoing overview is provided to outline some embodiments in order to provide a basic understanding of various aspects of the subject matter described herein. Therefore, the features described above are merely examples and should not be construed as narrowing the scope or spirit of the subject matter described herein in any way. Furthermore, the above and / or ongoing embodiments can be combined in any suitable combination to provide further embodiments. Features described in one aspect of this disclosure are to be construed as applicable to other aspects of this disclosure. For example, the device described herein is to be construed as applicable to the functions of a device performing the method, and vice versa. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following detailed description, drawings, and claims.

[0095] The present invention ultimately focuses on the several aspects described above, which are further disclosed in the following in the form of certain listed embodiments: This invention focuses on a method for thermoforming a membrane for producing a water-soluble dosing element, the method comprising the following steps: i) Heating the membrane and aligning it with the array of cavities in any order or simultaneously; ii) Moving the array of the membrane and the cavity through a stamping module, the stamping module including at least one punch movable into the cavity of the array; and iii) As each cavity from the array moves through the stamping module, the stamping module is operated to push the membrane into the cavity using the punch.

[0096] In a more preferred embodiment, the method further includes: filling the membrane in the cavity with one or more treatment agents; wherein, preferably, the method further includes: applying a membrane cap to the membrane in the cavity and sealing it to form a water-soluble dosing element.

[0097] In a more preferred embodiment, the method further includes: removing the dosing element from the cavity, and / or the method further includes: cutting the membrane between adjacent dosing elements or perforating the membrane.

[0098] In one embodiment, the method further includes applying a negative pressure to the cavity of the array before and / or after and / or during step iii).

[0099] In one embodiment, the membrane is aligned with an array of cavities via one or more rollers.

[0100] In one embodiment, the array of cavities includes cavities arranged in annular rings, optionally wherein the annular rings are continuous strips.

[0101] In one embodiment, the punch is heated to a surface temperature of 20°C to 170°C, or 50°C to 170°C, or 60°C to 120°C, or 70°C to 130°C, or 70°C to 90°C, or 80°C to 100°C.

[0102] In one embodiment, the method further includes applying a wetting agent to the membrane prior to step iii).

[0103] In one embodiment, the film is heated by a heat source prior to stamping, and the heat source is located adjacent to and prior to the punch. Optionally, the heat source includes one or more of a hot air source, a radiant heater, a piezoelectric element, and / or a resistance heating element.

[0104] In one embodiment, the membrane is aligned with an array of cavities by one or more rollers preceding the stamping module, and at least one of the rollers preceding the stamping module is heated to a temperature of 70°C to 220°C, or 85°C to 190°C, or 100°C to 170°C, or 115°C to 150°C, or 130°C to 135°C.

[0105] In one embodiment, the punch moves into the cavity at a rate of 10 m / s to 500 m / s, or 50 m / s to 400 m / s, or 75 m / s to 300 m / s, or 100 m / s to 200 m / s, or 125 m / s to 175 m / s.

[0106] In one embodiment, the array of membranes and cavities moves together at speeds of 4 m / min to 18 m / min, or 6 m / min to 16 m / min, or 8 m / min to 14 m / min, or 10 m / min to 12 m / min.

[0107] In one embodiment, the cavity has a depth of 5 mm to 30 mm, or 10 mm to 25 mm, or 15 mm to 20 mm.

[0108] In one embodiment, the average distance between the punch and the side of the cavity is 0.1 mm to 6 mm, or 0.3 mm to 3 mm, or 0.35 mm to 1.5 mm, or 0.4 mm to 0.9 mm, or 0.5 mm to 0.75 mm.

[0109] In one embodiment, the duration of the punch entering the cavity is between 0 and 4000 ms, or between 250 and 3500 ms, or between 500 and 3000 ms, or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500 ms.

[0110] In one embodiment, the punch penetrates at most 100%, or 99.99%, or 99.75%, or 99.5%, or 99.25%, or 99%, or 97.5%, or 95% of the total depth of the cavity; and optionally more than 50%, or 70%, or 80%, or 90%, or 95%, or 97.5% of the total depth of the cavity.

[0111] In one embodiment, as the punch enters and exits the cavity, the stamping module moves the punch in the machine direction at the same speed as the array of cavities.

[0112] In one embodiment, the cavities of the array of cavities are heated to a temperature of 70°C to 220°C, or 85°C to 190°C, or 100°C to 170°C, or 115°C to 150°C, or 130°C to 135°C.

[0113] In one embodiment, the membrane is heated to a temperature of 70°C to 220°C, or 85°C to 190°C, or 100°C to 170°C, or 115°C to 150°C, or 130°C to 135°C.

[0114] In one embodiment, the tension of the membrane prior to step ii) is greater than 1N, or 5N, or 10N, or 15N, or 20N or 25N, and does not exceed 45N, or 40N, or 35N, or 30N, or 25N, or 20N or 15N.

[0115] The present invention also focuses on an apparatus for thermoforming a film for producing a dosing element, the apparatus comprising: i) An array of movable cavities; ii) A membrane feeding device for aligning the membrane with the array of the cavities; iii) A heat source for heating the membrane; iv) A stamping module, the stamping module including a punch for pushing the membrane into the cavity as the cavity and the membrane move together through the stamping module.

[0116] In a preferred embodiment, the device further includes a filling device for filling the membrane in the cavity with one or more treatment agents.

[0117] In one embodiment, the device further includes: means for applying a membrane cap to the membrane in the cavity; and / or means for sealing the membrane cap to the membrane in the cavity to form a dosing element.

[0118] In a preferred embodiment, the device further includes means for removing a dosing element from the cavity; and / or the device further includes a cutting means configured to cut the membrane between adjacent cavities or to perforate the membrane to form individual dosing elements.

[0119] In one embodiment, the device further includes one or more vacuum sources to apply negative pressure to the array of cavities.

[0120] In one embodiment, the membrane feeding device includes one or more rollers.

[0121] In one embodiment, the array of cavities comprises cavities arranged as continuous bands.

[0122] In one embodiment, the heat source includes a heated punch, wherein the punch is heated to a surface temperature of 20°C to 170°C, or 50°C to 170°C, or 60°C to 120°C, or 70°C to 130°C, or 70°C to 90°C, or 80°C to 100°C.

[0123] In one embodiment, the device further includes a liquid application device for applying a wetting agent to the membrane prior to the stamping module.

[0124] In one embodiment, the heat source includes a radiant heater, a resistive element, or a hot air source, located adjacent to and before the stamping module.

[0125] In one embodiment, the device includes at least one roller preceding the stamping module, wherein the at least one roller is heated to a temperature of 70°C to 220°C, or 85°C to 190°C, or 100°C to 170°C, or 115°C to 150°C, or 130°C to 135°C.

[0126] In one embodiment, the stamping module is configured to move the punch into the cavity at a rate of 10 m / s to 500 m / s, or 50 m / s to 400 m / s, or 75 m / s to 300 m / s, or 100 m / s to 200 m / s, or 125 m / s to 175 m / s.

[0127] In one embodiment, the array of movable cavities and the membrane feeding device are configured to move together at speeds of 4 m / min to 18 m / min, or 6 m / min to 16 m / min, or 8 m / min to 14 m / min, or 10 m / min to 12 m / min.

[0128] In one embodiment, the cavity has a depth of 5 mm to 30 mm, or 10 mm to 25 mm, or 15 mm to 20 mm.

[0129] In one embodiment, the average distance between the punch and the side of the cavity is 0.1 mm to 6 mm, or 0.3 mm to 3 mm, or 0.35 mm to 1.5 mm, or 0.4 mm to 0.9 mm, or 0.5 mm to 0.75 mm.

[0130] In one embodiment, the punch is configured to enter the cavity for a duration between 0 and 4000 ms, or between 250 and 3500 ms, or between 500 and 3000 ms, or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500 ms when pushing the membrane into the cavity.

[0131] In one embodiment, the punch is configured to enter the cavity to at most 100%, or 99.99%, or 99.75%, or 99.5%, or 99.25%, or 99%, or 97.5%, or 95% of the total depth of the cavity; and optionally more than 50%, or 70%, or 80%, or 90%, or 95%, or 97.5% of the total depth of the cavity.

[0132] In one embodiment, the stamping module may include one or more actuators for moving the punch parallel to the machine direction at the same speed as the array of cavities.

[0133] In one embodiment, the device includes a heat source for heating cavities in an array of cavities.

[0134] In one embodiment of the method or apparatus, the dosing element is water-soluble to release the treatment agent.

[0135] In one embodiment of the method or apparatus, the dosing element comprises two or more compartments, wherein, optionally, different treatment agents are contained in each compartment.

[0136] In one embodiment of the method or apparatus, the treatment agent includes a detergent, optionally wherein the detergent is a laundry detergent or a dishwasher detergent.

[0137] In one embodiment of the method or apparatus, the membrane comprises a water-soluble polymer; wherein, the membrane preferably comprises a PVOH membrane.

[0138] In one embodiment of the method or apparatus, the membrane has a thickness between 100 μm and 240 μm, or between 120 μm and 220 μm, or between 140 μm and 180 μm, or between 150 μm and 170 μm.

[0139] The present invention also relates to the use of such an apparatus or method for producing dosing elements.

[0140] The present invention also relates to a method of manufacturing such a device, the method comprising: An apparatus is provided, the apparatus comprising: i) An array of movable cavities; and ii) A membrane feeding device for aligning the membrane with the array of the cavities; The following will be added to the device: iii) A heat source for heating the membrane; and iv) A stamping module including a punch for pushing the membrane into the cavity.

[0141] The present invention also relates to a kit in a method for manufacturing such a device, the kit comprising: A heat source for heating the membrane; and A stamping module, the stamping module including a punch for pushing the membrane into the cavity; Of these, 1) and 2) can be installed on the following equipment, which includes: i) An array of movable cavities; and ii) A membrane feeding device for aligning a membrane with an array of cavities. Attached Figure Description

[0142] Aspects, features, and advantages of embodiments of the present disclosure will become apparent from the following description of embodiments with reference to the accompanying drawings, in which like reference numerals denote like elements.

[0143] Figure 1a and Figure 1b This is a schematic diagram of a prior art device used for producing dosing elements.

[0144] Figure 2a This is a schematic diagram of the device disclosed herein.

[0145] Figure 2b This is a schematic diagram of an alternative device disclosed herein.

[0146] Figure 3a This is a schematic diagram of an alternative device disclosed herein.

[0147] Figure 3b It is based on Figure 3a A schematic diagram of the cavity.

[0148] Figure 3c It is based on Figure 3a A schematic diagram of a top view of a portion of the cavity array.

[0149] Figure 4 This is a schematic diagram of an alternative device disclosed herein.

[0150] Figure 5 This is a schematic diagram of a kit according to one aspect of this disclosure. Detailed Implementation

[0151] Before describing several embodiments of the device, it should be understood that the device is not limited to the details of the construction or process steps set forth in the following description. It will be apparent to those skilled in the art who benefit from this disclosure that the implemented device can be practiced or implemented in a variety of ways, and specifically, the following embodiments may be combined with any other disclosure described herein.

[0152] Figure 2a An apparatus 10 according to the second aspect is shown. The apparatus 10 can be used to perform the method according to the first aspect. The apparatus 10 includes an array of movable cavities 40, a membrane feeding device 60, a heat source 80, and a stamping module 100 including a punch 120. The array of cavities 40 is formed by a plurality of independent cavities (40a, 40b, 40c) arranged on an annular ring, which is partially shown in FIG. 2. The array of cavities 40 moves continuously to sequentially move the independent cavities (40a, 40b, 40c) through the stamping module 100.

[0153] Figure 2a The membrane feeding device 60 shown is a pair of rollers. The membrane feeding device 60 is used to align the membrane 20 with the array of cavities 40 and to move the membrane 20 along with the array of cavities 40. Therefore, the feeding device 60 brings the membrane 20 into contact with the array of cavities 40 and moves the membrane 20 to the individual cavities (40a, 40b, 40c) at the same or similar speed. The movement of the membrane 20 (i.e., the machine direction) is indicated by arrow A.

[0154] Figure 2a The heat source 80 shown is an infrared heat source. The heat source 80 heats the membrane 20 to a softening temperature. The heat-softened membrane 20a is then conveyed to the stamping module 100 along with the array of cavities 40. The stamping module 100 includes a punch 120. The punch 120 is configured to move into and out of each cavity (40a, 40b, 40c) as it passes through the stamping module 100. The punch 120 does not move laterally as it passes through the cavity. 40a is a cavity moving toward the membrane feed device 60. 40b is a cavity aligned with the membrane 20, which is heated to a softening temperature by the heat source 80. Cavity 40c is moving away from the membrane feed device 60 toward the stamping module 100. The movement of the punch 120 into the cavity pushes the softened membrane 20a into the cavity, thereby thermoforming the membrane 20b into the shape of the cavity. 40c shows a cavity in which a softened membrane 20b is pushed into a punch 120.

[0155] Figure 2a A single infrared heat source 80 is shown; however, as stated above, within the scope of this disclosure, heat sources include... Figure 2aThe heat source 80 shown is an additional or alternative heat source. A pair of rollers in... Figure 2a The image shows a membrane feeding device 60; however, within the scope of this disclosure, the membrane feeding device includes... Figure 2a Alternative devices to the equipment shown in the diagram, such as a single roller or any other film handling equipment.

[0156] Figure 2b It shows the relationship with Figure 2a The same equipment is used, but with an alternative stamping module 200. The stamping module includes an actuator to move a punch 220 linearly parallel to the machine direction A. The stamping module 200 starts with the punch in position B and moves the punch 220 at the same speed as the adjacent cavity. The punch 220 then enters the cavity, thereby pushing the membrane into the cavity. The punch 220 retracts from the cavity, and the stamping module 200 moves the punch 220 back to the starting position B at high speed. The stamping module 200 then follows the next cavity with the punch 220, repeating the process.

[0157] Figure 3a An alternative apparatus 300 according to the second aspect is shown. Apparatus 300 can be used to perform the method according to the first aspect. Apparatus 300 includes an array of movable cavities 340, a membrane feeding device 360, a heat source 380, a stamping module 310 including a punch 330, and a vacuum source 350. The array of cavities 340 is formed by a plurality of independent cavities 41 arranged on an annular ring, such as... Figure 3a As shown in the middle section. The array of cavities 340 moves continuously to sequentially move individual cavities through the stamping module 310. The membrane 320 is aligned with the array of cavities via a membrane feeding device 360. The membrane feeding device 360 ​​is a roller that guides the membrane into contact with the array of cavities 340. The membrane feeding device 360 ​​also includes a heat source 380 that heats the surface of the roller. The contact between the membrane and the roller heats the membrane to a softening temperature. The softened membrane is then moved together with the array of cavities 340 to the stamping module 310 and the vacuum source 350. The punch 330 of the stamping module 310 then moves into the cavity, thereby pushing the membrane to a partial or full depth of the cavity. The vacuum source 350 applies a negative pressure to the bottom portion of the cavity, thereby partially and additionally pulling the softened membrane into the cavity. The vacuum source 350 can be applied before, during, or after the punch 330 enters the cavity.

[0158] Figure 3b It shows that according to Figure 3a An enlarged view of the cavity 41 and the corresponding punch 330. The cavity 41 is formed by a solid body 43 and surrounds the internal volume 44. The internal volume 44 is formed at its upper surface by... Figure 3b The opening is defined by line 48. Cavity 41 has an internal depth 47, which is measured perpendicular to the opening 48, from the opening 48 to the deepest part of cavity 41, as shown. Figure 3b Line 47 is shown in the diagram. Figure 3bThe cavity 41 also includes two separate compartments 46 in the bottom of the cavity 41. The cavity has an inner radius between the bottom and the sides of the cavity, which inner radius is within Figure 3b The cavity is denoted by R. The cavity has a flat surface surrounding the opening, which can be shaped as a flange 42, to which the membrane 20 can contact. A vacuum port 45 in the bottom of the cavity 41 allows a vacuum to be applied to the cavity from a vacuum source 350.

[0159] Figure 3c It shows that according to Figure 3a A top view of a portion of the array of cavities 340. Four rows of cavities 41 are aligned side-by-side. Adjacent rows of cavities are connected by links 49. Optionally, the links can be flexible or hinged. That is, four cavities 41 are aligned perpendicular to the direction of movement of the array of cavities 340. The direction of movement (i.e., the machine direction) is indicated by arrow A. The array of cavities 340 moves toward a stamping module 310 comprising four punches 330. As each row of four cavities 41 enters the stamping module, each of the four punches simultaneously pushes a membrane into the cavity 41.

[0160] Figure 4 An alternative apparatus 400 according to the second aspect is shown. Apparatus 400 can be used to perform the method according to the first aspect. Apparatus 400 includes the same features as the apparatus of FIG. 2: an array of movable cavities 440, a membrane feed device 460, a heat source 480, and a stamping module 410 including a punch 430. Following the stamping module 410, apparatus 400 further includes a filling device 425 to place a treatment agent 475 onto the membrane 420 in the cavity 41. A second membrane feed device 435 places a second membrane 422 onto the first membrane 420. The second membrane 422 is then sealed to the first membrane 420 by a heat-sealing device 445. A cutting device 455 then cuts individual dose elements 485 from adjacent dose elements. A device 465 for removing dose elements then removes the dose elements 485 from their cavities. Apparatus 400 is shown having the same heat source, membrane feed device, and stamping module arrangement as FIG. 2; however, all other arrangements within the scope of this disclosure may be applied. Figure 4 The example shown.

[0161] Figure 5 A kit 500 according to the fifth aspect and a separate device 511 for use with the kit 500 are shown. The kit 500 includes a stamping module 510 and a heat source 580. The device 511 includes at least an array of membrane feeding devices and cavities 540. The kit 500 can be fitted onto the device 511 to form a device according to the present disclosure. The device 511 may already incorporate a heat source, such as a heated roller, wherein the heat source can be adapted to achieve a temperature sufficient for operation with the stamping module, and the kit may include only the stamping module. Alternatively, in addition to the pre-existing heat source of the device 511, a heat source 580 may also be applied to the device 511.

[0162] The phrases “at least one of A, B, or C” and “at least one of A, B, and C” used in this specification employ the disjunctive conjunctions “or” and “and”, such that these forms include any and all unions and permutations of A, B, and C, namely, A alone, B alone, C alone, A and B in any order, A and C in any order, B and C in any order, and A, B, and C in any order. More or fewer than three features may be used in such forms.

[0163] In the claims, any reference numerals placed between parentheses should not be construed as limiting the claims. The word “comprising” does not exclude the presence of other elements or steps besides those listed in the claims. Furthermore, the terms “a” or “an” as used herein are defined as one or more. Moreover, the use of introductory phrases such as “at least one” and “one or more” in the claims should not be construed as implying that the introduction of another claim element by the indefinite article “a” or “an” limits any particular claim containing such an introduced claim element to an invention containing only one such element, even when the same claim includes the introductory phrase “one or more” or “at least one” and an indefinite article such as “a” or “an.” This also applies to the use of specific articles. Unless otherwise stated, terms such as “first” and “second” are used to arbitrarily distinguish between the elements described by these terms. Therefore, these terms are not necessarily intended to indicate temporal or other priority of these elements. The mere fact that certain measures are recited in mutually different claims does not imply that a combination of these measures cannot be used advantageously.

[0164] Unless otherwise expressly stated as incompatible, or if the physics or other aspects of the embodiments, examples, or claims prevent such a combination, the features of the foregoing embodiments and examples, as well as the features of the following claims, can be integrated together in any suitable arrangement, especially arrangements that have beneficial effects when done so. This is not limited to any particular benefit, but can arise from "after-the-fact" benefits. That is to say, the combination of features is not limited to the forms described, particularly the forms of the examples, embodiments, or dependent claims (e.g., numbering). Furthermore, this also applies to phrases such as "in one embodiment," "according to an embodiment," etc., which are merely stylistic forms of wording and should not be construed as limiting the following features to the individual embodiments, or to all other examples of the same or similar wording. That is, references to "a," "an," or "some" embodiments can be references to any one or more and / or all embodiments disclosed, or combinations thereof. Similarly, references to "this" embodiment are not limited to the embodiments directly preceding them.

[0165] The foregoing description of one or more implementations provides illustration and description, but is not intended to be exhaustive or to limit the scope of the invention to the precise forms disclosed. Modifications and variations are possible in accordance with the foregoing teachings, and may be derived from practice of various implementations of this disclosure.

[0166] Tag list

[0167] 10, 100, 300, 400 equipment

[0168] 20, 120, 320, 420 membranes

[0169] 20a softening film

[0170] 20b thermoforming film

[0171] Arrays of 40, 340, 440, and 540 movable cavities

[0172] 40a, 40b, 40c Independent cavities

[0173] 41 cavities

[0174] 42 Flange

[0175] 43 Solid body

[0176] 44 Internal volume

[0177] 45 Vacuum Port

[0178] 46 compartments

[0179] 47. Internal depth of the cavity

[0180] 48 Opening

[0181] 49 Linkages

[0182] 60, 360, 460, 560 membrane feeding equipment

[0183] 80, 380, 480, 580 heat sources

[0184] 100, 200, 310, 410, 510 stamping modules

[0185] 120, 220, 330, 430 punches

[0186] 350 Vacuum Source

[0187] 425 Filling Equipment

[0188] 422 Second Membrane

[0189] 435 Second membrane feeding equipment

[0190] 445 Heat sealing device

[0191] 455 cutting equipment

[0192] 465 Devices for removing dosing elements

[0193] 485 Dosing Element

[0194] 475 treatment agent

[0195] 500 kits

Claims

1. A method for thermoforming a membrane for producing a water-soluble dosing element, the method comprising the following steps: i) Heating the membrane and aligning the membrane with the array of cavities in any order or simultaneously; ii) Moving the array of the membrane and the cavity through a stamping module, the stamping module including at least one punch movable into the cavity in the array; and iii) As each cavity from the array moves through the stamping module, the stamping module is operated to push the membrane into the cavity using the punch.

2. The method according to claim 1, further comprising: The membrane in the cavity is filled with one or more treatment agents.

3. The method according to claim 2, further comprising: A membrane cap is applied to the membrane in the cavity and sealed to form a water-soluble dosing element.

4. The method according to any one of the preceding claims, further wherein, The array of cavities includes cavities arranged in a ring, optionally wherein the ring is a continuous band.

5. The method according to any one of the preceding claims, wherein, The membrane is aligned with the array of the cavity by one or more rollers preceding the stamping module, and at least one of the one or more rollers preceding the stamping module is heated to a temperature of 70°C to 220°C, or 85°C to 190°C, or 100°C to 170°C, or 115°C to 150°C, or 130°C to 135°C.

6. The method according to any one of the preceding claims, wherein, The array of membranes and cavities moves together at speeds of 4 m / min to 18 m / min, or 6 m / min to 16 m / min, or 8 m / min to 14 m / min, or 10 m / min to 12 m / min.

7. The method according to any one of the preceding claims, wherein, As the punch enters and exits the cavity, the stamping module moves the punch in the machine direction at the same speed as the array of cavities.

8. The method according to any one of the preceding claims, wherein, The membrane is heated to a temperature of 70°C to 220°C, or 85°C to 190°C, or 100°C to 170°C, or 115°C to 150°C, or 130°C to 135°C.

9. An apparatus for thermoforming a membrane for producing a dosing element, the apparatus comprising: i) An array of movable cavities; ii) A membrane feeding device for aligning the membrane with the array of the cavities; iii) A heat source for heating the membrane; iv) A stamping module including a punch for pushing the membrane into the cavity as the cavity and the membrane move together through the stamping module.

10. The apparatus of claim 9, further comprising a filling device for filling the membrane in the cavity with one or more treatment agents.

11. The device according to claim 9 or 10, further comprising: A means for applying a membrane cap to the membrane in the cavity; And / or a device for sealing the membrane cap into the cavity to form a dosing element.

12. The device according to any one of claims 9 to 11, wherein, The array of cavities comprises cavities arranged as a continuous band.

13. The device according to any one of claims 9 to 12, wherein, The stamping module is configured to move the punch into the cavity at a rate of 10 m / s to 500 m / s, or 50 m / s to 400 m / s, or 75 m / s to 300 m / s, or 100 m / s to 200 m / s, or 125 m / s to 175 m / s.

14. The device according to any one of claims 9 to 13, wherein, The array of movable cavities and the membrane feeding device are configured to move together at speeds of 4 m / min to 18 m / min, or 6 m / min to 16 m / min, or 8 m / min to 14 m / min, or 10 m / min to 12 m / min.

15. The device according to any one of claims 9 to 14, wherein, The stamping module may include one or more actuators for moving the punch at the same speed as the array of cavities parallel to the machine direction.

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