METHOD FOR MANUFACTURING DETERGENT DOSER UNITS WITH IMPROVED PROPERTIES

Description

[0001] The present invention relates to a method for producing a detergent portion unit, in the course of which water-soluble packaging films are heated and plastically deformed.

[0002] The packaging and distribution of detergents and cleaning agents are constantly evolving. A key focus for some time now has been on convenient dosing of detergents and cleaning agents by the consumer and simplifying the steps required for a washing or cleaning process. Pre-portioned detergents or cleaning agents, for example, foil pouches with one or more compartments for solid or liquid detergents or cleaning agents, offer a technical solution.

[0003] A relevant trend for the production of these film bags is the miniaturization of these bags. In addition to increased consumer acceptance due to easier handling, this development is driven by sustainability considerations, for example, with regard to the amount of packaging used.

[0004] The film bags described above are manufactured using multi-stage processes during which water-soluble film materials are formed into cavities, for example by applying heat and negative pressure, filled, and then sealed. While heating the film increases its plasticity, the force resulting from the negative pressure applied to the heated film causes it to stretch and plastically deform. In this process, the film is not stretched homogeneously across its surface; rather, areas of high stretch, for example in the edge area of ​​the cavity, alternate with areas of lower stretch. A film material with a homogeneous film thickness is thus transformed into a deformed film in the shape of a receptacle with a heterogeneous film thickness distribution. This heterogeneous film thickness distribution becomes more pronounced the more the original film material is deformed.The degree of deformation generally increases, for example, with the number of receiving chambers formed in the receiving container or their depth.

[0005] Among other factors, both the film thickness distribution and the absolute film thickness determine the haptic, optical, and mechanical properties of the film pouch. Film pouches with large differences in film thickness are often perceived as less appealing. Film pouches with a low minimum film thickness deform more easily under their own weight than corresponding film pouches with a higher film thickness and appear flabby. These film pouches withstand mechanical stress to a lesser extent and detach too quickly when exposed to water. The last two points mentioned are relevant for film pouches not only in the areas of production, transport, and storage, but also have a particularly significant impact on product safety, for example, in the event of accidental oral ingestion.

[0006] The international application WO 2020 / 152044 A1 describes a process for producing water-soluble containers, in the course of which a water-soluble film is heated by means of a two-part heating device with a heterogeneous temperature profile and subsequently deep-drawn.

[0007] Against this technical background, the application was based on the objective of providing detergent portion units that offer maximum stability and an appealing appearance and feel while minimizing the use of film materials for packaging. Furthermore, the detergent portion units should be efficiently producible on an industrial scale.

[0008] A first subject of the application is a method for producing a detergent portion unit with at least one filled receiving chamber surrounded by a water-soluble film, comprising the steps a) Transporting a first water-soluble film towards a heating device; b) Bringing the first water-soluble film into contact with the heating device; c) Heating the first water-soluble film by means of the heating device; d) Breaking the contact between the first water-soluble film and the heating device; e) Forming the first heated water-soluble film into the cavities of a deep-drawing die located beneath the first water-soluble film to form a receiving container with at least one receiving chamber; f) Filling the at least one receiving chamber with a detergent; g) Optionally closing and separating the filled receiving containers to form the detergent portion unit; wherein the surface of the heating device has adjacent heated surface areas which in step c) are in contact with film sections which are deformed in step e) to form a receiving container with at least one receiving chamber, and the heated surface areas are each heated by at least one separately controllable heating element, in step b) the heating device is lowered towards the water-soluble film and the water-soluble film is brought into contact with the heating device and held by the action of a negative pressure, in step c) the water-soluble film is located between the heating device and the deep-drawing die used in step e) and the distance between the surface of the heating device and the deep-drawing die is less than 10 mm, the controllable heating elements of at least two adjacent heated surface areas in step c) have a temperature difference between 10 and 60°C, the temperature of the controllable heating elements is reduced to values ​​below the temperature provided for step c) at a time after the heating of the water-soluble film in step c),in step d) the negative pressure between the heating device and the water-soluble film is removed and simultaneously or subsequently the heating device is raised.

[0009] The process according to the invention enables the efficient production of detergent portion units. Due to the uniform thickness of the water-soluble film, the detergent portion units are characterized by high mechanical stability and minimal packaging.

[0010] In the process according to the invention, water-soluble films are formed in a deep-drawing apparatus and combined with detergent preparations to form detergent portion units.

[0011] The water-soluble film in which the detergent preparation is packaged can comprise one or more structurally different water-soluble polymers. Particularly suitable water-soluble polymers for the first water-soluble film are polymers from the group of (optionally acetalized) polyvinyl alcohols (PVAL) and their copolymers.

[0012] Water-soluble films for producing the water-soluble coating are preferably based on a polyvinyl alcohol or a polyvinyl alcohol copolymer whose molecular weight is in the range from 10,000 to 1,000,000 gmol -1< , preferably from 20,000 to 500,000 gmol -1< , particularly preferably from 30,000 to 100,000 gmol -1< and in particular from 40,000 to 80,000 gmol -1<.

[0013] The production of polyvinyl alcohol and polyvinyl alcohol copolymers generally involves the hydrolysis of intermediate polyvinyl acetate. Preferred polyvinyl alcohols and polyvinyl alcohol copolymers have a degree of hydrolysis of 70 to 100 mol%, preferably 80 to 90 mol%, particularly preferably 81 to 89 mol%, and especially 82 to 88 mol%.

[0014] Preferred polyvinyl alcohol copolymers comprise, in addition to vinyl alcohol, an ethylenically unsaturated carboxylic acid, its salt, or its ester. Particularly preferably, such polyvinyl alcohol copolymers contain, in addition to vinyl alcohol, sulfonic acids such as 2-acrylamido-2-methyl-1-propanesulfonic acid (AMPS), acrylic acid, methacrylic acid, acrylic acid esters, methacrylic acid esters, or mixtures thereof; among the esters, C 1-4 alkyl esters or hydroxyalkyl esters are preferred. Other suitable monomers include ethylenically unsaturated dicarboxylic acids, for example, itaconic acid, maleic acid, fumaric acid, and mixtures thereof.

[0015] Suitable water-soluble films for use in the wrappers of the water-soluble packages according to the invention are films sold by MonoSol LLC, for example, under the designation M8630, M8720, M8310, C8400, or M8900. Other suitable films include films designated Solublon®< PT, Solublon®< GA, Solublon®< KC, or Solublon®< KL by Aicello Chemical Europe GmbH, or VF-HP films by Kuraray.

[0016] The first water-soluble film preferably has a thickness of 10 to 90 µm, more preferably 30 to 60 µm.

[0017] The water-soluble films may contain additional active ingredients or fillers as well as plasticizers and / or solvents, especially water.

[0018] The group of other active ingredients includes, for example, materials that protect the detergent ingredients enclosed in the film material from decomposition or deactivation by light exposure. Antioxidants, UV absorbers, and fluorescent dyes have proven particularly suitable for this purpose.

[0019] Plasticizers that can be used include, for example, glycerin, ethylene glycol, diethylene glycol, propanediol, 2-methyl-1,3-propanediol, sorbitol or mixtures thereof.

[0020] To reduce its friction coefficient, the surface of the water-soluble film of the detergent dispenser can optionally be dusted with fine powder. Sodium aluminosilicate, silicon dioxide, talc, and amylose are examples of suitable powdering agents.

[0021] The deep-drawing apparatus used in the process can be operated continuously or discontinuously. To increase process efficiency, a continuous process is preferred. In a particularly preferred embodiment of the process, the first water-soluble film is transported continuously in step a). With regard to process economy and process reliability, it is preferable to transport the first water-soluble film in step a) at a speed of 0.04 m / s, preferably above 0.08 m / s.

[0022] In step b) of the process, the first water-soluble film is brought into contact with the heating device. This heating device is characterized by the heterogeneous temperature distribution of its surface, which is achieved by the surface of the heating device having adjacent heated surface regions, which in step c) are in contact with film sections that are deformed in step e). The heated surface regions are each heated by at least one separately controllable heating element, and the controllable heating elements of at least two adjacent heated surface regions have a temperature difference of between 10 and 60°C in step c).

[0023] The heating device serves to heat the water-soluble film in step c) of the process. The heat transfer occurs at least partially through direct contact between a surface of the heating device and the water-soluble film. The surface of the heating device that is decisive for the heat transfer has heated surface areas. A heated surface area is understood to be an area of ​​the surface of the heating device that is heated by one or more separately controllable heating elements, wherein these controllable heating elements have a comparable temperature. Two temperatures are comparable if they differ by less than 10°C, preferably less than 8°C. Preferred heated surface areas of the heating device have 1 to 8, preferably 1 to 6, in particular 1 to 4 separately controllable heating elements.If a heated surface area has more than one separately controllable heating element, the temperature difference between the separately controllable heating elements of the heated surface area in step c) is particularly preferably less than 5°C and in particular less than 2°C. It is very particularly preferred if the separately controllable heating elements of each heated surface area have an identical temperature in step c). The temperature of the heating elements is set in a manner known to the person skilled in the art via the control of the heating elements. The temperature of each individual separately controllable heating element can vary during the course of the process. According to the invention, the temperature of the heating element set via the control is reduced to values ​​below the temperatures provided for step c) at a time after the heating of the water-soluble film in step c).A corresponding temperature reduction, for example to 60% to 90%, preferably to 73% to 83% of the temperature intended for step c), supports the formation of a constantly heterogeneous temperature profile of the surface of the heating device.

[0024] In addition to the separately controllable heating elements, the heating device preferably also has a cooling system. This cooling system is preferably designed to allow a reduction in the temperature of the heating device surface. This cooling system also supports the formation of a consistently heterogeneous temperature profile on the surface of the heating device.

[0025] As described above, the controllable heating elements of at least two adjacent heated surface areas in step c) have a temperature difference between 10 and 60°C. The heterogeneous temperature profile resulting from this temperature difference enables the production of receptacles with complex geometries while maintaining a homogeneous film thickness distribution. While temperature differences below 10°C are less suitable for achieving these advantageous product properties, temperature differences above 60°C can only be utilized economically with considerable effort, since increasing temperature differences increase the requirements for cooling and precise adherence to the contact times between the heating device and the water-soluble film.

[0026] Of course, a temperature difference of 10 to 60°C can be achieved between more than two adjacent heated surface areas. Due to the technical advantages achieved, in preferred process variants, the controllable heating elements of at least 60%, preferably at least 80%, and in particular of all adjacent heated surface areas that are in contact with film sections that are deformed in step e) in step c) have a temperature difference of between 10 and 60°C compared to the controllable heating elements of at least one adjacent heated surface area in step c).

[0027] In addition to the relative temperature differences between adjacent heating elements, the course of the process and the process result are also influenced by their absolute temperature. Process variants in which the controllable heating elements of the heated surface areas of the heating device in step c) have a temperature in the range of 40 to 150°C, preferably 60 to 135°C, have proven particularly advantageous.

[0028] The water-soluble film is brought into contact with the heating device in step b) and deformed in step e) to form a receiving container with at least one receiving chamber. Adjacent sections of the water-soluble film form the bottom or side walls of the receiving chamber, or the edge or web surrounding the receiving chamber, and are consequently stretched in different ways. To equalize the stretch factors of the different sections of the water-soluble film forming the receiving container, it has proven advantageous, particularly when using polyvinyl alcohol-based films, if the controllable heating elements of the heating device have a temperature in the range of 100 to 150°C, preferably 110 to 135°C, in the regions in which the surface section of the water-soluble film forming the edge region of the receiving chamber(s) of the receiving container is heated in step c).For the same reasons, it is preferred that the controllable heating elements of the heating device in the areas in which the surface portion of the water-soluble film forming the bottom region of the receiving chamber(s) of the receiving container is heated in step c) have a temperature in the range of 50 to 90°C, preferably 60 to 85°C.

[0029] The density of separately controllable heating elements in the surface areas of the heating device that can be heated in step b) is preferably between 4 and 64 cm -2 , more preferably between 8 and 32 per cm -2 . At the same time, it is preferred if the heated surface of the heating device that is in contact with film sections in step c) has a density of heated surface areas above 1.2 per cm 2 , preferably above 1.5 per cm 2 and in particular between 1.7 and 4.2 per cm 2 . Different densities of heating elements and heated surface areas arise in all cases in which a heated surface area has more than one separately controllable heating element. The above-mentioned densities of controllable heating elements and heated surface areas have proven to be particularly suitable for processing water-soluble films into detergent portion units.

[0030] The heating rate of the separate heating elements is preferably 5 to 70 K / s, more preferably 10 to 50 K / s.

[0031] The surface of the heating device with which the water-soluble film is brought into contact in step b) is preferably flat. Particularly preferred materials for manufacturing the surface with which the water-soluble film is in contact in step b) are ceramic or metal, especially steel.

[0032] In a preferred process variant, the first water-soluble film is brought into contact with the heating device on only one side in step b). This procedure has proven sufficient, particularly due to the pronounced temperature differences between the heated surface areas. Compared to processes using two heating devices, the process according to the invention not only requires less equipment, but also allows for a more compact production line design.

[0033] In step b), the upper side of the water-soluble film is preferably brought into contact with the heating device. The upper side is the side of the film that is still spatially oriented upwards.

[0034] In a preferred embodiment, the heating device is lowered in step b) towards the water-soluble film.

[0035] To reduce the process time and ensure reproducible contact between the first water-soluble film and the surface of the heating device, the water-soluble film is brought into contact with the heating device in step b) by means of a negative pressure. Furthermore, the invention maintains contact between the water-soluble film and the heating device by maintaining a negative pressure. The level of a corresponding negative pressure, which is established in step b) between the heating device and the water-soluble film, is preferably 200 to 800 mbar and in particular 400 to 700 mbar.

[0036] In step c), the water-soluble film is preferably heated for a period of 0.5 to 7 seconds, preferably 1 to 6 seconds and in particular 2 to 5 seconds.

[0037] In order to increase the process efficiency, it has proven to be structurally advantageous that, according to the invention, the water-soluble film in step c) is located between the heating device and the deep-drawing die used in step e) and the distance between the surface of the heating device and the deep-drawing die is less than 10 mm, preferably less than 5 mm and in particular between 0.1 and 2 mm, particularly preferably between 0.2 and 1 mm.

[0038] In step d), the contact between the first water-soluble film and the surface of the heating device is removed. To this end, the negative pressure acting between the heating device and the water-soluble film is eliminated. According to the invention, in step d), a negative pressure previously created between the heating device and the water-soluble film is eliminated, and the heating device is raised simultaneously or subsequently.

[0039] At the beginning of step e), the water-soluble film preferably has a temperature above its glass transition temperature.

[0040] In step e), the water-soluble film is molded into the cavity of a thermoforming die. For this purpose, a negative pressure is created between the water-soluble film and the thermoforming die, preferably for a period of 0.5 to 7 seconds, preferably 1 to 5 seconds. This negative pressure created between the water-soluble film and the thermoforming die is preferably 100 to 600 mbar, and in particular 200 to 400 mbar.

[0041] During molding into the cavity of the deep-drawing die, the surface area of ​​the water-soluble film is preferably increased by at least 80%, preferably by at least 120%, in particular by 120 to 300%. At the same time, the maximum local stretch factor of the water-soluble film following step e) is preferably 2 to 4 and in particular 2 to 3.

[0042] It is particularly preferred if the water-soluble film is molded in step e) to form a receiving container with at least two, preferably at least three and in particular at least four receiving chambers.

[0043] The filling volume of the receiving container in step e) is preferably from 1 to 50 ml, preferably from 10 to 40 ml and in particular from 13 to 25 ml.

[0044] In preferred process variants in which the receiving container has at least two, preferably at least three and in particular at least four receiving chambers, the ratio of the volume of the largest receiving chamber to the volume of the smallest receiving chamber is 4:1 to 1:1, preferably 3:1 to 1:1.

[0045] For reasons of process efficiency, the process according to the invention is designed such that not just a single detergent portion unit is produced in one process run, but rather a plurality of detergent portion units in parallel. Preferably, in step e), a sheet-like structure with at least 14, preferably at least 20, receptacles is formed.

[0046] In this sheet-like structure, the receiving containers are preferably arranged in rows. With regard to subsequent filling, the sheet-like structures formed in step e) are rows of receiving containers arranged orthogonally to the transport direction of the water-soluble film.

[0047] In an alternative embodiment, in step e), a sheet-like structure is formed in which the receiving containers are arranged in rows that extend orthogonally to the transport direction of the water-soluble film and are offset from one another by one-third of the width of a receiving container, preferably by half the width of a receiving container. In the sheet-like structure, the receiving containers are preferably arranged such that each receiving container is adjacent to at least one intermediate region, which in turn is surrounded by three receiving containers.

[0048] At least one of the receiving chambers of the receiving container is filled in step f). Solid and liquid detergents or cleaning agents are suitable for filling.

[0049] Particularly in cases where the added detergents or cleaning agents are not adhesively bonded to the water-soluble film material, as may be the case with melts, for example, the filled receiving chamber of the receiving container is sealed. Corresponding processes, in which the receiving chamber of the receiving container is filled in a further step f) and the filled receiving chamber is sealed in a subsequent step g) using a second water-soluble film, are preferred with regard to product aesthetics and handling.

[0050] The following embodiments of the invention are disclosed: 1. A method for producing a detergent portion unit with at least one filled receiving chamber surrounded by a water-soluble film,comprising the steps of a) transporting a first water-soluble film towards a heating device; b) bringing the first water-soluble film into contact with the heating device; c) heating the first water-soluble film by means of the heating device; d) breaking the contact between the first water-soluble film and the heating device; e) molding the first heated water-soluble film into the cavities of a deep-drawing die located beneath the first water-soluble film to form a receiving container with at least one receiving chamber; f) filling the at least one receiving chamber with a detergent; g) optionally closing and separating the filled receiving containers to form the detergent portion unit; wherein the surface of the heating device has adjacent heated surface areas which, in step c), are in contact with film sections.which are deformed in step e) to form a receiving container with at least one receiving chamber, and the heated surface areas are each heated by at least one separately controllable heating element, in step b) the heating device is lowered towards the water-soluble film and the water-soluble film is brought into contact with the heating device and held there by the action of a negative pressure, the water-soluble film is located between the heating device and the deep-drawing die used in step e) in step c) and the distance between the surface of the heating device and the deep-drawing die is less than 10 mm, the controllable heating elements of at least two adjacent heated surface areas in step c) have a temperature difference between 10 and 60°C,the temperature of the controllable heating elements is reduced to values ​​below the temperature intended for step c) at a time after the heating of the water-soluble film in step c), in step d) the negative pressure between the heating device and the water-soluble film is released and simultaneously or subsequently the heating device is raised. 2. Method according to embodiment 1, wherein the first water-soluble film comprises polyvinyl alcohol or polyvinyl alcohol copolymers. 3. Method according to one of the preceding embodiments, wherein in step, the first water-soluble film has a thickness of 10 to 90 µm, preferably of 30 to 60 µm. 4. Method according to one of the preceding embodiments, wherein the transport of the first water-soluble film in step a) takes place continuously. 5. Method according to one of the preceding embodiments, wherein the transport of the first water-soluble film in step a) takes place at a speed of 0,04 m / s, preferably above 0.08 m / s. 6. Method according to one of the preceding embodiments, wherein each heated surface area of ​​the heating device has 1 to 8, preferably 1 to 6, in particular 1 to 4 separately controllable heating elements. 7. Method according to one of the preceding embodiments, wherein the separately controllable heating elements of each heated surface area have a temperature difference of less than 5°C, preferably less than 2°C, relative to one another in step c). 8. Method according to one of the preceding embodiments, wherein the separately controllable heating elements of each heated surface area have an identical temperature in step c). 9. Method according to one of the preceding embodiments, wherein the controllable heating elements of at least 60%, preferably of at least 80%, and in particular of all adjacent heated surface areas which are in contact with film sections in step c),which are deformed in step e), have a temperature difference of between 10 and 60°C to the controllable heating elements of at least one adjacent heated surface area in step c). 10. Method according to one of the preceding embodiments, wherein the controllable heating elements of the heated surface areas of the heating device in step c) have a temperature in the range of 40 to 150°C, preferably from 60 to 135°C. 11. Method according to one of the preceding embodiments, wherein the controllable heating elements of the heating device in the areas in which the surface section of the water-soluble film is heated in step c), which forms the edge area of ​​the receiving chamber(s) of the receiving container, has a temperature in the range of 100 to 150°C, preferably from 110 to 135°C, in step c). 12. Method according to one of the preceding embodiments, wherein the controllable heating elements of the heating device in the areas,in which in step c) the surface section of the water-soluble film which forms the bottom region of the receiving chamber(s) of the receiving container is heated, in step c) has a temperature in the range of 50 to 90°C, preferably 60 to 85°C. 13. Method according to one of the preceding embodiments, wherein the heating device in step b) has heatable surface areas with a density of separately controllable heating elements of 4 to 64 cm -2 , preferably 8 to 32 per cm -2 . 14. Method according to one of the preceding embodiments, wherein the heated surface of the heating device which is in contact with film sections in step c) has a density of heated surface areas above 1.2 per cm -2 , preferably above 1.5 per cm -2 , and in particular of 1.7 to 4.2 per cm -2 . 15. Method according to one of the preceding embodiments, wherein the heating elements of the heating device have a heating rate of 5 to 70 K / s,preferably from 10 to 50 K / s. 16. Method according to one of the preceding embodiments, wherein the heating device in step b) has a flat surface. 17. Method according to one of the preceding embodiments, wherein the heating device in step b) is in contact with the water-soluble film via a ceramic surface. 18. Method according to one of the preceding embodiments, wherein the heating device in step b) is in contact with the water-soluble film via a metal surface. 19. Method according to one of the preceding embodiments, wherein the first water-soluble film is brought into contact with the heating device on only one side in step b). 20. Method according to one of the preceding embodiments, wherein in step b) the top side of the water-soluble film is brought into contact with the heating device. 21. Method according to one of the preceding embodiments,wherein in step b) a pressure of 200 to 800 mbar, preferably 400 to 700 mbar, is built up between the heating device and the water-soluble film. 22. Method according to one of the preceding embodiments, wherein the water-soluble film is heated in step c) for a period of 0.5 to 7 seconds, preferably 1 to 6 seconds and in particular 2 to 5 seconds. 23. Method according to one of the preceding embodiments, wherein the water-soluble film in step c) is located between the heating device and the deep-drawing die used in step e) and the distance between the surface of the heating device and the deep-drawing die is less than 5 mm and in particular between 0.1 and 2 mm, particularly preferably between 0.2 and 1 mm. 24. Method according to one of the preceding embodiments, wherein in step e) for a period of 0,5 to 7 seconds, preferably 1 to 5 seconds, a negative pressure is built up between the water-soluble film and the deep-drawing die. 25. Process according to one of the preceding embodiments, wherein in step e) a pressure of 100 to 600 mbar, preferably 200 to 400 mbar, is built up between the water-soluble film and the deep-drawing die. 26. Process according to one of the preceding embodiments, wherein the water-soluble film is heated to temperatures above its glass transition temperature at the beginning of step e). 27. Process according to one of the preceding embodiments, wherein in step e) the surface of the water-soluble film is enlarged by at least 80%, preferably by at least 120%, in particular by 120 to 300%. 28. Process according to one of the preceding embodiments, wherein the water-soluble film, following step e), has a maximum local stretch factor of 2 to 4,preferably from 2 to 3. 29. Method according to one of the preceding embodiments, wherein the water-soluble film is molded in step e) to form a receiving container with at least two, preferably at least three and in particular at least four receiving chambers. 30. Method according to one of the preceding embodiments, wherein the receiving container in step e) has a filling volume of 1 to 50 ml, preferably from 10 to 40 ml and in particular from 13 to 25 ml. 31. Method according to one of the preceding embodiments, wherein the receiving container has at least two, preferably at least three and in particular at least four receiving chambers and the ratio of the volume of the largest receiving chamber to the volume of the smallest receiving chamber is 4:1 to 1:1, preferably 3:1 to 1:1. 32. Method according to one of the preceding embodiments, wherein in step e) a sheet-like structure with at least 14,preferably at least 20 receptacles. 33. Method according to one of the preceding embodiments, wherein in step e) a sheet-like structure is formed in which the receptacles are arranged in rows. 34. Method according to one of the preceding embodiments, wherein in step e) a sheet-like structure is formed in which the receptacles are arranged in rows that run orthogonal to the transport direction of the water-soluble film. 35. Method according to one of the preceding embodiments, wherein in step e) a sheet-like structure is formed in which the receptacles are arranged in rows that run orthogonal to the transport direction of the water-soluble film and are offset from one another by one-third of the width of a receptacle, preferably by half the width of a receptacle. 36. Method according to one of the preceding embodiments,wherein in step e), a sheet-like structure is formed in which each receiving container is adjacent to at least one intermediate region, which in turn is surrounded by three receiving containers. 37. Method according to one of the preceding embodiments, wherein the receiving chamber of the receiving container is filled in a further step f), and the filled receiving chamber is sealed in a subsequent step g) by means of a second water-soluble film.

Claims

1. Method for producing a detergent portion unit with at least one filled receiving chamber surrounded by a water-soluble film, comprising the steps a) transporting a first water-soluble film toward a heating device; b) bringing the first water-soluble film into contact with the heating device; c) heating the first water-soluble film by means of the heating device; d) removing the contact between the first water-soluble film and the heating device; e) forming the first heated water-soluble film into the cavities of a deep-drawing die located below the first water-soluble film to form a receiving container with at least one receiving chamber; f) filling the at least one receiving chamber with a detergent; g) if necessary, sealing and separating the filled receiving containers to form the detergent portion units; wherein the surface of the heating device has adjacent heated surface areas which, in step c), are in contact with film sections which, in step e), are deformed to form a receiving container with at least one receiving chamber, and - the heated surface areas are each heated by at least one separately controllable heating element, - in step b), the heating device is lowered in the direction of the water-soluble film and the water-soluble film is brought into contact with the heating device by the action of a vacuum and held there, - in step c), the water-soluble film is located between the heating device and the deep-drawing die used in step e), and the distance between the surface of the heating device and the deep-drawing die is less than 10 mm, - the controllable heating elements have at least two adjacent heated surface areas in step c) with a temperature difference between 10 and 60°C. - the temperature of the controllable heating elements is reduced to values below the temperature specified for step c) at a point in time after the water-soluble film has been heated in step c), - in step d), the negative pressure between the heating device and the water-soluble film is removed and, at the same time or subsequently, the heating device is raised.

2. Method according to claim 1, wherein each heated surface area of the heating device has 1 to 8, preferably 1 to 6, in particular 1 to 4 separately controllable heating elements.

3. Method according to one of the previous claims, wherein the separately controllable heating elements of each heated surface area have a temperature difference of less than 5°C, preferably less than 2°C, relative to each other in step c).

4. Method according to one of the previous claims, wherein the controllable heating elements of at least 60%, preferably at least 80% and in particular all adjacent heated surface areas which are in contact in step c) with film sections which are deformed in step e), have a temperature difference of between 10 and 60°C relative to the controllable heating elements of at least one adjacent heated surface area in step c).

5. Method according to one of the previous claims, wherein the controllable heating elements of the heated surface areas of the heating device in step c) have a temperature in the range of 40 to 150°C, preferably of 60 to 135°C.

6. Method according to one of the previous claims, wherein the controllable heating elements of the heating device in the areas in which, in step c), the surface section of the water-soluble film forming the edge area of the receiving chamber(s) of the receiving container is heated, have a temperature in the range of 100 to 150°C, preferably from 110 to 135°C.

7. Method according to one of the previous claims, wherein the controllable heating elements of the heating device in the areas in which, in step c), the surface section of the water-soluble film which forms the bottom area of the receiving chamber(s) of the receiving container is heated, have a temperature in the range of 50 to 90°C, preferably from 60 to 85°C.

8. Method according to one of the previous claims, wherein the first water-soluble film is brought into contact with the heating device in step b) on only one side.

9. Method according to one of the previous claims, wherein the water-soluble film is heated in step c) for a period of 0.5 to 7 seconds, preferably 1 to 6 seconds and in particular 2 to 5 seconds.

10. Method according to one of the previous claims, wherein the water-soluble film in step c) is located between the heating device and the deep-drawing die used in step e) and the distance between the surface of the heating device and the deep-drawing die is less than 5 mm and, in particular, between 0.1 and 2 mm, particularly preferably between 0.2 and 1 mm.

11. Method according to one of the previous claims, wherein the water-soluble film is formed in step e) to form a receiving container with at least two, preferably at least three and in particular at least four receiving chambers.

12. Method according to one of the previous claims, wherein the receiving container in step e) has a filling volume of 1 to 50 ml, preferably 10 to 40 ml and in particular 13 to 25 ml.

13. Method according to one of the previous claims, wherein the receiving container has at least two, preferably at least three and in particular at least four receiving chambers and the ratio of the volume of the largest receiving chamber to the volume of the smallest receiving chamber is 4:1 to 1:1, preferably 3:1 to 1:1.