METHOD FOR MANUFACTURING DETERGENT DOSER UNITS WITH IMPROVED PROPERTIES

Description

[0001] The present invention relates to washing or cleaning agent dosing units with at least one receiving chamber formed from a water-soluble film material, which in turn is filled with a washing or cleaning agent. The application further relates to methods for manufacturing these washing or cleaning agent dosing units.

[0002] The packaging and presentation of detergents and cleaning agents are subject to constantly changing requirements. For some time now, a major focus has been on convenient dosing by the consumer and simplifying the steps required for washing or cleaning. Pre-portioned detergents and cleaning agents, such as foil pouches with one or more compartments for solid or liquid detergents or cleaning agents, offer a technical solution.

[0003] A relevant trend in the production of these foil bags is their miniaturization. This development is driven not only by increased consumer acceptance due to simplified handling, but also, and perhaps more importantly, by sustainability considerations, such as the amount of packaging material used.

[0004] The production of the previously described film bags involves multi-stage processes in which water-soluble film materials are formed into cavities, filled, and subsequently sealed, for example, by applying heat and a vacuum. While heating the films increases their plasticity, the force resulting from the vacuum applied to the heated film causes it to stretch and deform plastically. In this process, the film is not stretched homogeneously across its surface; rather, areas of high stretch, such as at the edge of the cavity, alternate with areas of lower stretch. Thus, a film material with a homogeneous thickness is transformed into a deformed film in the form of a container 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 usually increases, for example, with the number of receiving chambers molded into the receiving container or their depth.

[0005] Among other factors, both the film thickness distribution and the absolute film thickness determine the haptic, visual, and mechanical properties of the foil pouch. Foil pouches with large variations in film thickness are often perceived as less appealing. Foil pouches with a low minimum film thickness deform more easily under their own weight than comparable pouches with a higher film thickness and appear flimsy. These pouches are less resistant to mechanical stress and detach too quickly when exposed to water. The latter two points are not only relevant for foil pouches in the areas of manufacturing, transport, and storage, but also have a particular impact on product safety, for example, in the event of accidental oral ingestion.

[0006] International patent application WO 2020 / 152044 A1 describes a process for the production of 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] Patent applications DE 102 59 848 A1, EP 3 025 983 A1 and DE 2 230 895 and granted patents EP 1 161 370 B1 and US 3,484,518 describe methods for forming films and for film packaging of consumer goods.

[0008] Against this technical background, the application aimed to provide detergent portion units that offer maximum stability, an appealing look and feel, and minimal use of packaging film materials. Furthermore, the detergent portion units should be capable of efficient large-scale production.

[0009] A first subject matter of the application is a process for manufacturing 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 using the heating device; d) Breaking contact between the first water-soluble film and the heating device; e) Forming the first heated water-soluble film into the cavities of a thermoforming die located below the first water-soluble film, creating 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. where the surface of the heating device which is brought into contact with the water-soluble film has at least one protrusion and the water-soluble film is brought into contact with the surface of the protrusion in step b), the water-soluble film is brought into contact with the surface of the protrusion in step b) but not with the further surface of the heating device and the protrusion in step b) is in contact with the surface portion of the water-soluble film which is formed into the cavity of the deep-drawing trough in step e).

[0010] The method 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 with minimal packaging material usage.

[0011] In the process according to the invention, water-soluble films are formed in a thermoforming apparatus and combined with detergent preparations to form detergent portion units.

[0012] The water-soluble film in which the detergent preparation is packaged can comprise one or more structurally different water-soluble polymers. Polymers from the group of (optionally acetalized) polyvinyl alcohols (PVALs) and their copolymers are particularly suitable as water-soluble polymers for the first water-soluble film.

[0013] 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 of 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 particularly from 40,000 to 80,000 gmol⁻¹.

[0014] The production of polyvinyl alcohols and polyvinyl alcohol copolymers generally involves the hydrolysis of intermediate polyvinyl acetates. 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%.

[0015] Preferred polyvinyl alcohol copolymers comprise, in addition to vinyl alcohol, an ethylene-unsaturated carboxylic acid, its salt, or its ester. Particularly preferred are such polyvinyl alcohol copolymers containing, besides 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, C1-4 alkyl esters or hydroxyalkyl esters are preferred. Further monomers include ethylene-unsaturated dicarboxylic acids, for example, itaconic acid, maleic acid, fumaric acid, and mixtures thereof.

[0016] Suitable water-soluble films for use in the wrappings of the water-soluble packaging according to the invention are films marketed by MonoSol LLC, for example, under the designations M8630, M8720, M8310, C8400, or M8900. Other suitable films include films designated Solublon® PT, Solublon® GA, Solublon® KC, or Solublon® KL from Aicello Chemical Europe GmbH, or the VF-HP films from Kuraray, as well as the Hi-Selon series from Mitsubishi Chemical Corporation.

[0017] The first water-soluble film preferably has a thickness of 10 to 90 µm, preferably of 30 to 60 µm.

[0018] The water-soluble films may contain additional active ingredients or fillers, as well as plasticizers and / or solvents, especially water.

[0019] Other active ingredients include, for example, materials that protect the detergent ingredients encapsulated by the film from degradation or deactivation by light exposure. Antioxidants, UV absorbers, and fluorescent dyes have proven particularly suitable for this purpose.

[0020] Examples of plasticizers that can be used include glycerin, ethylene glycol, diethylene glycol, propanediol, 2-methyl-1,3-propanediol, sorbitol or mixtures thereof.

[0021] To reduce its coefficient of friction, the surface of the water-soluble film of the detergent portion unit can optionally be dusted with fine powder. Sodium aluminosilicate, silicon dioxide, talc, and amylose are examples of suitable powders.

[0022] The thermoforming apparatus used in the process can be operated continuously or discontinuously. A continuous process is preferred to increase process efficiency. In a particularly preferred embodiment of the process, the transport of the first water-soluble film in step a) is continuous. With regard to process economy and reliability, it is preferred to transport the first water-soluble film in step a) at a speed of 0.04 m / s, preferably above 0.08 m / s.

[0023] 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 comes into contact in step b) are ceramic or metal, especially steel.

[0024] In a preferred embodiment of the method, the heating device in step b) has a flat surface from which at least one projection protrudes.

[0025] Preferred elevations are planar. It is particularly preferred if the elevation has a flat top surface.

[0026] The height of the elevation is preferably 0.5 to 5 mm, in particular 1 to 3 mm.

[0027] Preferably, 5 to 50%, in particular 10 to 35% of the surface of the top of the heating device is formed as a raised area.

[0028] The surface of the heating device can have a homogeneous or a heterogeneous temperature profile. Preferably, the heating rate of the heating device is 5 to 70 K / s, and particularly 10 to 50 K / s.

[0029] In step b), the water-soluble film is brought into contact with the heating device and, in step e), deformed 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 rim or web surrounding the receiving chamber, and are consequently stretched differently. To equalize the strain factors of the different sections of the water-soluble film forming the receiving container, it has proven particularly advantageous, especially when using polyvinyl alcohol-based films, if the raised section in step b) is in contact with the surface portion of the water-soluble film that is formed into the cavity of the thermoforming die in step e). In step b), the water-soluble film is brought into contact with the surface of the raised section but not with the rest of the heating device's surface.

[0030] In a preferred method embodiment, the first water-soluble film is brought into contact with the heating device only on one side in step b). Compared to methods using two heating devices, the method according to the invention not only requires less equipment, but also allows for a more compact design of the production line.

[0031] Preferably, in step b), the top side of the water-soluble film is brought into contact with the heating device. The top side is defined as the side of the film that is still oriented upwards.

[0032] In a preferred embodiment, the heating device is lowered in step b) in the direction of the water-soluble film.

[0033] 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 vacuum. Furthermore, it is preferred to maintain the contact between the water-soluble film and the heating device by maintaining a vacuum. The level of the corresponding vacuum, which is established in step b) between the heating device and the water-soluble film, is preferably 200 to 800 mbar and particularly 400 to 700 mbar.

[0034] To facilitate the uniform formation of a vacuum between the heating device and the water-soluble film, the surface of the heating device preferably has bores through which gas located between the heating device and the film can be vented. These bores are preferably located 60%, more preferably 90%, particularly 95%, and most preferably completely outside the raised areas.

[0035] 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 particularly 2 to 5 seconds.

[0036] The surface of the heating device preferably has a temperature in the range of 23 to 150°C, preferably 80 to 135°C. It is particularly preferred if the surface of the heating device in the area of ​​the protrusion(s) with which the water-soluble film in step b) is in contact has a temperature in the range of 90 to 150°C, preferably 110 to 135°C.

[0037] To further equalize the expansion factors of the different sections of the water-soluble film forming the receiving container, it has also proven advantageous if the at least one protrusion in step c) is in contact with each surface section of the water-soluble film that forms the boundary region of the receiving chamber(s) of the receiving container. For the same reasons, it is preferred that the surface sections of the water-soluble film that form the bottom region of the receiving chamber(s) of the receiving container are not in contact with the heating device in step c).

[0038] To increase process efficiency, it has proven structurally advantageous if 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, most preferably between 0.2 and 1 mm.

[0039] In step d), the contact between the first water-soluble film and the surface of the heating device is broken. For this purpose, any negative pressure that may be present between the heating device and the water-soluble film is eliminated. In a particularly preferred embodiment of the method, in step d), a negative pressure previously generated between the heating device and the water-soluble film is eliminated, and simultaneously or subsequently, the heating device is raised.

[0040] At the beginning of step e), the water-soluble film preferably has a temperature above its glass transition temperature.

[0041] In step e), the water-soluble film is formed into the cavity of a thermoforming die. For this purpose, a vacuum is preferably created between the water-soluble film and the thermoforming die for a duration of 0.5 to 7 seconds, more preferably 1 to 5 seconds. This vacuum generated between the water-soluble film and the thermoforming die is preferably 100 to 600 mbar and particularly 200 to 400 mbar.

[0042] During the forming process 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%, and in particular by 120 to 300%. Simultaneously, the maximum local stretch factor of the water-soluble film following step e) is preferably 2 to 4 and in particular 2 to 3.

[0043] It is particularly preferred if the water-soluble film is formed in step e) to create a receiving container with at least two, preferably at least three and in particular at least four receiving chambers.

[0044] The filling volume of the receiving container in step e) is preferably 1 to 50 ml, preferably 10 to 40 ml and particularly 13 to 25 ml.

[0045] 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.

[0046] For reasons of process efficiency, the method according to the invention is designed such that not just a single detergent portion unit, but a plurality of detergent portion units are produced in parallel in a single process run. Preferably, in step e), a planar structure with at least 14, preferably at least 20 receiving containers is formed.

[0047] In this flat structure, the receiving containers are preferably arranged in rows. With regard to the subsequent filling process, the flat structures formed in step e) are rows of receiving containers arranged orthogonally to the transport direction of the water-soluble film.

[0048] In an alternative embodiment, in step e) a planar structure is formed in which the receiving containers are arranged in rows which run orthogonally to the transport direction of the water-soluble film and are offset from each other by one third of the width of a receiving container, preferably by half the width of a receiving container.

[0049] In the planar structure, the receiving containers are preferably arranged such that each receiving container is adjacent to at least one intermediate area, which in turn is surrounded by three receiving containers.

[0050] The at least one receiving chamber of the receiving container is filled in step f). Solid and liquid washing or cleaning agents are suitable for filling.

[0051] Particularly in cases where the added washing or cleaning agents do not adhere to the water-soluble film material, as can be the case with melts, for example, the filled receiving chamber of the receiving container is sealed. Corresponding methods, in which the receiving chamber of the receiving container is filled in a further step (f) and then sealed in a subsequent step (g) by means of a second water-soluble film, are preferred with regard to product aesthetics and handling.

Claims

1. A method for producing a detergent portion unit having at least one filled receiving chamber surrounded by a water-soluble film, comprising the steps of: a) transporting a first water-soluble film in the direction of 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 beneath the first water-soluble film to form a receiving container having at least one receiving chamber; f) filling the at least one receiving chamber with a detergent; g) optionally sealing and separating the filled receiving containers to form the detergent portion unit, - the surface of the heating device that is brought into contact with the water-soluble film comprising at least one elevation, and the water-soluble film being brought into contact with the surface of the elevation in step b), characterized in that - the water-soluble film is brought into contact with the surface of the elevation in step b), but not with the further surface of the heating device, and - the elevation in step b) is in contact with the surface portion of the water-soluble film that is molded into the cavity of the deep-drawing depression in step e).

2. The method according to claim 1, wherein the heating device in step b) comprises a planar surface from which the at least one elevation protrudes.

3. The method according to one of the preceding claims, wherein the elevation is formed flat.

4. The method according to one of the preceding claims, wherein the elevation comprises a planar upper side.

5. The method according to one of the preceding claims, wherein the elevation is 0.5 to 5 mm high, preferably 1 to 3 mm high.

6. The method according to one of the preceding claims, wherein 5 to 50%, preferably 10 to 35% of the surface of the upper side of the heating device is formed as an elevation.

7. The method according to one of the preceding claims, wherein the at least one elevation in step c) is in contact with each surface portion of the water-soluble film that forms the edge region of the receiving chamber(s) of the receiving container.

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

9. The method according to one of the preceding claims, wherein the water-soluble film is molded in step e) to form a receiving container having at least two, preferably at least three, and in particular at least four, receiving chambers.

10. The method according to one of the preceding claims, wherein the receiving container comprises 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.

11. The method according to one of the preceding points, wherein in step e), the surface of the water-soluble film is increased by at least 80%, preferably by at least 120%, in particular by 120 to 300%.

12. The method according to one of the preceding claims, wherein after step e), the water-soluble film has a maximum local stretching factor of 2 to 4, preferably of 2 to 3.

13. The method according to one of the preceding claims, wherein in step e), a two-dimensional structure is formed, in which the receiving containers are arranged in rows which run orthogonally to the transport direction of the water-soluble film and are respectively offset from one another by a third of the width of a receiving container, preferably by half of the width of a receiving container.