Methods of packaging toilet blocks

Abstract

The invention describes novel methods of manufacturing an in-the-bowl toilet block wrapped by a water-soluble film using thermoforming technology to prepare an adhesive toilet block.

Description

[0001] METHODS OF PACKAGING TOILET BLOCKS

[0002] FIELD OF INVENTION

[0003] The present invention relates generally to methods of packaging solid or semi-solid toilet blocks in a water-soluble or water-dispersible film.

[0004] BACKGROUND

[0005] Adherable sanitary agents for use in toilet bowls or cisterns have also been described in the art. At least one hurdle in using these agents is the application of such products directly to the sides of the bowl or cistern. Applying these agents requires the use of an applicator generally made from plastic which is environmentally unfriendly. In addition, the applicator itself may come in contact with the inside walls of a toilet bowl, further contaminating the applicator which when stored in the bathroom environment can cause the spreading of toilet pathogens in the and around the storage space.

[0006] U.S. Pat. No. 6,667,286 discloses a gel based sanitary composition for cleaning and / or disinfecting and / or releasing an odorant, that contains an adhesion promoter, water anionic and / or non-ionic and / or amphoteric surface-active agent. The disclosed sanitary agents require an applicator.

[0007] US 8,927,477 B2 describes sanitary agents for adhering to a wall of a sanitary appliance, wherein the body of the agent has an external surface covered by a removable water-soluble film. However, this document fails to provide any specifics as to the methods of manufacturing a functional product. Neither does the document provide any guidance as how to wrap the water soluble film around the sanitary composition with the consistency and integrity for the desired use. Moreover, the composition of such sanitary products may themselves come into contact with user’s skin at the time of application, causing skin irritation and sensitivity. To that end, there is a need for new single use sanitary cleaning products that are environmentally friendly, breaks the chain of toilet bowl pathogen spreading outside of the toilet bowl environment, while minimizes the risk of the chemicals coming in contact with the user’s skin. The present invention addresses these needs.

[0008] SUMMARY OF THE INVENTION

[0009] The present invention is directed to methods of manufacturing single use adhesive toilet bowl sanitary products that directly adhere to the inclined walls of the toilet bowls.

[0010] In the first aspect, the present invention describes methods of packaging a sanitary in-the- bowl toilet block wrapped by a film comprising the steps of: (a) providing a base plate (10) having at least one cavity (11) and an anvil profile surrounding the perimeters of the cavity (12), wherein the cavity has an evacuation means associated therewith, (b) placing a first flexible water soluble film (20) having a thickness ranging between 10 to 75 microns, preferably 25 to 50 microns, over said plate and cover the cavity, (c) placing an extruded semi-solid cleaning composition (30) comprising at least one surfactant over said cavity, (d) placing a second flexible polymeric film (40) over the composition, (e) stamping the composition into the cavity with a pressure plate (50) having suitable amount of force ranging between 150 to 700 Newtons (N), preferably 250 to 600 N, applied from above the second flexible thermoformable film, and (f) applying heat to join and seal the first and the second flexible films providing a toilet block wrapped in the films. In some embodiments, the sealing force may be in the range of 0.5 to 4 N / mm2 and the temperature may range between 140 to 200 °C applied from a heating plate onto the anvil profile. In some embodiments, the method further comprises the step of cutting the wrapped toilet block along the cavity. In some embodiments the method may further include the step of printing words, logos or shapes on the surfaces of the films. In some embodiments, the base plate of step (a) may be of metallic material such as aluminum or plastic such as polyamide. In some embodiments, the anvil profile of the plate and the base plate may be of two different materials. For example, the plate material may be metallic, while the anvil profile may be rubber or silicone.

[0011] The pressure plate may be of any suitable material that can withstand the force. Such plate can be metallic, ceramic, plastic or the like. In some embodiments, the second polymeric film is also a water-soluble film.

[0012] In some embodiments, the cavity on the metallic plate is in a hexagonal shape. In some embodiments, both the first and the second film are flexible, water-soluble and thermoformable and are independently selected from the group consisting of polyvinyl alcohols (PVOH), polyethylene terephthalate, polyethylene terephthalate-glycols, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl pyrrolidone, polyalkylene oxides and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamides, polypeptides, polyamides and any combinations thereof, preferably wherein both the first or the second film is PVOH either blown or cast film having a thickness ranging between 25 microns to 75 microns.

[0013] In some embodiments, the sanitary composition is semi-solid and malleable having a weight ranging between 5 grams to 25 grams, which contains a surfactant that is selected from the group consisting of an anionic surfactant, a non-ionic surfactant, a cationic surfactant, and any combinations thereof. In some embodiments, the sanitary composition is an extrudable semisolid having a hardness ranging between 5 to 20 N / mm and a density ranging between 1.0 to about 1.5 grams / liter. In some embodiments, the stamping force provided by the pressure plate (50) is applied between 1 second to about 20 seconds, preferably between 2 to 10 seconds and the sealing pressure ranges between 1.0 to about 3.00 N / mm2, preferably between 1.5 to 2.5 N / mm2. In some embodiments, the sealing temperature ranges between 125° to 250° C, preferably between 150° to 180° C.

[0014] In some embodiments, the present method further includes a step of printing a logo, a shape, a design, words on the external layer of said polymeric films.

[0015] In another aspect the present invention is directed to a system for packaging a toilet block wrapped by water soluble film comprising (a) a plurality of metallic or plastic base plates, each plate having a plurality of cavities and an anvil profile, wherein each of the cavities has an evacuation means associated therewith, (b) a roller containing flexible sheets of a first water- soluble film having a thickness ranging between 10 to 75, preferably 25 to 50 microns configured to place the first water-soluble film over the cavities of said plate, (c) a vacuum component for each of the cavities configured to position the first flexible water-soluble film into each cavity, (d) a loading component to place extruded semi-solid sanitary composition comprising at least one surfactant over said cavities, (e) a second roller configured to place flexible sheets of a second water-soluble film over the cavities containing the composition along the plate, (f) a stamping component having a pressure plate configured to stamp the composition into the cavities. (g) a heating component for sealing the first and the second films are sealed to provide a toilet block wrapped in the films.

[0016] According to this aspect the semi-solid composition has a hardness ranging between 5 to 20 N / mm and a density ranging between 1.0 to about 1.5 grams / liter. In some embodiments, the stamping force is applied between 1 second to about 20 seconds, preferably between 2 to 10 seconds. In other embodiments according to the second aspect of the invention, wherein the sealing pressure ranges between 1.0 to about 3.00 N / mm2, preferably between 1.5 to 2.5 N / mm2. In some embodiments, the composition has a weight ranging between 5 grams to 25 grams. In other embodiments, the system has a printing mechanism incorporated into the process preferably before or after the placement of the first or the second polymeric sheets on the metallic plates for printing logos, shapes, words on the external layers of the polymeric films.

[0017] In a third aspect, the present invention is directed to a method of making an adhesive toilet block having a three dimensional shape with an upper and a lower surface, the method comprising: (a) providing a base plate having a plurality of cavities, wherein each of the cavities has an evacuation means associated therewith and an anvil profile surrounding the perimeters of the cavity, (b) placing a first flexible film having a thickness ranging between 10 to 75 microns, preferably 25 to 50 microns, over said plate, (c) covering the plurality of cavities with the first flexible film, (d) applying vacuum in each of the cavities to place the first flexible film into each cavity, (e ) placing at least one extruded semi-solid detergent composition comprising at least one surfactant over each of said cavities, (f) placing a second flexible film over the plate and covering said composition along the cavities (g) stamping the composition with a pressure plate from above the second flexible form, having a force ranging between 150 to 700 N, preferably 250 to 600 N, and (h) applying heat sealing whereby the first and the second flexible films are joined and sealed around the toilet block wrapping the toilet block within the films. In some embodiments, the sealing force may be in the range of 0.5 to 4 N / mm2 and the temperature may range between 140 to 200 °C. In some embodiment the adhesive toilet block according to the present invention is a semi-solid extruded composition containing at least one surfactant that is wrapped inside a water-soluble film. In other embodiments, the stamping of the sanitary composition drives the composition into said cavities to form the upper or the lower surface of the adhesive block. In some embodiments, at least one of the upper or the lower surface is a oval, circular, pentagonal, hexagonal shape, heptagonal or octagonal shape.

[0018] In some embodiments according to the third aspect of the invention, the adhesive toilet block has at least 1 symmetrical edge, but no more than 20, preferably 16 and the adhesive toilet block has at least 3 to 20 side surfaces, preferably 16.

[0019] In another aspect, the present invention is directed to all products manufactured according to the aforementioned processes.

[0020] BRIEF DESCRIPTION OF DRAWINGS

[0021] The drawings illustrate the process of the present invention as well as the product formed thereby.

[0022] Figure 1 is a perspective view of the plate (10) having a cavity and placement of the first polymeric film over the metallic plate in accordance to the present invention.

[0023] Figure 2 illustrates the order of components that are placed over the metallic plate and the cavity.

[0024] Figure 3 illustrates one embodiment and the shape of a semi-solid composition wrapped in a polymeric film and different edges and surfaces of the adhesive toilet block according to the present invention.

[0025] DETAILED DESCRIPTION OF THE INVENTION

[0026] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs and shall be understood to have the meanings described below. All publications and patents referred to herein are incorporated by reference in their entirety. Unless otherwise specified, the following terms have the meaning as described herein.

[0027] As used herein, “about” will mean up to plus or minus 5% of the particular term.

[0028] As used herein, “'consisting essentially of” refers to excluding other active ingredients but.including the recited optional excipients.

[0029] As used herein, "sanitary appliance" generally refers to toilet bowl, urinal, fixtures, and similar objects in lavatory and bathroom environment.

[0030] By the term “substantially free”' it is meant that the final composition contains less than 2.5% of the total weight of the respective composition to the extent that it could be detected by general quantitative assays known in the art for detection of such ingredient in the final composition. For example, the phrase substantially free of water would mean that the respective composition contains less than 2.5% water. By the term "free" it is meant that the final_15 composition is free of any traces of the identified ingredient to the extent that it could be identified using the same assays as described herein above.

[0031] As used herein, the term “semi-solid” refers to a physical state that lies between solid and liquid and has the ability to support its own weigh and hold and conform in a solid shape. Yet, it maybe malleable and compressible when subject to external pressures and capable of changing its shape from its original form. Example of such products include playdoh-like consistency, paste, solidified cream and wax-like. A semi-solid does not refer to a gel or liquid states.

[0032] As used herein, the term “edge” or “edges” refers to the outside limit of an object, a product, or surface; a place or part farthest away from the center of such object or product where at least two sides of a line from different surfaces come together. This may reflect a point where a side surface meets an upper or a lower surface. The term “cavity” is used interchangeably with the term “mold” and is intended to refer to a hollow container used to give shape to the semi-solid compositions according to the present invention, which are extrudable or wax-like compositions containing at least one surfactant.

[0033] The present invention is primarily directed to methods of manufacturing a semi-solid block, soap or detergent compositions wrapped with a polymeric film for direct application to the internal walls of a toilet bowl. More specifically, in the first aspect, the present invention describes methods of packaging a sanitary in-the- bowl toilet block wrapped by a film comprising the steps of: (a) providing a base plate (10) having at least one cavity or mold (11), wherein the cavity or mold has an evacuation means associated therewith and an anvil profile surrounding the perimeter of the cavity on the base plate, (b) placing a first flexible water soluble film (20) having a thickness ranging between 10 to 75 microns, preferably 25 to 50 microns, over said plate and cover the cavity, (c) placing an extruded semi-solid cleaning composition (30) comprising at least one surfactant over said cavity, (d) placing a second flexible polymeric film (40) over the composition, (e) stamping the composition into the cavity with a pressure plate (50) having suitable amount of force ranging between 150 to 700 N, preferably 250 to 600 N, applied from above the second polymeric film, (f) applying heat sealing whereby the first and the second polymeric films are joined and sealed to provide a toilet block wrapped in the films. In some embodiments, the method further comprises the step of cutting the wrapped toilet block along the cavity borders. In some embodiment, the heat sealing is applied from a heating plate directly above the base plate and the heating is applied on the anvil profile to join the upper and lower films enwrapping the detergent semi-solid composition.

[0034] In some embodiments, the first or the second film are flexible, biodegradable, water- soluble and thermoformable. The biodegradable and water soluble polymeric films according to the present invention suitable for the external wrapping of a toilet block composition are generally those that can dissolve, disperse or swell in the presence of water, preferably selected from the group consisting of polyethylene glycol, polyacrylamides, polyacrylic acid copolymer, and polyvinyl alcohol that can be classified as natural (isolated from plant or animal sources), semisynthetic, or synthetic polymers. Natural water-soluble polymers may be used as-is or can be modified. Semisynthetic water-soluble polymers are derived from chemical alteration of natural polymers or from microbial sources. A large number of natural and semisynthetic water-soluble polymers are polysaccharides which may differ greatly in their basic sugar units, linkages. Any combinations of such polymeric entities may be used in preparing the first or the second film to be used to wrap the toilet blocks according to the present invention.

[0035] Suitable first or second polymeric films are independently selected from the group consisting of polyvinyl alcohols (PVOH), polyethylene terephthalate, polyethylene terephthalateglycols, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl pyrrolidone, polyalkylene oxides and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamides, polypeptides, polyamides and any combinations thereof, preferably wherein both the first or the second film are the same. In most preferred embodiment, both the first and the second film is PVOH.

[0036] In some embodiments, the cavity (11) or the mold of the base plates (10) can be in any shape or form such as an oval, circular, pentagonal, hexagonal shape, heptagonal or an octagonal shape, preferably a hexagonal shape. The anvil profile surrounding the perimeter of the cavity has a width ranging between 0.5 to 2.5 mm, preferably 2 mm; a height ranging between 0.5 to 2.5mm, preferably 2 mm, and is of material that is either not conductive or has a lower heat conductivity as compared to the material used to form the base plate. In some embodiments, the anvil profile is of material having a thermal conductivity of less than 0.1 W / m K (Watts per meter Kelvin) to facilitate proper heat sealing. In some embodiments, the anvil profile of the plate and the base plate may be of two different materials. For example, the plate material may be metallic, while the anvil profile may be rubber or silicone.

[0037] In some embodiments, the sanitary composition is semi-solid and malleable having a weight ranging between 5 grams to 25 grams, which contains a surfactant that is selected from the group consisting of an anionic surfactant, a non-ionic surfactant, a cationic surfactant, and

[0038] In other embodiments, the sealing pressure ranges between 1.0 to about 3.00 N / mm2, preferably between 1.5 to 2.5 N / mm2and the sealing temperature ranges between 125 to 250° C, preferably between 150 to 180° C.

[0039] In certain embodiment of the first aspect of the invention, the respective cavities and molds of the metallic plates have a depth ranging between about 1 to 40 mm, preferably between 2 to 35 mm, and may be in the form of an oval, circular, pentagonal, hexagonal shape, heptagonal or an octagonal shape, preferably in a hexagonal shape. To that end, the finalized toilet block units according to the present invention can be formed into any shape, such as a sachet, sphere, cylinder, cube, cuboid, triangle, oval, circular, rectangle, pentagonal, hexagonal, heptagonal, octagonal or the like. The dimensions of the unit dose may vary having a length of 0.25 to 15cm, preferably between 1.5 to 5.0 cm, a width of 0.5 to 7.0 cm, preferably between 1.5 to 5.0 cm, and a height of 0.1 to 5 cm, preferably between 0.5 to 2.5cm. However, there is no theoretical limitation, in either size, amount or shape so long as it can be wrapped sealed with a water-soluble film and adhered to the wall of a sanitary appliance for sufficient duration of time as intended herein.

[0040] In other embodiments of the first aspect of the present invention, the in the bowl toilet block is a sanitary composition containing at least one the surfactant that is selected from the group consisting of an anionic surfactant, a non-ionic surfactant, a cationic surfactant, and any combinations thereof.

[0041] FIG 1 illustrates the base plate (10) according to the present invention, having at least one cavity (11) with suitable depth to accept an extruded composition to be molded and / or engraved into a desired shape. The plate may be a metallic or plastic material that is non-reactive towards the extruded compositions such as aluminum or of polyamide material. In some embodiments, the plate may contain plurality of cavities and be a part of a machinery designed to perform multiple function in series of steps to manufacture the presently described sanitary adhesive block products. In some embodiments, the plate also contains at least one anvil profile (12) at the perimeters of the cavities to facilitate heat transfer and sealing of the films used to wrap the detergent compositions therein. The base plate further contains plurality of holes (13) to facilitate vacuum pressure for holding and maintaining the water-soluble film on the base plate throughout the process. In some embodiments, the water-soluble film (20) is preferably PVOH, and may be placed on top surface and over the base plate to cover said at least one cavity and the anvil profiles. The cavity is then subject to an evacuation step removing the air from the cavity and allowing the PVOH film into the cavity and respectively adopting and forming the shape of the cavity thereby acting as a false bottom of the cavity to form a half open pouch. The open pouch is then served as the container to receive the extruded sanitary composition.

[0042] In alternative embodiments, a roller of thermoformable water-soluble film is provided, and at the inception of the process, the leading edge of the roll of film is moved into position over the base plate (10) and positioned in overlying relationship with respect to the cavities (11) and the anvil profiles (12) to spread across the entire base plate covering the cavities. An evacuator is then activated, and air is then removed from each of the cavities (11) such that the film (20) is formed by being drawn into the cavities (11).

[0043] In some embodiments, the anvil profile (12) may be of different material having a lower heat conductivity as the material used to make the base plate. Accordingly, in some embodiments, the base material may be metallic, such as aluminum and the anvil profile may be of rubber or silicone. In some embodiments, the anvil profile may be of material that has no heat conductivity. In some embodiments, the anvil profile has a width ranging between 0.5 to 2.5 mm; a height ranging between 0.5 to 2.5mm.

[0044] Those of ordinary skill in the art would appreciate that at least one distinguishing feature of the present invention is the actual covering of the extruded composition with a second polymeric film and applying suitable force to neither improperly squash the semi-solid composition while avoid adhesion of such material to the pressure plate or the respective cavities.

[0045] In preferred embodiments, the thickness of the film ranges between 5 to 75 microns, preferably between 10 to 50 and more preferably between 15 to 35 microns.

[0046] In some embodiments, the plurality of cavities is preferably in the shape of an oval, circular, cylindrical, pentagonal, hexagonal, heptagonal or octagonal shape having a depth ranging between 2 mm to 35 mm. In other embodiments, the cavities are configured to manufacture toilet block compositions having a three-dimensional shape with at least 3 symmetrical edges (60), but no more than 20, preferably 16 and at least 8 to 20 side surfaces (70), preferably 16.

[0047] The second aspect of the present invention is directed to machinery having multiple stages for performing the wrapping a thermoformable film around an extruded sanitary toilet block composition. Accordingly, the second aspect of the present invention is directed to systems for packaging a toilet block wrapped by thermoformable films comprising the steps: (a) providing a plate (10) having a plurality of cavities, wherein each of the cavities (11) has an evacuation means associated therewith such as a vacuum and an anvil profile (12) having a width ranging between 0.5 to 2.5 mm; and a height ranging between 0.5 to 2.5mm (b) placing a first flexible thermoformable film (20) having a thickness ranging between 10 to 75 microns over said plate, (c) applying vacuum in each of the cavities to place the first flexible thermoformable film (20) into each cavity, (d) placing an extruded solid or semi-solid detergent composition (30) comprising at least one surfactant over said cavities, (e) placing a second flexible thermoformable film (40) over the detergent composition along the plate, (f) stamping the extruded composition by providing a pressure plate (50) having suitable amount of force ranging between 150 to 700 N, preferably 250 to 600 N, applied from above the second flexible thermoformable film, and (g) applying heat sealing whereby the first and the second flexible thermoformable films are sealed to provide a toilet block wrapped in the thermoformable films. In some embodiments, the films may be preheated for proper degree of flexibility. In some embodiments, the heat sealing is provided by a hotplate positioned on top of the base plate. In some embodiments the heat sealing is applied on the anvil profile to facilitate proper sealing.

[0048] In certain embodiment, the cavity is a mold having a depth ranging between 1 millimeters to 40 millimeter(mm), preferably about 2 to 35 mm and may be in the form of an oval, circular, pentagonal, hexagonal shape, heptagonal or an octagonal shape, preferably a hexagonal shape. In other embodiments, In other embodiments, the first or the second thermoformable film are independently selected from the group consisting of first or the second film are flexible, water- soluble and thermoformable and are independently selected from the group consisting of polyvinyl alcohols (PVOH), polyethylene terephthalate, polyethylene terephthalate-glycols, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl pyrrolidone, polyalkylene oxides and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamides, polypeptides, polyamides and any combinations thereof, preferably wherein both the first or the second film is PVOH.

[0049] The sealing pressure ranges between 1.0 to about 3.00 N / mm2, preferably between 1.5 to 2.5 N / mm2and the sealing temperature ranges between 125 to 250° C, preferably between 150 to 180° C. In some embodiments, the stamping force is applied between 1 second to about 20 seconds, preferably between 2 to 10 seconds. In other embodiments, the final in the bowl sanitary composition has a weight ranging between 5 grams to 25 grams.

[0050] In another aspect, the present invention is directed to methods of manufacturing adhesive toilet blocks having a three dimensional shape with an upper and a lower surfaces, the method comprising: (a) providing a plate having a plurality of cavities and a plurality of anvil profiles in the perimeters of said cavities, wherein each of the cavities has an evacuation means associated therewith, (b) placing a first flexible film having a thickness ranging between 10 to 50 microns over said plate, (c) covering the plurality of cavities with the first flexible film, (d) applying vacuum in each of the cavities to place the first flexible film into each cavity, (e ) placing at least one extruded solid or semi-solid detergent composition comprising at least one surfactant over each of said cavities, (f) placing a second flexible film over the plate and covering said composition along the plate, (g) stamping the detergent composition with a pressure plate from above the second flexible form, having a force ranging between 150 to 700 N, preferably 250 to 600 N, and (h) applying heat sealing whereby the first and the second flexible films are joined and sealed around the toilet block wrapping the toilet block within the films. In some embodiments, the heat sealing is provided by a hotplate positioned on top of the base plate. In some embodiments the heat sealing is applied on the anvil profile to facilitate proper sealing.

[0051] The preferred water soluble polymer suitable for the present invention is PVOH. PVOH is typically prepared by hydrolyzing polyvinyl acetate in ethanol at the presence of an alkali hydroxide and depending on its thickness is may be wrapped around the toilet blocks further enhancing the adhesiveness of the product when it is directly applied to a hard surface.

[0052] In another aspect, the present invention is directed to methods of manufacturing adhesive toilet blocks having a three dimensional shape with an upper and a lower surfaces, the method comprising: (a) providing a plate having a plurality of cavities and anvils profiles around the perimeters of the cavities, wherein each of the cavities has an evacuation means associated therewith, (b) placing a first flexible film having a thickness ranging between 10 to 50 microns over said plate, (c) covering the plurality of cavities with the first flexible film, (d) applying vacuum in each of the cavities to place the first flexible film into each cavity, (e) placing at least one extruded solid or semi-solid detergent composition comprising at least one surfactant over each of said cavities, (f) placing a second flexible film over the plate and covering said composition along the plate, (g) stamping the detergent composition with a pressure plate from above the second flexible form, having a force ranging between 150 to 700 N, preferably 250 to 600 N, and (h) applying heat sealing whereby the first and the second flexible films are joined and sealed around the toilet block wrapping the toilet block within the films. In some embodiments, the heat sealing is provided by a hotplate positioned on top of the base plate and the heat is applied onto the anvil profile.

[0053] In some embodiments according to the present invention, the method of the present invention includes the steps of providing a plate with plurality of cavities each of which has evacuation means associates with those cavities, placing a flexible thermoformable film over the cavities and overlaying the plurality of cavities and evacuating the cavities thereby forcing the thermoform to be sucked into the cavity forming a plurality of pouches ready to accept a sanitary composition comprising at least one surfactant.

[0054] Fig 2 illustrates, an extruded block composition (30) being placed on top of the plate over the cavity which has already formed and adapted the water-soluble film (21) into the shape of the cavity. In the next step the plate (10) is moved to a station which has series of holders positioned immediately above respective cavities and when activated, will position the extruded sanitary composition on top of the cavities to fill the cavity. In some embodiments, a second water soluble film (40) is placed on top of the block composition and the plate to fully cover the entire plate (10) and the extruded block composition having been place inside the cavity (30).

[0055] In some embodiments, a pressure plate (50) positioned above the film is move downwardly pressing the extruded composition (30) into the respective cavities to assume the final shape of the semi-solid block. Once the extruded composition (30) is stamped into the cavity, it adapts the base design, the engraving and the shape of the cavity with suitable parameters having a length of 0.25 to 10 cm, preferably between 1.5 to 6.0 cm; a width of 0.5 to 7.0 cm, preferably between 1.5 to 5.0 cm; and a height of 0.3 to 5 cm, preferably between 0.5 to 2.5cm. The film is then heated to seal the film along the anvil borders of the cavity to facilitate heat sealing of the film forming a wrapped block (see Fig 3, 80). The water-soluble film is subsequently cut along the plate and the cavity borders to manufacture the unique modified hexagonal design (80) of Fig 3.

[0056] The block compositions according to the present invention may be prepared by combining cleaning ingredients including but not limited to an anionic surfactant, a non-ionic surfactant, a cationic surfactant, an adhesion promoter, a chelating agent, an antioxidant and an inorganic salt. In preferred embodiments, the sanitary toilet block compositions according to the present invention are extruded and malleable lavatory cleaning compositions containing: (a) from about 10% to about 60% by weight of an inorganic sodium salt; (b) from about 10% to about 80%, preferably about 15% to about 75% by weight of an anionic surfactant; (c) from about 0.1% to about 10% by weight ofc an adhesion promoter; (d) from about 0.05% to about 10% of a chelating agent, (e) from about 0.05% to about 1.0 % by weight of an antioxidant; wherein the composition is wrapped and sealed by a water-soluble film and is capable of adhering to sanitary object when applied directly against the wall of a sanitary appliance. In some embodiments, the extruded compositions of the preset invention optionally contain one non-ionic surfactant in amounts up to 5%, preferably up to 2.5% by weight of the composition, but most preferably less than 2% by wight of the composition. In some embodiments the extruded composition is substantially free of any non-ionic surfactants.

[0057] In some embodiments, the composition according to the present invention is an extruded combination of (a) from about 12.5% to about 45% by weight of an inorganic sodium salt; (b) from about 25% to about 75% by weight of anionic surfactants, preferably from about 45% to about 70%; (c) from about 0.5% to about 5% by weight of an adhesion promoter, preferably from about 0.5% to about 3%, more preferably from about 1.0% to about 2%; and / or (d) from about 0.5% to about 3% of a chelating agent, and / or (e) from about 0.1% to about 1.0 % by weight of an antioxidant, preferably from about 0.1% to about 0.5%, more preferably from about 0.1% to about 0.3%. In some embodiments, the total amount of all non-ionic surfactants is less than 2.5% by weight of the composition. In some embodiments, the extruded composition is free of any non-ionic surfactants. In some embodiments, the block compositions are a malleable semi solid and consists essentially of a sodium salt, an anionic surfactant, a chelating agent, an adhesive promoter, an antioxidant, a dye and a fragrance extruded prior to being wrapped in a water-soluble film. In some embodiments, the anionic surfactant is sodium dodecyl benzene sulfonate, sodium lauryl sulphate or a combination thereof and the adhesion promoter is n-methyl-alkyl glucamide.

[0058] In some embodiments, the block compositions prepared according to the process described herein has a length of 0.25 to 10 cm, preferably between 1.5 to 6.0 cm, a width of 0.5 to 7.0 cm, preferably between 1.5 to 5.0 cm, and a height of 0.3 to 5 cm, preferably between 0.5 to 2.5cm. In the preferred embodiments, the block composition has at least 2 parallel up and down surfaces. In some embodiments, the block composition has a weight ranging between 5 to 25 grams and a footprint of 30 to 45 mm, preferably 35 to 40 mm. In other embodiments, the block composition according to the present invention is wrapped in a transparent water-soluble film having a thickness ranging from about 5 microns to about 75 microns, preferably between 15 microns to 35 microns.

[0059] In certain embodiments, the present invention also includes a packaging system containing plurality of metallic plates having at least one cavity, configured to execute a process according to the first aspect of the present invention. Such system may further include executable software, stamping apparatus, tracking, and monitoring tools to identify movement of the metallic plates, the location of the cavities, the weight of the extruded compositions to be wrapped and the final manufactured products. The packaging system according to the present invention further includes such components as computer hardware integrated with the executable software, computer-based networks, access systems, web based portals, databases, and processing units to provide the ability to drive changes to products themselves in many aspects. The system according to the present invention is intended for use by someone skilled in the art to modify manufacturing parameters and navigate the speed of the process, heat sealing temperatures, base plates vacuum control and modulate structural or thermal parameters involved in the process.

[0060] Those of ordinary skill would appreciate that the manufactured product according to the present invention ideally has at least one of the upper or the lower surface is an oval, circular, pentagonal, hexagonal shape, heptagonal or octagonal shape and at least 4 symmetrical edges (60), but no more than 20, preferably 16, and at least 8 to 20 surfaces (70), preferably 16. Insofar as the shape of the blocks are concerned, it will be observed that the blocks according to the present invention are preferably designed to substantially have a modified hexagonal. Such modified hexagonal shape may comprise a flat hexagonal surface on one side, and triangular (72) and / or rectangular (71) flat surfaces, as shown in Fig 3 to maximized surface area for exposure to the flushing water.

[0061] While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may he made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.

Claims

Claims1. A method for packaging an in-the-bowl toilet block wrapped by a film comprising the steps: a) providing a plate having at least one cavity, wherein the cavity has an evacuation means associated therewith and an anvil profile surrounding the perimeters of the cavity, b) placing a first water soluble polymeric film having a thickness ranging between 10 to 75 microns over said at least one cavity, c) placing an extruded semi-solid cleaning composition comprising at least one surfactant over said cavity, d) placing a second polymeric film over the composition across the entire plate, e) stamping the composition with a pressure plate having suitable amount of force ranging between 150 to 700 N, preferably 250 to 600 N, applied from above the second film, and f) applying heat sealing whereby the first and the second films are sealed to provide a toilet block wrapped in said films.

2. The method of claim 1 , further comprising the step of cutting the wrapped toilet block along the shape of the cavity.

3. The method according to any of the prior claims, wherein the second polymeric film is a water-soluble film.

4. The method according to any of the prior claims, wherein the cavity has is in oval, circular, pentagonal, hexagonal shape, heptagonal, octagonal shape, or hexagonal shape.

5. The method according to any of the prior claims, wherein at least one of the first or the second film are independently selected from the group consisting of polyvinyl alcohols (PVOH), polyethylene terephthalate, polyethylene terephthalate-glycols, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl pyrrolidone, polyalkylene oxides and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamides, polypeptides, polyamides and any combinations thereof, preferably wherein both the first or the second film is PVOH.

6. The method according to any of the prior claims, wherein the surfactant is selected from the group consisting of an anionic surfactant, a non-ionic surfactant, a cationic surfactant, and any combinations thereof.

7. The method according to any of the prior claims, wherein the detergent composition has a hardness ranging between 5 to 20 N / mm and a density ranging between 1.0 to about 1.5 grams / liter.

8. The method according to any of the prior claims, wherein the stamping force is applied between 1 second to about 20 seconds, preferably between 2 to 10 seconds.

9. The method according to any of the prior claims, wherein the sealing pressure ranges between 1.0 to about 3.00 N / mm2, preferably between 1.5 to 2.5 N / mm2.

10. The method according to any of the prior claims, wherein the sealing temperature ranges between 125° to 250° C, preferably between 150° to 180° C.

11. The method according to any of the prior claims, wherein the heat sealing is applied onto the anvil profile.

12. The method according to any of the prior claims, wherein the detergent composition has a weight ranging between 5 grams to 25 grams.

13. The method according to any of the prior claims, further comprising a step of printing a logo, a shape, a design, words on the external layer of said polymeric films.

14. A wrapped toilet block made according to any of the prior claims 1-13.

15. A system for packaging a toilet block wrapped by water soluble film comprising: a) a plurality of metallic plates, each plate having a plurality of cavities, wherein each of the cavities has an evacuation means associated therewith, b) a roller configured to place flexible sheets of a first water-soluble film having a thickness ranging between 10 to 75 microns over said plate, c) a vacuum component for each of the cavities configured to position the first flexible water-soluble film into each cavity,d) a loading component to place extruded semi-solid sanitary composition comprising at least one surfactant over said cavities, e) a second roller configured to place flexible sheets of a second water-soluble film over the cavities containing the composition along the plate, f) a stamping plate configured to stamp the composition into the cavities, and g) a heating system for sealing the first and the second films are sealed to provide a toilet block wrapped in the films.

16. The system according to claim 15, wherein at least one of the first or the second film are independently selected from the group consisting of polyvinyl alcohols (PVOH), polyethylene terephthalate, polyethylene terephthalate-glycols, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl pyrrolidone , polyalkylene oxides and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamides, polypeptides, polyamides and any combinations thereof, preferably wherein both the first or the second film is PVOH.

17. The system according to any of the prior claims 15-16, wherein the surfactant is selected from the group consisting of an anionic surfactant, a non-ionic surfactant, a cationic surfactant, and any combinations thereof.

18. The system according to any of the prior claims 15-17, wherein the detergent composition has a hardness ranging between 5 to 20 N / mm and a density ranging between 1.0 to about 1.5 grams / liter.

19. The system according to any of the prior claims 15-18, wherein the stamping force is applied between 1 second to about 20 seconds, preferably between 2 to 10 seconds.

20. The system according to any of the prior claims 15-19, wherein the sealing pressure ranges between 1.0 to about 3.00 N / mm2, preferably between 1.5 to 2.5 N / mm2.

21. The system according to any of the prior claims 15-20, wherein the sealing temperature ranges between 125 to 250° C, preferably between 150 to 180° C.

22. The system according to any of the prior claims 15-21, wherein the composition has a weight ranging between 5 grams to 25 grams.

23. The system according to any of the prior claims 15-22, further comprising a component for printing logos, shapes, words on the external layers of the polymeric films.

24. A method of making an adhesive toilet block having a three dimensional shape with an upper and a lower surface, the method comprising: a. providing a plate having a plurality of cavities, wherein each of the cavities has an evacuation means associated therewith, b. placing a first flexible film having a thickness ranging between 10 to 75 microns over said plate, c. covering the plurality of cavities with the first flexible film, d. applying vacuum in each of the cavities to place the first flexible film into each cavity, e. placing at least one extruded solid or semi-solid detergent composition comprising at least one surfactant over each of said cavities, f. placing a second flexible film over the plate and covering said composition along the plate, g. stamping the detergent composition with a pressure plate from above the second flexible form, having a force ranging between 150 to 700 N, preferably 250 to 600 N, and h. applying heat sealing whereby the first and the second flexible films are sealed around the toilet block wrapping the toilet block within the films.

25. The method of claim 24, wherein at least one of the upper or the lower surface is oval, circular, pentagonal, hexagonal shape, heptagonal or octagonal shape.

26. The method of claim 24-25, wherein the adhesive toilet block has at least 4 symmetrical edges, but no more than 20, preferably 16.

27. The method of claim 24-26, wherein the adhesive toilet block has at least 8 to 20 side surfaces, preferably 16.

28. The method of claim 24-27, wherein the stamping of the sanitary composition drives the composition into said cavities to form the upper or the lower surface of the adhesive block.

29. The method of claims 24-28, further comprising cutting the film along the edge of the toilet block wrapped within the film.

30. The method of claims 24-29, wherein the thickness of the film ranges between 5 to 75 microns, preferably between 10 to 35 microns.

31. The method of claims 24-30, wherein at least one of the first or the second film are independently selected from the group consisting of polyvinyl alcohols (PVOH), polyethylene terephthalate, polyethylene terephthalate-glycols, polypropylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl pyrrolidone , polyalkylene oxides and linear low-density polyethylene (LLDPE), acrylic acid, polyacrylamides, polypeptides, polyamides and any combinations thereof, preferably wherein both the first or the second film is PVOH.

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