Process for making non-fibrous water-soluble products

Abstract

Included herein are methods of manufacturing water-soluble, non-fibrous substrates having particles thereon, and apparatus for disposing particles on the water-soluble, non-fibrous substrates.

Description

[Technical Field]

[0001] A process for making non-fibrous water-soluble products utilizing discretized elements. [Background technology]

[0002] Non-fiber water-soluble products are highly desired by consumers.These non-fiber water-soluble products are easy to use, because consumers can easily and simply administer desired amount of product to desired process.This is much easier than having to inject liquid or powder into the process, in which accurate administration of correct amount of active substance can be very difficult, and some consumers may find it physically difficult.

[0003] The manufacturing process for non-fibrous water-soluble products is complex, requiring many steps to form the non-fibrous water-soluble product and to administer the required amounts of ingredients, such as particles, to the non-fibrous water-soluble product in an efficient and consistent manner.

[0004] Typically, a first non-fibrous water-soluble film is formed into a cavity, bulk particles such as a detergent composition are dispensed into the cavity, and the cavity is sealed with a second non-fibrous water-soluble film. The process of dispensing particles into the cavity can be inefficient, and it can be difficult to control the consistency of the chemicals dispensed into the cavity. This is particularly problematic for ingredients such as enzymes, which are typically present at very low levels in detergent compositions. Summary of the Invention [Problem to be solved by the invention]

[0005] Therefore, there remains an unmet need for a process for making non-fibrous water-soluble unit dose products having particles in an efficient manner. [Means for solving the problem]

[0006] The present application includes a method of producing a water-soluble product comprising particles, the method including: a) providing a first continuous, water-soluble, non-fibrous substrate having a first side moving in a first direction; b) providing a discretization unit comprising one or more pockets having an inlet and an outlet; c) providing a first supply of first particles to the inlet of at least one of the one or more pockets; d) delivering the first particles from the outlet of the one or more pockets of the discretization unit onto at least a portion of the first side of the first continuous, water-soluble, non-fibrous substrate; and e) at least partially covering the first side of the first continuous, water-soluble, non-fibrous substrate with a covering.

[0007] The present application also includes a method of producing a water soluble product comprising particles, the method comprising: a) providing a first continuous, water soluble, non-fibrous substrate moving in a first direction; b) providing a discretization unit comprising one or more pockets having an inlet and an outlet; c) providing a supply of first particles to the inlet of at least one of the one or more pockets; and d) delivering the first particles from the outlet of the one or more pockets of the discretization unit onto a portion of a first side of the first continuous, water soluble, non-fibrous substrate, wherein while receiving the first particles, at least one of the one or more pockets receiving the first particles is nested with an adjacent pocket.

[0008] These and other iterations are described in more detail below. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a representation of an apparatus for depositing discretized particle doses onto a substrate. [Figure 2] 1 is a representation of an apparatus for depositing discrete particle doses onto a continuous substrate. [Figure 3] 1 is a schematic representation of a weir system on a hopper. [Figure 4] 1 is a schematic representation of a process for forming a single substrate into multiple substrates. [Figure 5]1 is a schematic representation of a process for making a non-fibrous water-soluble product in which pockets advance toward and contact a water-soluble non-fibrous substrate during application of particles. [Figure 6] 1 is a schematic representation of a process for making a non-fibrous water-soluble product in which a water-soluble non-fibrous substrate contacts a pocket during application of particles and then descends away from the pocket. [Figure 7] 1 is a schematic representation of a process for making a water-soluble product in which two adjacent pockets nest within each other during particle reception. [Figure 8] 1 is a schematic representation of a process for making a non-fibrous water-soluble product in which at least a portion of a shield-like pocket advances toward and contacts a water-soluble non-fibrous substrate during application of particles. [Figure 9] FIG. 1 is a top view of a schematic representation of a process for making a non-fibrous water-soluble product, in which the discretization unit operates in a loop configuration. [Figure 10] FIG. 1 is a top view of a unit for depositing particles onto a substrate utilizing multiple feed systems in an in-line configuration. [Figure 11] FIG. 1 is a top view of a unit for depositing particles onto a substrate utilizing multiple feed systems in a radial configuration. [Figure 12] 10 is a representation of adjacent pockets with flushing in both minimum and maximum pitch configurations. DETAILED DESCRIPTION OF THE INVENTION

[0010] The production of non-fibrous water-soluble products can be a delicate balance of materials and processes to achieve the desired end product, functionality, and performance, and to meet the economic requirements for mass production. Previous methods for producing non-fibrous water-soluble products with particles have involved incorporating small amounts of particles directly into the substrate, for example, by incorporating the particles into the substrate during the substrate preparation process or by spraying the particles onto the finished substrate. However, these methods have several drawbacks. When incorporating particles into the substrate during substrate preparation, the particles can interfere with the entrapment and entanglement process of the substrate preparation. This can lead to insufficient or uncontrolled dissolution of the substrate and / or the actual inability to form the substrate. These issues significantly limit the types and properties of particles that can be added in this type of process. These potentially limiting particle properties can include particle size, particle size distribution, chemical composition, particle surface properties (such as adhesiveness and cohesiveness), particle stability within the substrate preparation process, and difficulty in separating incompatible particles. This addition method can also add cost to the manufacturing process because it may require solubilization of solid components to add them to the substrate. Another drawback is that it is difficult to control where the particles are applied to the substrate, which can create problems with sealing when the particles reach areas of the substrate that are to be sealed.

[0011] Despite the difficulties associated with known manufacturing methods, it remains desirable to be able to load larger quantities of particles, different particle types, control where particles are located within a non-fibrous, water-soluble product, and manufacture it in an economically viable manner. This would allow for greater product flexibility. A review of possible solutions in the industry for unit dose applicators did not identify an intermittent particle applicator that could meet the basic requirements of dose frequency, individual dose mass (mass flow rate), dosing footprint, and manufacturing flexibility within practical limits. For example, auger-type intermittent particle filler applications are typically limited to an operating frequency of 3.33 doses / second (nearly half the target start rate of 6 doses / second). Utilizing such technology requires substantial capital investment to "number" units in succession in an attempt to achieve a target start rate of 6 doses / second.

[0012] Another problem with adding particles to non-fibrous water-soluble products is the production of non-fibrous water-soluble products.For example, one method of making non-fibrous water-soluble products is to use a continuous substrate.However, this continuous substrate is utilized to produce individual products.This means that even though the substrate is continuous, particles must be applied intermittently to create individual products.To create individual products on a continuous substrate, particles must be delivered to the substrate so that they remain primarily within a defined area, i.e., a target area.Other particle delivery devices, such as rotary feeders, are generally designed for bulk flow control and are not designed to create uniform, discrete doses.Without controlled particle delivery, this may lead to variations in the amount of particles per product, or the inability to form individual products due to particles being located within the area required for sealing.

[0013] An additional challenge in controlling particle delivery to a substrate occurs where the substrate is moving. This requires coordination between the delivery of particles to the substrate and the positioning of the substrate by the delivery mechanism. In unit dose applications, the dosing interruptions are phased with the position of uncut non-fibrous substrate product locations on the substrate to form individual units. Therefore, the timing of particle dose delivery and substrate movement must be coordinated to allow for the formation of individual units.

[0014] Furthermore, the movement of the substrate during and after particle application can exacerbate attempts to deliver particles to the desired portion of the substrate, as the particles may roll and / or fly off as they land on the moving substrate or continue to move with the substrate to complete the manufacturing process. In addition, failure to control the footprint of the particles deposited on the substrate can result in some of the particles flowing into the area used to seal the substrate and create the non-fibrous water-soluble product. While a small amount of particles in this area may be acceptable, too many particles in this area can interfere with sealing and cause product defects or poor product formation. Ideally, these issues are controlled through manufacturing conditions that do not require additional corrective steps, such as vacuuming to remove loose particles, to enable more cost-effective and rapid production of products.

[0015] In searching for a solution, the inventors were interested in finding something that could be utilized for intermittent particle delivery with the ability to precisely control particle deposition onto target areas of a substrate. Additionally, it was desired to be able to accommodate many different types of particles, not just free-flowing particles. It was also desired for the process to be insensitive to variations in production rate and product dimensions. This process solution is referred to as a traveling mask.

[0016] Generally, in a traveling mask process, a continuous supply of particles is provided, and the particles are separated into discretized doses through the use of a discretization unit having pockets (described in more detail below). The primary rate-limiting factor in a traveling mask is gravity, as gravity is the primary force used for particle deposition onto the substrate, although other forces can also be used.

[0017] Specifically, the speed at which gravity can pull particles through the discretization unit pocket onto a moving or stationary substrate is a limiting factor. Given a particular pocket design and particle type, the time it takes for a particle to progress through the discretization unit pocket onto the substrate is relatively fixed. When attempting to speed up the manufacturing process, this time can become a limiting factor in the system due to the physics of particle flow. However, the progress mask concept allows this fixed time component to be taken into account without fundamentally affecting other parameters of the system. All that needs to be done is to increase the residence time during which a given pocket is properly aligned with the substrate. In a linear manufacturing process, this requires a distance in the machine direction, which is relatively small.

[0018] The progressing mask concept also allows for the accommodation of a wider range of particles through the design of the feeding system and discretization unit. By manipulating specific properties, the system can accommodate particles exhibiting a variety of flow characteristics, from cohesive to free-flowing. This can be done while still maintaining the independence of the three main tasks performed within the system: discretization, particle flow control, and particle laydown control.

[0019] Given the ability to independently control the pocket outlet design, both through the pocket itself (e.g., shape, outlet placement, baffles, etc.) and the design of the system (e.g., height from the pocket outlet to the top of the substrate), it can essentially be designed with rapid workmanship to meet changing end-product requirements. For example, today, a water-soluble non-fibrous product may have a size of approximately 76 x 76 mm, and if the form is compressed to an area of ​​60 x 60 mm, the particles need to be applied in a smaller footprint. This can be achieved, for example, with a single design change to the pocket outlet, while keeping all other design aspects fixed.

[0020] Furthermore, while the traveling mask operation is fairly insensitive to substrate type, substrate type can play a role in particle footprint. Therefore, the properties of the target substrate can be taken into account when designing the traveling mask. For example, the coefficient of restitution between the particle and the substrate may vary depending on the substrate's properties. However, the traveling mask system can be optimized to counteract and / or work with these type characteristics. Furthermore, the substrate can be modified to aid in particle laydown and / or distribution. For example, the substrate can be at least partially coated with a material to aid in particle adhesion to the substrate and / or minimize particle bounce upon application to the substrate. This can include any material that makes the substrate itself sticky, such as water or any material that partially wets the particles and makes them sticky. These materials can be, for example, other liquid actives such as fragrances, silicones (e.g., antifoam agents), etc. The substrate can also be, for example, an adhesive. Suitable adhesives can be found in "Viscoelastic Windows of Pressure-Sensitive Adhesives," EPChang, J. Adhesion 34 (1991) 189-200. These materials can be applied to the substrate, for example, by spraying. This can be in a pattern or randomly. Additionally, a vacuum can be applied to the substrate to help draw the particles onto the substrate and / or hold the particles in place.

[0021] Therefore, what the inventors have discovered is a process for separating the discretization of a continuous supply of particles into individual doses, controlling the mass and / or volumetric flow rate of the particles, and controlling the laydown of the particles onto a substrate.

[0022] Device An apparatus for use with a progressive mask process can include, for example, a feed system and a discretization unit. Generally speaking, the feed system can be used to control the mass and / or volumetric flow rate of particles. If necessary, another task the feed system can perform is to spread the particles in the cross direction ("CD"). Meanwhile, the discretization unit receives a feed of particles and converts it into individual doses of particles.

[0023] The feeding system 300 can include, for example, a feeder 505, a conveying device 400, or a combination thereof. The discretization unit can include a conveying system, one or more pockets, a guard, or any combination thereof. The apparatus can include multiple feeding systems and / or portions of feeding systems, and multiple discretization units and / or portions of discretization units. The distance from the particle outlet of the feeding system (e.g., from the conveying device or particle feeder) to the inlet of the discretization unit can be, for example, about 0 to about 1.0 m.

[0024] When a traveling mask system is used to deposit particles onto a substrate, the substrate can be provided, for example, in the form of a roll. The substrate can be fed into the traveling mask system to receive the particles and / or be made into water-soluble unit doses containing the particles. For example, a roll of substrate can be fed into the system for delivering particles using rollers, belts, conveyors, or any combination thereof. Additionally, the substrate can be fed into and / or through the system under tension. The tension can be set, for example, through the use of a vacuum conveyor.

[0025] Supply System The feeding system may include a feeder and / or a conveying device (see FIG. 1). The feeding system 300 may include one or more feeders 505 and one or more conveying devices 400. The feeders and conveying devices may be identical or different. For example, the feeders and / or conveying devices may be arranged in a line to allow particles to be added to the same or different pockets in the discretization unit (e.g., FIG. 10). In addition, multiple feeders and / or conveying devices may provide the same or different particles. The feeders and / or conveying devices may also be arranged in a radial configuration to deliver the same or different particles (e.g., FIG. 11). The feeding system may also be configured such that one provides a first supply of particles and the other provides a second supply of particles. The first and second supply of particles may be deposited on the same or different substrates. In addition, the first and second supply of particles may be for the same or different pockets. The first and second supply of particles may be compositionally identical or different.

[0026] When utilized, the conveying device 400 conveys particles from the feeder 505 to the discretization unit 700. The conveying function of the conveying device can be passive or active depending on the system configuration. The conveying device 400 can include, for example, a belt, a slide, a trough, a tray, or a combination thereof. The conveying device can be stationary or in motion. When in motion, the motion can be rotational, reciprocating, oscillating, translating, vibrating, etc.

[0027] An example of a feeder in a feeding system is a hopper. The hopper 500 can hold particles for application onto a substrate. The hopper 500 can be of any suitable shape. For example, the hopper can have one straight vertical wall and another slanted vertical wall, as can be seen in FIG. 1. In FIG. 1, the rear wall 510 of the hopper 500 is slanted toward the front wall 520. The rear wall can be slanted, for example, at an angle of about 60 degrees or more from the horizontal. Having a slanted rear wall helps prevent backflow of particles within the hopper and helps prevent clogging.

[0028] The front wall 520 of the hopper 500 may include an opening. The opening may be, for example, a vertical slot 530 or a horizontal slot (not shown). The vertical and horizontal slots may be sized to accommodate the particles and manufacturing setup. The slots have dimensions and cross-sectional areas that can function as an extrusion process. Area (m 2 ), belt speed (m / s), and particle density to determine the volumetric flow rate (m 3 / sec) and mass flow rate can be estimated. Therefore, the slot height and width can be adjusted for optimal particle and manufacturing options.

[0029] The slots can be any suitable shape, with the most common shape being rectangular. Horizontal slots can be, for example, from about 20 mm to about 500 mm in CD, or about 25 mm in CD, with adjustable height.

[0030] The hopper can be part of a more complex feeder, such as a point source feeder or a broad front particle feeder. In these more complex feeders, the hopper can act as a particle reservoir, while another part of the feeder moves the particles from the hopper. These can include things like screw feeders, belts, or combinations thereof. Some examples of more complex feeders with hoppers include, for example, point source feeders and broad front feeders. The feeder can use motion, such as vibration and / or friction, and / or a combination of mechanisms and motion, to move the particles from the hopper.

[0031] Point source feeders and broad front feeders, alone or in combination with other components of the feed system, can distribute particles across the CD. This particle profile can cover most of the CD length in one or more pockets, or it can be split / segmented to create individual particle streams to individual discretization units. Spreading the particle stream within the CD allows, for example, two or more particle feeders to be installed side by side, thus allowing for greater production capacity.

[0032] The feeder can provide particles onto the conveying device 400 or directly to the discretization unit. The exit of the particles from the opening of the hopper 500 can be controlled, for example, with a weir 540. The weir 540 is a dam-like device that can be used to regulate the amount of particles that can exit the opening. As can be seen in Figure 3, the weir 540 can include, for example, a gate 550 that can be adjusted up or down by a mechanism.

[0033] The hopper 500 can contact a portion of the discretization unit, such as the belt 600 and / or pockets. The contact can be a press fit. A press fit is generally when the hopper or an extension of the hopper, such as an elastomeric blade, contacts a portion of the conveying device (e.g., belt) or discretization unit (e.g., pockets) to prevent or at least minimize leakage and / or spillage of particles. This allows for more control over the particles and where they exit the hopper 500.

[0034] When a conveying device is utilized, the particles can contact the conveying device as they exit a feeder such as hopper 500. When the conveying device is a belt 600, the conveying device generally preferably moves in the machine direction. However, the direction of the conveying device can be adjusted, for example, anywhere between the machine direction and a direction perpendicular to the machine direction, as needed to help most efficiently deliver the particles to the discretization unit. The speed of the conveying device can also be adjusted.

[0035] The particles can travel along a conveying device, for example, belt 600, and flow over the edge of the conveying device into discretization unit 700. If the conveying device is belt 600 or a similar device, a continuous loop can be created that picks up particles from hopper 500 and delivers them to discretization unit 700.

[0036] If no conveying device is utilized, the particles exit the feeder and enter the discretization unit.

[0037] Discretization Unit The discretization unit 700 receives a stream of particles from a feeder and / or conveyor and separates the particle stream into individual particle loads. These individual particle loads, when viewed in terms of a single-use consumer product, can be, for example, from about 0.1 g to about 30 g. The size of the individual particle loads can vary widely depending on the end product use. The discretization unit can be a single unit, multiple units in a line, multiple units in a row, or a combination of units in a line and units in a row to create an array.

[0038] The discretization unit may comprise a conveyor system, one or more pockets, a guard, or any combination thereof. The discretization unit or any part thereof may be in motion. For example, the discretization unit or any part thereof may be moving in the same direction as the belt, in the machine direction ("MD"), or in the opposite direction. Additionally, the discretization unit or any part thereof may have vertical motion.

[0039] The conveyor system can include, for example, a track. One or more pockets can be movably or statically attached to the track. The conveyor system can be utilized to move one or more pockets attached to the conveyor system. The conveyor system can move one or more pockets in a set pattern, for example, in a loop. The conveyor system can be utilized to move one or more pockets to a location where they can receive particles from a feeder and / or conveying device. The conveyor system can also move vertically, allowing movement toward or away from a feeder and / or conveying device for receiving particles into one or more pockets. The conveyor system can also move vertically to move one or more pockets closer to a substrate for particle deposition. Vertical movement can allow for better control of particle delivery to both the discretization unit and the substrate. For example, the conveyor system can bring one or more pockets near a feeder or conveying device when picking up particles, and then drop one or more pockets near a target substrate for particle application.

[0040] Additionally, the discretization unit or any portion of the discretization unit may be in contact with, for example, a feeder, a belt, a target substrate, or any combination thereof. Contact between these entities may help minimize particle spillage into or out of the pockets of the discretization unit or from the target substrate during particle transfer.

[0041] The discretization unit may include a guard. The guard can be utilized, for example, to help guide particles into and / or from the pocket onto the substrate, to help dissipate kinetic energy, splash / rebound protection, and / or laydown control. The guard can be in contact with the feeder, the conveying device, the substrate, the pocket, or any combination thereof. The guard can be attached to any portion of the discretization unit, for example, the pocket. The guard can be affixed to the pocket. The guard can be movably affixed to the pocket. For example, the guard can be in one position while the pocket receives particles and in another position when the pocket deposits particles onto the substrate. The guard can be made of a flexible material, a rigid material, or a combination thereof. For example, a portion of the guard that contacts the feeder, the conveying device, and / or the substrate can be flexible, and the remainder can be rigid.

[0042] As described above, the discretization unit 700 may include one or more pockets 710. Each pocket may have a height and a width. The height and / or width of the pocket may be adjustable. Each pocket may receive particles from a single particle stream or multiple particle streams. If from multiple particle streams, the particles may be the same or different. One or more pockets may have an inlet 720 and an outlet 730. The inlet and outlet may be different or the same. In addition, the inlet and outlet may be different sizes and / or shapes. For example, the inlet 720 may be larger than the outlet 730. In addition, the inlet may be smaller than the outlet. The outlet may have a smaller surface area than the inlet. The inlet may have a characteristic length (e.g., diameter, width, etc., depending on the shape of the inlet), such as a diameter of about 15 mm to about 150 mm, preferably about 76 mm and / or about 5 mm to about 150 mm.

[0043] One or more pockets may be in motion. The pockets may move vertically and / or horizontally. One or more pockets may move in the machine direction ("MD") or the opposite direction. One or more pockets may move in the CD direction. Additionally, any of the one or more pockets may be in contact with, for example, a feeder, a conveyor, a target substrate, another pocket, or any combination thereof. Contact with these entities may help minimize particle shedding into or from the pockets and from the target substrate.

[0044] The pockets may contact each other to minimize or eliminate gaps between two or more adjacent pockets, for example, as shown in Figure 1. The pockets may completely contact one or more sides, or may contact only a portion of one or more sides. This kissing of at least a portion of two or more pockets prevents loss of particles between the pockets, particularly while particles are being filled into one or more pockets.

[0045] The pockets can be rigid, flexible, or a combination thereof. For example, one or more of the sides of the pockets can have a flexible portion that allows for compression and / or contraction of at least one of the pockets. This compression or contraction allows two pockets to have a smaller pitch (i.e., the distance from the center of one pocket to the center of an adjacent pocket). The ability to adjust this pitch provides manufacturing flexibility to the process. For example, if there is a misalignment between the unit dose and the cutting device, the ability to adjust the pitch of one or more pockets can reduce and / or minimize this misalignment.

[0046] If the pockets are rigid and make contact while receiving particles, it is difficult to make any significant adjustments to the pitch. Another way to allow for pitch adjustment, even without pocket compression, is through the intentional design of gap space between the pockets. However, as mentioned above, leaving only gaps allows many particles to pass between the pockets, resulting in a wasteful and messy manufacturing process. While it is desirable to create some space between the pockets, flashing can be used to allow for minimal particle spillage between two adjacent pockets. An example of flashing 750 on a pocket and how it can be used to help adjust pitch can be seen in FIG. 12.

[0047] It can also be used to force particles in a given feed stream to self-segregate into one pocket or another. The pockets may contact the feeder, conveying device, and / or substrate. When the pockets contact the target substrate, they can act as guards to dissipate any kinetic energy left in the particles, which could cause the particles to bounce or otherwise move out of the intended laydown zone by falling from the feeder and / or conveying device. This implementation allows for greater specificity in the laydown of particles onto the target substrate. It can even enable particle printing, where, with appropriate design of the pocket outlets on the discretization unit (e.g., adding a screen), a pattern is created on the target substrate with particles.

[0048] The inlet 720 is a portion of the discretization unit 700 that receives particles from a feeder and / or conveying device. For example, as can be seen in FIG. 1 , multiple pockets 710 in the discretization unit travel under the conveying device, belt 600, and particles are received into one or more pockets 710 through the inlet 720. The inlet can have any acceptable shape. If it is desired that adjacent pockets be in contact to minimize particles entering between adjacent pockets, the adjacent pockets should have complementary shapes. Complementary shapes can include nesting shapes; for example, at least the portions of adjacent pockets that contact during particle delivery can be flat. The inlet of one or more pockets can be square, rectangular, hexagonal, octagonal, etc.

[0049] While it is important to slow and / or stop particle motion when applying particles to a target substrate, it is also desirable for particles to continue moving up to that point in the process. This is more important with particles that have low flowability, because particles that slow down too much or stop during their journey from the feeder to the pocket have the opportunity to form particle bridges and / or interlocking arches that can clog the feeder, conveying device, and / or pocket. The pocket can be designed to help promote particle flow and / or minimize clogging. This can be done, for example, by the shape of the pocket. The pocket can have, for example, one or more sloping sides. The pocket 710 can have any acceptable shape for particle delivery to the substrate 800. For example, one or more pockets 710 can be funnel-shaped, as can be seen in FIG. 1 .

[0050] One way to promote particle flow through the pocket is by designing the slope of one or more walls of the pocket. For example, a slope of about 70° to about 120° from horizontal can help maintain particle flow through the pocket. Exit size can also help. An exit size that is at least three times the maximum particle size of the particles to be deposited on the target substrate can help minimize bridging and / or clogging.

[0051] Additionally, the interior of the pocket may include design features, such as baffles, that may be used, for example, to direct particles to the outlet, control particle energy between the inlet and outlet, minimize clogging, etc.

[0052] Particles proceed through at least one of the one or more pockets 710 to the outlet 730, where they exit the one or more pockets 710 and are deposited on the substrate 800. The distance from the pocket outlet to the substrate can be, for example, from about -50 mm to about 50 mm. Negative values ​​correspond to when the pocket and / or guard and the substrate come into contact, and the substrate can compress and advance below the plane of the substrate to negative values. Additionally, negative values ​​represent where the pocket outlet may sink into a cavity formed in the substrate and also below the plane of the substrate.

[0053] Once the particles are deposited on the substrate, the substrate can be folded over itself to create a covering. A second substrate or substrates can be placed on the particle-containing substrate to form the covering. The second substrate or substrates used as a covering can be brought about, for example, through its own roller and unwinder. The second substrate or substrates travel along with the substrate on which the particles are deposited and are superimposed on the particle-containing substrate, for example, through a folding board, idler, etc.

[0054] Once the cover is in place, it can be sealed to the particle-containing substrate to form the unit dose. The substrate can be sealed by any conventional method, for example, heat sealing. Heat sealing can also serve as a method for separating the individual unit doses from the continuous substrate, or a separate cutting step can be utilized. If utilized, the separate cutting step can include a die cutting device.

[0055] In addition to the equipment described above with respect to the traveling mask process, additional equipment may be used to begin and / or finish the production of the final product. For example, additional equipment may include that utilized to transport the substrate from a roll through the traveling mask process and to package the formed unit dose articles.

[0056] Manufacturing Process A process for making a non-fibrous water-soluble product can include first making a non-fibrous water-soluble substrate. The substrate can be continuous or discontinuous. Once the substrate is formed, it can be provided to the process. A single substrate can be provided, or a parent substrate can be provided that is cut into multiple substrates during the manufacturing process. An example of a single substrate being formed into multiple substrates can be seen in FIG. 4. In FIG. 4, a parent continuous substrate 59 can be formed on a die block assembly 40 and then cut in the machine direction MD by a knife 70, such as a rotary cutting knife that cuts in the machine direction MD, to form a first continuous substrate 60 and a second continuous substrate 65. Cutting a second substrate from the parent continuous ply substrate 59 can be practical to provide better manufacturing quality control.

[0057] Along the lines of the apparatus described above, a process for producing a unit-dose product, such as a water-soluble non-fibrous product, can include providing one or more substrates (e.g., a first water-soluble non-fibrous substrate) to a traveling mask system in either a continuous or discontinuous manner. Exemplary process diagrams for utilizing both continuous and discrete substrates can be seen in FIGS. 1 and 2. The substrate (e.g., a water-soluble non-fibrous substrate) can be provided in roll form or any other suitable known manner. The substrate (e.g., a first water-soluble non-fibrous substrate) can be fed to the traveling mask system to receive particles thereon, for example, on a first side of the substrate (e.g., a water-soluble non-fibrous substrate). The substrate can be fed to the traveling mask system to receive particles using rollers, belts, conveyors, or any combination thereof. Additionally, the substrate can be fed into and / or passed through the system under tension. Tension can be established, for example, through the use of a vacuum conveyor.

[0058] The substrate fed into the traveling mask system can be continuously moving, discontinuously moving, or a combination thereof. The substrate can be moving in a first direction, e.g., a machine direction. The substrate can also be moving in a cross direction. The substrate can be moving at a speed of, for example, about 5 m / min to about 100 m / min. The direction of substrate movement can be determined based, for example, on the footprint of the space in which the manufacturing process operates and / or what is needed to operate the process most efficiently.

[0059] The substrate can enter, for example, a traveling mask system adjacent to the feeding system, the discretization unit, or a combination thereof. Particles are delivered to a feeding system, such as a hopper. Generally, particles are fed into the feeding system by, for example, a belt, a chute, or the like. Particles generally enter the feeding system into a feeder. Particles move from a feeder inlet, where the feeder accepts the particles, to a feeder outlet, where the particles exit the feeder. This movement of particles within the feeder can be passive, for example, through the use of gravity, or active, through the use of mechanisms and / or motion (e.g., vibration). Once the particles move to the feeder outlet, they can be distributed directly into a discretization unit for application onto the substrate, or they can be distributed onto another part of the feeding system, such as a conveying device. The feeder can control (i.e., measure) the rate at which the particles exit the feeder and / or the rate at which the particles are delivered to the next stage (e.g., the discretization unit or the conveying device). One way to control this rate is through the use of structures such as the weirs described above.

[0060] When a conveying device is utilized, the conveying device also moves particles from a portion of the conveying device itself where the particles are received to another portion where the particles are dispensed. This conveying device can control the rate at which particles move from one portion to another. It can also control the rate at which particles are dispensed from there to the discretization unit. Moreover, intermediate structures such as feeders and conveying devices can cooperate to control the rate at which particles are transferred to the discretization unit. Particles dispensed from the feeders and from the intermediate structures can be at a constant or variable rate as needed to meet the demands of the manufacturing process. This control can be either passive or active. Particles can exit the conveying device and enter the discretization unit. The flow of particles from the feeder system to the discretization unit can be continuous or discontinuous.

[0061] In one example, a feeder system includes a vibratory feeder (i.e., feeder) and a trough (i.e., conveying device). Particles are fed into the vibratory feeder, which deposits the particles in the trough. The vibratory motion of the feeder moves the particles along the trough, where they reach the end. At this point, the particles proceed to the discretization unit. This can be done by gravity, for example, the particles cascade over the end of the trough and descend toward the discretization unit.

[0062] The discretization unit can receive particles and deliver them to a substrate. This delivery can be continuous, intermittent, or a combination thereof. The discretization unit can include, for example, pockets and tracks. The track can be configured so that at least a portion of one or more pockets travel over at least a portion of a substrate, such as a water-soluble, non-fibrous substrate. In one example, the track is configured in a loop, such as a circle or ellipse (e.g., FIG. 9). In this loop configuration, one or more pockets can be in line and / or side by side. Pockets can be nested with adjacent pockets during all or part of the particle reception and / or delivery process (see, for example, FIG. 7). As the pockets travel along a path, for example, by a track, they pass through a feed system that receives the particles. The one or more pockets can be moving at a constant or variable speed as they receive the particles. The one or more pockets can be moving in the machine direction, the cross direction, or any combination thereof. The particles received from the feed system can be in a continuous stream. The ability to utilize a continuous flow of particles simplifies delivery to the discretization unit as it does not require precise coordination of timing between the feeder and the discretization unit to get the correct amount of particles in the pockets of the unit.

[0063] The use of a continuous stream of particles from a feeder can be facilitated by nesting pockets. Nesting pockets allows for the separation of a continuous particle stream into unit doses in one or more pockets. Nesting forces particles into the pockets while minimizing any particle spillage that may occur through gaps between the pockets. Thus, nesting pockets involves minimizing the gap between adjacent pockets during particle reception. This nesting can be achieved, for example, by having a predetermined distance between adjacent pockets during particle reception. This gap can be maintained during multiple stages of the particle application process, or adjacent pockets can be moved to a position with a predetermined gap at any time before receiving particles. Such a gap can be defined based on the particles (e.g., particle size, shape, and / or flowability) being received by the pocket. Two adjacent pockets may also not have an effective gap between them if their adjacent sides are in contact.

[0064] Another method for nesting adjacent pockets during particle reception is to utilize features of adjacent pockets, such as flanges and / or flashing. Such flanges and / or flashing may be positioned to effectively eliminate gaps between products during particle reception by the pockets. The flanges and / or flashing may overlap at least a portion of the entrance of the adjacent pocket, or may be positioned to align with the edge of the adjacent pocket without overlapping.

[0065] Particles can enter the pocket through the pocket inlet and exit through the pocket outlet. The height between the substrate and the pocket outlet can be any desired height. In addition, this height can be adjustable (see Figures 5-6 and 8). For example, the substrate can start at a height H1 and rise towards the pocket to a height H2 upon particle application. Furthermore, the pocket and / or at least a portion of the pocket can be raised to a height H, like a guard. P1 Starting from the HP2 At least one of the one or more pockets may move downward toward the substrate to deposit particles, or the substrate may move upward toward one or more pockets to receive particles, or a combination thereof. The substrate may be held at a fixed distance from one or more pockets and / or discretization units while beneath them. Movement of the substrate and / or pockets may be achieved, for example, by positioning cams and / or rollers.

[0066] Ideally, during particle application, at least one pocket of the discretization unit can move synchronously with the substrate, at least during particle deposition on the substrate, but may also move synchronously with the substrate before and / or after particle application. Ideally, at least the portion of the substrate on which particles are being deposited and the portion of the discretization unit that delivers the particles (e.g., the pocket outlet) are in close proximity to each other during particle application to the substrate. In practice, a portion of the pocket, e.g., the pocket outlet and / or guard, can contact the substrate any time during particle application, before particle application, after particle application, or any combination thereof. This contact may even result in substrate depression. Contact of the pocket and / or guard with the substrate can aid in particle laydown on the substrate by restricting the initial portion of the substrate for delivery to a specific area of ​​the substrate defined by the portion of the pocket and / or guard in contact with the substrate. However, contact also requires coordination between the independently moving pocket (and / or guard) and the substrate; otherwise, contact between the pocket (and / or guard) and the substrate may cause damage to the substrate.

[0067] The substrate can have a target area for particle application and / or laydown. The target area is the portion of the substrate where particle application is desired. The configuration of the travel mask can affect the ability of the delivered particles to be applied to the target area and remain within the target area. The travel mask can allow about 75% or more, about 80% or more, about 85% or more, about 90% or more, about 95% or more, or most preferably about 97% or more of the particle deposits delivered from the pocket to remain within the target area after exiting the discretization unit, e.g., the pocket outlet, or until the substrate containing the particles is covered and / or sealed. Multiple pockets can deliver particles to the same target area of ​​the substrate.

[0068] The discretization unit or part of the discretization unit may be configured to separate approximately 20 mm of the substrate to form a single dose. 2 ~approx. 10,000mm 2 The particles can be delivered over an area of ​​1000 μm. Once the particles are deposited on the substrate, the side of the substrate containing the particles can be at least partially covered. This covering can be achieved, for example, by folding a portion of the substrate over itself, and / or another substrate can be placed over at least a portion of the substrate bearing the particles. The substrate can then be sealed around the particles, trapping at least a portion of the particles between the substrate and the covering to form a non-fibrous, water-soluble product. The sealed pockets of particles can then be cut to separate them from each other and / or from the external substrate material and packaging for transport and / or use.

[0069] Non-fibrous water-soluble products The non-fibrous water-soluble product can include a water-soluble non-fibrous substrate. The substrate can be continuous or discrete, as shown in Figures 1 and 2. The non-fibrous water-soluble substrate can be utilized to form a non-fibrous water-soluble product, which is discussed in more detail below.

[0070] The non-fibrous water-soluble product can include one or more layers. These layers can be stacked on top of each other. The layers can be placed directly on top of each other, can have particles between the layers, or a combination thereof. The layers of the non-fibrous water-soluble product can include a non-fibrous water-soluble substrate, particles, or a combination thereof.

[0071] The non-fibrous water soluble unit dose article can contain 50% or more bio-derived material, for example, 50% to 95% bio-derived material. Some of the individual components of the non-fibrous water soluble unit dose article can be entirely bio-derived to create an article having a total bio-derived content of greater than 50%.

[0072] These non-fibrous, water-soluble unit dose articles are capable of dissolving under a variety of washing conditions, such as low temperatures, low water volumes, and / or short wash cycles or cycles where the consumer overloads the washing machine, especially with items having high water absorption capacity, while delivering sufficient active agent to exert the intended effect on the targeted consumer substrate (with performance similar to today's liquid products).

[0073] The surface of the non-fibrous water-soluble unit dose article may include a printed area. The printed area may cover from about 10% to about 100% of the surface of the article. The printed area may include ink, pigment, dye, bluing agent, or a mixture thereof. The printed area may be opaque, translucent, or transparent. The printed area may include a single color or multiple colors. The printed area may be present on two or more sides of the article and may include explanatory text, graphics, etc. The surface of the water-soluble unit dose article may include an aversive agent, such as a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octaacetate, quinine hydrochloride, denatonium benzoate, or mixtures thereof. Any suitable concentration of the aversive agent may be used. Suitable concentrations include, but are not limited to, 1 to 5000 ppm, or even 100 to 2500 ppm, or even 250 to 2000 ppm.

[0074] Non-fibrous water-soluble unit dose articles may, for example, exhibit a thickness of greater than 0.01 mm, and / or greater than 0.05 mm, and / or greater than 0.1 mm, and / or not greater than about 100 mm, and / or not greater than about 50 mm, and / or not greater than about 20 mm, and / or not greater than about 10 mm, and / or not greater than about 5 mm, and / or not greater than about 2 mm, and / or not greater than about 0.5 mm, and / or not greater than about 0.3 mm.

[0075] The non-fibrous water-soluble unit dose article has a density of about 500 grams / m 2 ~approximately 5,000 grams / m 2 , or about 1,000 grams / m 2 ~approximately 4,000 grams / m 2 , or about 1,500 grams / m 2 ~approximately 3,500g / m 2 , or about 2,000 grams / m 2 ~approximately 3,000 grams / m 2 , or any combination thereof.

[0076] The non-fibrous water-soluble unit dose article may exhibit different regions, for example, regions of different basis weight, density, caliper, and / or wetting characteristics. The non-fibrous water-soluble unit dose article may be compressed at the end sealing points. The non-fibrous water-soluble unit dose article may include a texture on one or more of its surfaces. The surface of the non-fibrous water-soluble unit dose article may include a pattern, such as a non-random repeating pattern. The non-fibrous water-soluble unit dose article may include apertures. The non-fibrous water-soluble unit dose article may include a non-fibrous structure having discrete regions of non-fibrous elements that are distinct from other regions of the non-fibrous elements in the structure. The non-fibrous water-soluble unit dose article may be used as is or may be coated with one or more active agents.

[0077] The non-fibrous water-soluble unit dose article may include one or more plies. The non-fibrous water-soluble unit dose article may include at least two, and / or at least three, and / or at least four, and / or at least five plies. The non-fibrous plies may be of a non-fibrous structure. Each ply may include one or more layers, for example, one or more non-fibrous element layers, one or more particle layers, and / or one or more non-fibrous element / particle mixture layers. The layers may be sealed. In particular, the particle layer and the non-fibrous element / particle mixture layer may be sealed to prevent particle leakage. The water-soluble unit dose article may include multiple plies, each including two layers, one non-fibrous element layer and one non-fibrous element / particle mixture layer, and the multiple plies are sealed together (e.g., at the edges). In addition to preventing particle leakage, the sealing may help the unit dose article maintain its original structure. However, when the water-soluble unit dose article is added to water, the unit dose article dissolves, releasing particles into the wash solution.

[0078] The non-fibrous water-soluble unit dose may be in the form of any three-dimensional structure. The non-fibrous water-soluble unit dose article may be perforated. The article may also be cut or shaped into various sizes for different uses. For example, the water-soluble unit dose may be in the form of a square, a rolled square, a kite, a rectangle, a triangle, a circle, an oval, or a mixture thereof.

[0079] A non-fiber water-soluble unit dose may contain fewer than 10 ingredients. A water-soluble unit dose may contain, for example, 3 to 9 ingredients, such as 4 ingredients, 5 ingredients, 6 ingredients, 7 ingredients, or 8 ingredients.

[0080] The non-fibrous water-soluble unit dose articles disclosed herein include a water-soluble non-fibrous substrate and one or more particles. The non-fibrous substrate can be, for example, a water-soluble film, a foam, a nonwoven fabric, or a combination thereof.

[0081] The non-fibrous substrate may be a dissolvable foam sheet and may include a polyvinyl alcohol (PVA) polymer or copolymer thereof as a film-forming agent, a carrier for any other optional ingredients such as structurants and surfactants, and other active ingredients (e.g., emulsifiers, builders, chelating agents, fragrances, colorants, etc.). The PVA polymer or copolymer is preferably present in the non-fibrous foam substrate in an amount ranging from about 5% to about 50%, preferably from about 10% to about 40%, preferably from about 15% to about 30%, more preferably from about 20% to about 25% by weight of the total weight of the non-fibrous foam substrate. Most preferably, the total amount of PVA present in the non-fibrous substrate is 25% by weight or less of the total weight of the substrate.

[0082] Suitable PVA polymers or copolymers herein are selected to have a weight average molecular weight ranging from about 50,000 to about 400,000 daltons, preferably from about 60,000 to about 300,000 daltons, more preferably from about 70,000 to about 200,000 daltons, and most preferably from about 80,000 to about 150,000 daltons, calculated by adding the average molecular weights of each polymer raw material and multiplying by their relative weight percentages based on the total weight of polymers present in the porous solid.

[0083] The non-fibrous foam substrate is preferably prepared by first forming a wet premix containing PVA, surfactant, and other optional active ingredients, subsequently forming the wet premix into a sheet, and then drying the sheet of the wet premix to form a solid non-fibrous substrate. Correspondingly, the weight average molecular weight of the PVA polymer or copolymer can affect the overall film-forming properties of the wet premix and its compatibility / incompatibility with any desired additional components. Furthermore, the weight average molecular weight of the PVA polymer or copolymer used herein can affect the viscosity of the wet premix, which in turn can affect various physical properties of the resulting non-fibrous substrate thus formed.

[0084] The PVA polymer or copolymer may be further characterized by a degree of hydrolysis ranging from about 40% to about 100%, preferably from about 50% to about 95%, more preferably from about 70% to about 92%, and most preferably from about 80% to about 90%.

[0085] The PVA copolymer may comprise a vinyl alcohol monomer and one or more monomers of any other type. Preferred PVA copolymers may comprise, in addition to the vinyl alcohol monomer, one or more anionic monomers represented by the following formulas (I) and / or (II):

[0086] [ka] (wherein R1, R2, and R3 are each independently H or methyl, and n is independently an integer from 0 to 3.) When present, the above-described anionic monomer units are preferably present in an amount ranging from about 0.5 to about 5 mol %.

[0087] Commercially available polyvinyl alcohols may include those sold under the trade name CELVOL from Celanese Corporation (Texas, USA), including but not limited to CELVOL 523, CELVOL 530, CELVOL 540, CELVOL 518, CELVOL 513, CELVOL 508, CELVOL 504, those sold under the trade names Mowiol® and POVAL™ from Kuraray Europe GmbH (Frankfurt, Germany), PVA 1788 (also referred to as PVA BP17) available from various sources including Lubon Vinylon Co. (Nanjing, China), and combinations thereof. In one embodiment, the non-fibrous substrate comprises from about 10% to about 25%, more preferably from about 15% to about 23%, by weight of the total weight of such article, of polyvinyl alcohol having a weight average molecular weight in the range of 80,000 to about 150,000 daltons and a degree of hydrolysis in the range of about 80% to about 90%.

[0088] In addition to the PVA described above, a single starch or combination of starches may be used as a filler material in an amount that reduces the overall level of PVA required, as long as it helps provide a non-fibrous substrate with the requisite structure and physical / chemical properties described herein. However, too much starch may affect the solubility and structural integrity of the non-fibrous article. Therefore, it is preferred that the non-fibrous substrate contain no more than 20% by weight of the solid sheet article, preferably 0% to 10% by weight, more preferably 0% to 5% by weight, and most preferably 0% to 1% by weight of the solid sheet article.

[0089] The non-fibrous substrate may be a film. Preferred film materials are polymeric materials. Film materials may be obtained, for example, by casting, blow molding, extrusion, or blow-extrusion of polymeric materials, as is known in the art. Preferred polymers, copolymers, or derivatives thereof suitable for use herein include polyvinyl alcohol, polyvinylpyrrolidone, polyalkylene oxide, acrylamide, acrylic acid, cellulose, cellulose ether, cellulose ester, cellulose amide, polyvinyl acetate, polycarboxylic acids and salts, polyamino acids or peptides, polyamides, polyacrylamides, maleic acid / acrylic acid copolymers, polysaccharides including starch and gelatin, and natural gums such as xanthan and caramel gum. More preferred polymers are selected from polyacrylates and water-soluble acrylate copolymers, methylcellulose, sodium carboxymethylcellulose, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropylmethylcellulose, maltodextrin, polymethacrylates, and most preferably selected from polyvinyl alcohol, polyvinyl alcohol copolymers and hydroxypropylmethylcellulose (HPMC), or combinations thereof.

[0090] Preferably, the level of polymer, e.g., PVA polymer, in the film is at least 60%. The polymer may have any weight-average molecular weight, preferably about 1,000 to 1,000,000, more preferably about 10,000 to 300,000, and even more preferably about 20,000 to 150,000. Mixtures of polymers can also be used as films. This can be beneficial for controlling the mechanical and / or dissolution properties of the compartment or film depending on the application and required requirements. Suitable mixtures include, for example, mixtures in which one polymer has higher water solubility and / or higher mechanical strength than another polymer. Also suitable are mixtures of polymers with different weight-average molecular weights, such as PVA or its copolymers with a weight-average molecular weight of about 10,000 to 40,000, preferably about 20,000. Also suitable is PVA or a copolymer thereof having a weight average molecular weight of about 100,000 to 300,000, preferably about 150,000.

[0091] Also suitable herein are polymer blend compositions containing hydrolytically degradable, water-soluble polymer blends, such as a polymer blend of polylactide and polyvinyl alcohol, typically containing about 1 to 35% by weight of polylactide and about 65 to 99% by weight of polyvinyl alcohol. Preferred for use herein are polymers that are about 60% to about 98% hydrolyzed, preferably about 80% to about 90% hydrolyzed, to improve the dissolution properties of the material.

[0092] Of course, different film materials and / or films of different thicknesses may be used herein. An advantage of selecting different films is that the resulting products and / or compartments may exhibit different solubility or release characteristics.

[0093] The most preferred film materials are the PVA films known as MonoSol product serial numbers M8630, M8900, H8779, those described in U.S. Pat. Nos. 6,166,117 and 6,787,512, which are incorporated herein by reference, and PVA films of corresponding solubility and deformation characteristics.

[0094] The film material herein may also contain one or more additive-containing components. For example, it may be beneficial to add a plasticizer such as glycerol, ethylene glycol, diethylene glycol, propylene glycol, sorbitol, and mixtures thereof. Other additives include functional detergent additives delivered to the wash water, such as organic polymer dispersants.

[0095] particle The particles may be incorporated into the fibrous water-soluble product described above, for example, at a level of about 0.1 g to about 30 g. The type of particles utilized may be any that is compatible with the manufacturing system. One parameter that may contribute to the success of particle deposition by this method is particle flowability. Particle flowability (f p ) can be defined as the ratio of the consolidation stress (cs) to the unconfined yield strength (ys). p The larger the f, the better the particle flow. p <1 is not liquidity, f p >1 but less than 2 is very cohesive, f p is considered to be cohesive when f is between 2 and 4. p is considered to be free-flowing when f is between 4 and 10. p An f of 10 or greater is considered free-flowing. In the process described above, an f of about 4 or greater is considered free-flowing. pParticles having a value of 0.05 or less are preferred. The level of fluidity can be determined by the fluidity methods listed below. The fluidity of a particle can be, for example, about 1 or more, about 2 or more, about 3 or more, about 4 or more, about 5 or more, about 5 or more, about 6 or more, about 7 or more, about 8 or more, about 9 or more, about 10 or more, or up to about 1000 or less. The particles can be powders, granules, aggregates, inclusions, microcapsules, and / or small spheres. The particles can be produced using many methods well known in the art, such as spray drying, agglomeration, extrusion, granulation, encapsulation, tableting, and combinations thereof. The shape of the particles can be in the form of a sphere, rod, dish, tube, square, rectangle, disk, star, fiber, or can have a regular or irregular random shape. The particles can have a D50 particle size of about 100 μm to about 1600 μm.

[0096] The particles may comprise a mixture of chemically different particles such as surfactant particles, including surfactant aggregates, surfactant extrudates, surfactant needles, surfactant noodles, surfactant flakes; phosphate particles; zeolite particles; silicate particles, especially sodium silicate particles; carbonate particles, especially sodium carbonate particles; polymer particles, such as carboxylate polymer particles, cellulose-based polymer particles, starch particles, polyester particles, polyamine particles, terephthalate polymer particles, polyethylene glycol particles; aesthetic particles, such as colored noodles, needles, lamellar particles and ring particles; enzyme particles, such as protease granules, amylase granules, lipase granules, cellulase granules, mannanase granules, pectate lyase granules, xyloglucanase granules, bleaching enzyme granules, and co-granules of any of these enzymes (these enzyme granules may contain sodium sulfate); bleach particles, such as percarbonate particles, especially carbonate, sulfate, silicate particles. coated percarbonate particles, such as percarbonates coated with acid salts, borosilicates, or any combination thereof; perborate particles; bleach activator particles, such as tetraacetylethylenediamine particles and / or alkyloxybenzenesulfonate particles; bleach catalyst particles, such as transition metal catalyst particles and / or isoquinolinium bleach catalyst particles; preformed peracid particles, particularly coated preformed peracid particles; filler particles, such as sulfate particles and chloride particles; clay particles, such as montmorillonite particles and clay and silicone particles; flocculating agent particles, such as polyethylene oxide particles; wax particles, such as wax aggregates; silicone particles, whitening agent particles; dye transfer inhibitor particles; dye fixative particles; perfume particles, such as perfume microcapsules and starch-encapsulated perfume accord particles, or pro-perfume particles, such as Schiff base reaction product particles; hue dye particles; chelating agent particles, such as chelating agent aggregates; and any combination thereof.

[0097] combination 1. A method for producing a water-soluble product comprising particles, the method comprising: a) providing a first continuous, water-soluble, non-fibrous substrate having a first side moving in a first direction; b) providing a discretization unit having one or more pockets having an inlet and an outlet; c) providing a first supply of first particles to the inlet of at least one of the one or more pockets; d) delivering the first particles from the outlet of the one or more pockets of the discretization unit onto at least a portion of the first side of the first continuous, water-soluble, non-fibrous substrate; and e) at least partially covering the first side of the first continuous, water-soluble, non-fibrous substrate with a covering.

[0098] 2. A method for producing a water-soluble product comprising particles, the method comprising: a) providing a first continuous, water-soluble, non-fibrous substrate moving in a first direction; b) providing a discretization unit having one or more pockets having an inlet and an outlet; c) providing a first supply of first particles to the inlet of at least one of the one or more pockets; and d) delivering the first particles from the outlet of the one or more pockets of the discretization unit onto a portion of a first side of the first continuous, water-soluble, non-fibrous substrate, wherein while receiving the first particles, at least one of the one or more pockets receiving the first particles is nested with an adjacent pocket.

[0099] 2a. The method of claim 2, further comprising at least partially covering the first side of the first continuous, water-soluble, non-fibrous substrate with a covering.

[0100] 3. The method of 1 or 2a, further comprising sealing a first continuous, water-soluble, non-fibrous substrate and a covering that traps at least a portion of the first particle between the first water-soluble substrate and the covering, wherein the covering comprises a second non-fibrous, water-soluble substrate.

[0101] 4. The method of any one of 1-3, wherein the first particles are delivered to a target area on a first side of the first continuous water-soluble substrate, and at least 75%, about 80% or more, about 85% or more, about 90% or more, about 95% or more, or most preferably about 97% or more of the first particles remain on the target area upon exiting the discretization unit.

[0102] 5. The method of claim 4, wherein a plurality of pockets provide particles to a target area.

[0103] 6. The method of any one of 1-5, further comprising providing a second supply of particles, which may be compositionally identical or different from the first supply of particles, and which may be delivered to the same one or more pockets as the first supply of particles or to one or more pockets different from the first supply of particles.

[0104] 7. The method according to any one of 1 to 6, wherein the discretization unit discretizes the continuous flow of first particles into one or more individual doses, preferably one or more pockets of the discretization unit.

[0105] 8. The method of any one of 1 to 7, wherein the outlet has a smaller surface area than the inlet.

[0106] 9. The method of any one of 1 to 8, wherein at least one pocket of the discretization unit advances synchronously with the first continuous, water-soluble, non-fibrous substrate during deposition of particles onto the first continuous, water-soluble, non-fibrous substrate.

[0107] 10. The method of any one of 1 to 9, wherein the first continuous, water-soluble, non-fibrous substrate is moving in the first direction at about 5 m / min to about 100 m / min.

[0108] 11. The method of any one of 1 to 10, wherein the first particles are delivered intermittently from the discretization unit, preferably from one or more pockets of the discretization unit.

[0109] 12. The method of any one of 1 to 11, wherein the particles have a fluidity of about 1 or more, about 2 or more, about 3 or more, about 4 or more, about 5 or more, about 5 or more, about 6 or more, about 7 or more, about 8 or more, about 9 or more, about 10 or more, to about 1000 or less.

[0110] 13. Remove the particles from the discretization unit to approximately 20 mm of the first continuous substrate to form a single dose. 2 ~approx. 10,000mm 2 13. The method of any one of 1 to 12, wherein the area is

[0111] 14. The method of any one of 1 to 13, wherein the distance from the pocket outlet to the first water-soluble non-fibrous substrate during delivery of the first particles is 0 to about 50 mm.

[0112] 15. The method of any one of 1 to 14, wherein at least two adjacent pockets are nested while receiving the first particle.

[0113] 16. The method of claim 15, wherein at least one of the adjacent pockets includes a flashing on the side of the pocket closest to the adjacent pocket, the flashing overlapping a portion of the entrance of the adjacent pocket.

[0114] 17. The method of any one of 1 to 16, wherein one or more pockets move at a constant speed in a first direction while receiving particles, or a combination thereof.

[0115] 18. The method of any one of 1-17, wherein the first water-soluble non-fibrous substrate is held at a fixed distance from the discretization unit while underneath the discretization unit.

[0116] 19. The method of any one of 1-17, wherein at least one of the one or more pockets moves downward toward the first water-soluble, non-fibrous substrate to deposit the first particles, or the first water-soluble, non-fibrous substrate moves upward toward the one or more pockets to receive the first particles, or a combination thereof.

[0117] 20. The method of any one of claims 1 to 19, wherein one or more pockets move in a loop.

[0118] 21. The method of any one of claims 1-20, wherein the water-soluble non-fibrous web comprises a foam, a film, a nonwoven, or a combination thereof.

[0119] liquidity method The following comparative tests are performed to demonstrate particle flowability at ambient temperature and humidity.

[0120] The device adapted for this test is a commercially available flowability testing system, Flodex™ (Teledyne Hanson Research, Chatsworth, Calif., USA), which includes a flat-bottomed cylindrical hopper with a removable bottom and a set of interchangeable bottom disks containing different sized orifices therein. Additionally, additional bottom disks with smaller sized orifices (having diameters below 4 mm) are fabricated to provide a more complete range of orifice diameters, including 3 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 12 mm, 14 mm, 16 mm, 18 mm, and up to 34 mm.

[0121] The Flodex™ instrument includes a funnel for loading a particulate test sample into a stainless steel, flat-bottomed, cylindrical hopper having a diameter of approximately 5.7 cm. The hopper has a removable bottom defined by a removal bottom disk having a specific sized orifice therein. As described above, multiple removal bottom disks having different sized orifices are provided and can be interchangeably attached to the bottom of the hopper in place of the disk to define different sized bottom orifices. A discharge gate is positioned directly below the orifice and above the receiver. When a flowability measurement is initiated, the discharge gate is moved to expose the bottom orifice, allowing the particulate test sample to flow from the hopper through the bottom orifice and into the receiver.

[0122] To test the flowability of a particular test sample, the following steps are followed. Fill the hopper by pouring approximately 75 ml of test sample through the funnel, which corresponds to approximately a 1 inch (25 mm) layer of powder in the cylindrical hopper. b. After the sample has settled for 30 seconds, the spring-loaded discharge gate is opened, allowing the sample to flow through the orifice into the receiver. c. Steps (a) and (b) are repeated for the same test sample using different bottom disks with orifices of gradually increasing orifice size. When a bottom disk with a relatively small orifice is used initially, the flow of the test sample typically stops at some point due to clogging, i.e., the test sample is unable to pass through the orifice due to the small orifice size. Once the test sample flow stops, a clogging is declared, and the particular bottom disk that caused the clogging is removed and replaced with another bottom disk with a slightly larger orifice for another repetition of steps (a) and (b). When the test sample can flow completely through a particular size orifice three consecutive times without clogging, such orifice size is recorded as the Flodex™ blockage parameter, where B refers to the diameter of the orifice in the flow disk used in the test. The smaller the Flodex™ blockage parameter, the better the test sample's flowability (i.e., it can flow through a smaller orifice without clogging).

[0123] Liquidity is calculated according to the following equation:

[0124]

number

[0125]

number

[0126] The dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0127] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest, or disclose, either alone or in combination with any other reference or references, any such invention. Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall control.

[0128] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. 1. A method for producing a water-soluble product comprising particles, comprising: a) providing a first continuous water-soluble non-fibrous substrate having a first side moving in a first direction; b) providing a discretization unit comprising one or more pockets having an inlet and an outlet; c) providing a first supply of first particles to the inlet of at least one of the one or more pockets; d) delivering the first particles from the outlet of the one or more pockets of the discretization unit onto at least a portion of the first side of the first continuous, water-soluble, non-fibrous substrate; e) at least partially covering the first side of the first continuous, water-soluble, non-fibrous substrate with a covering.

2. 10. The method of claim 1, further comprising sealing the first continuous, water-soluble, non-fibrous substrate and the covering to trap at least a portion of the first particles between the first water-soluble substrate and the covering, the covering comprising a second non-fibrous, water-soluble substrate.

3. 3. The method of claim 1 or 2, wherein the first particles are delivered to a target area on the first side of the first continuous water-soluble substrate, and at least 75%, preferably 80% or more, more preferably 85% or more, even more preferably 90% or more, even more preferably 95% or more, or most preferably 97% or more of the first particles remain on the target area upon exiting the discretization unit.

4. 4. The method of any one of claims 1 to 3, further comprising providing a second supply of particles, which may be compositionally identical or compositionally different from the first supply of particles, and which may be delivered to the same one or more pockets as the first supply of particles or to one or more pockets different from the first supply of particles.

5. The method of any one of claims 1 to 4, wherein the discretization unit discretizes the continuous stream of first particles into one or more individual doses.

6. The method of any one of claims 1 to 5, wherein the outlet has a smaller surface area than the inlet.

7. 7. The method of any one of claims 1 to 6, wherein at least one pocket of the discretization unit advances synchronously with the first continuous, water-soluble, non-fibrous substrate during deposition of the particles onto the first continuous, water-soluble, non-fibrous substrate.

8. The method according to any one of claims 1 to 7, wherein the first particles are delivered intermittently from the discretization unit, preferably from the one or more pockets.

9. The method according to any one of claims 1 to 8, wherein the particles have a flowability of about 1 or greater, preferably as measured according to a flowability method.

10. The particles are then spaced from the discretization unit to about 20 mm of the first continuous substrate to form a single dose. ２ ~ Approximately 10,000 mm ２ 10. The method of any one of claims 1 to 9, wherein the area is

11. 11. The method of any one of claims 1 to 10, wherein the distance from the pocket outlet to the first water-soluble, non-fibrous substrate during delivery of the first particles is 0 to 50 mm.

12. The method of any one of claims 1 to 11, wherein at least two adjacent pockets are nested while receiving the first particles.

13. 13. The method of any one of claims 1 to 12, wherein at least one of the adjacent pockets comprises flashing on a side of the pocket closest to the adjacent pocket, the flashing overlapping a portion of the entrance of the adjacent pocket.

14. 14. The method of any one of claims 1 to 13, wherein while receiving particles, the one or more pockets move in the first direction, move at a constant velocity, or a combination thereof.

15. 15. The method of any one of claims 1 to 14, wherein at least one of the one or more pockets moves downward toward the first water-soluble, non-fibrous substrate to deposit the first particles, or the first water-soluble, non-fibrous substrate moves upward toward the one or more pockets to receive the first particles, or a combination thereof.

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