Process for producing non-fibrous, water-soluble products

Abstract

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

Description

[Technical Field]

[0001] A process for producing non-fibrous, water-soluble products using discretized elements. [Background technology]

[0002] Non-fibrous water-soluble pouches are highly desired by consumers. These non-fibrous water-soluble products are easy to use because consumers can easily and simply administer the desired number of products to their desired processes. This is far easier than having to inject liquids or powders into processes where accurately administering the correct amount of active substance can be very difficult and may even be physically difficult for some consumers.

[0003] The process for manufacturing non-fibrous water-soluble products is complex, requiring numerous steps to form the non-fibrous water-soluble product and to efficiently and consistently dispense the required amount of particle-like components into the product.

[0004] Typically, a first non-fibrous, water-soluble film is formed in the cavity into which bulk particles, such as a detergent composition, are administered, and the cavity is sealed by a second non-fibrous, water-soluble film. The process of administering particles into the cavity can be inefficient, and controlling the consistency of the chemicals administered into the cavity can be difficult. This is particularly problematic for components such as enzymes, which are typically present only at very low levels in the detergent composition. [Overview of the project] [Problems that the invention aims to solve]

[0005] Therefore, there remains an unmet need for a process to efficiently produce non-fibrous, water-soluble unit-dose products containing particles. [Means for solving the problem]

[0006] This specification includes a method for producing a non-fibrous water-soluble product containing particles, comprising: a) providing a first continuous water-soluble non-fibrous substrate having a first side and moving in a first direction; b) providing a discretization unit having one or more pockets having an opening; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket opening to at least partially fill at least one of the one or more pockets; d) delivering the first particles from the pocket through the opening onto 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.

[0007] Furthermore, this specification includes a method for producing a non-fibrous water-soluble product containing particles, comprising: a) providing a first continuous water-soluble non-fibrous substrate having a first side surface and moving in a first direction; b) providing a discretization unit having one or more pockets having openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket openings; d) intermittently delivering the first particles from the pocket openings onto a portion of the first side surface of the first continuous water-soluble non-fibrous substrate; e) measuring the first particles to a target dose; and f) at least partially covering the first side surface of the first continuous water-soluble non-fibrous substrate.

[0008] These and other iterations will be explained in more detail below. [Brief explanation of the drawing]

[0009] [Figure 1] This is a representation of a discretized element that has pockets. [Figure 2] This is a representation of the status. [Figure 3] This is an exploded view of the discretized elements and the stator. [Figure 4] This is a representation of the combination of a stator and a hopper. [Figure 5]It is a graph showing the administration time with respect to the angle from the horizontal at the stator outlet. [Figure 6] It is a cross-sectional view of the discretized element and the stator. [Figure 7] It is the time course of the cross-sectional view of the discretized element and the stator.

DETAILED DESCRIPTION OF THE INVENTION

[0010] The production of non-fibrous water-soluble products can be a delicate balance of materials and processing to achieve the desired final product, functionality, performance, and meet the economic requirements for mass production. Conventional methods of administering particles onto a non-fibrous substrate have been complex. Despite the difficulties associated with known manufacturing methods, it is still desired to be able to load larger amounts of particles, different types of particles, control where the particles are located within the non-fibrous water-soluble product, and do so in an economically feasible way. This allows for greater product flexibility. In a review of possible solutions in the industry, an intermittent particle applicator that could meet the basic requirements of dosing frequency, individual dose mass (mass flow rate), application area, and manufacturing flexibility within practical limits was not identified. For example, the application of a auger-type intermittent particle filler is typically limited to an operating frequency of 3.33 doses / second (approximately half of the target starting rate of 6 doses / second). Utilizing such technology requires a substantial capital investment for continuously "numbering" the units for trials to achieve the target starting rate of 6 doses / second.

[0011] Another challenge associated with adding particles to non-fibrous water-soluble products lies in the manufacturing of these products. For example, one method of producing non-fibrous water-soluble products is to use a continuous substrate. However, this continuous substrate is used to manufacture individual products. This means that even though the substrate is continuous, particles need to be applied intermittently to produce individual products. To produce individual products on a continuous substrate, particles need to be delivered to the substrate so that the particles remain primarily within a specified area. Other devices for delivering particles, such as rotary feeders, are generally designed for bulk flow control and not for producing uniform, discretized doses. Without controlled particle delivery, this can lead to variations in the amount of particles from product to product, or the inability to deliver particles in distinct doses to enable the formation of distinct products.

[0012] A further challenge in controlling particle delivery to a substrate arises when the substrate is moving. This requires coordination between particle delivery to the substrate and the positioning of the substrate. Intermittent dosing must be synchronized with the position and phase of the uncut, non-fibrous substrate product on the substrate. Therefore, the timing of dosing and the movement of the substrate must be coordinated.

[0013] Furthermore, the movement of the substrate can worsen attempts to deliver particles to the desired portion of the substrate, as particles may rotate and / or scatter as they land on the moving substrate. In addition, if the contact area of ​​particles deposited on the substrate cannot be controlled, some particles may flow into the area used to seal the substrate and produce a non-fibrous, water-soluble product. While a small amount of particles in this area may be acceptable, too many particles in this area may interfere with sealing and lead to product defects or poor product formation. Ideally, these problems should be controlled through manufacturing conditions that do not require additional corrective steps such as vacuuming to remove free particles, in order to enable more cost-effective and rapid production of the product.

[0014] In searching for a solution, the inventors were interested in finding something that could be adapted to intermittent particle delivery. One possible solution was the use of a gravure applicator; however, gravure applicators are most commonly known for gravure printing, which involves liquids rather than particles. In the gravure printing process, an image is machined into the surface of a metal cylinder. These recesses are very small microcavities that contain ink. The ink is, in most cases, placed in an ink tray that is in contact with the cylinder to pick up the ink, and then the ink is transferred onto the substrate by pressing the cylinder against the substrate. The dimensions of the cavities and the contact between the inked gravure and the substrate are designed so that the dominant force governing mass transfer is surface tension / capillary force / compressive force. In addition, gravure printing is highly dependent on ink viscosity, substrate velocity, and the pressure applied between the gravure applicator and the substrate to facilitate the gravure printing process. In this application, since particles cannot be applied in the same manner, it is impossible to directly apply a gravure-type applicator, and conventional gravure processes required significant modifications to achieve the desired manufacturing.

[0015] Firstly, the scale is adapted to accommodate particle delivery from a gravure applicator. Microcavities are removed, and larger pockets are incorporated on the applicator (i.e., the discretization element). The use of larger pockets makes it possible to accommodate both smaller and larger particles at the desired level for addition to a non-fibrous substrate. In addition, it is desirable to have the flexibility to dynamically change the amount of material administered using fixed pockets on the discretization element. Unlike conventional gravure rotors, which are almost always locked to the desired image to be printed, the use of oversized pockets on the discretization element allows for the use of inserts to adjust the particle dosage as desired, without the need to replace the entire discretization element. Oversized pockets also allow for undesirable voids in printing applications.

[0016] In addition, physical contact between the gravure applicator and the target substrate must be eliminated because contact between the discretizing elements and the substrate can damage the substrate. If there is no physical contact between the discretizing elements and the substrate, a process for transferring particles to the substrate is required, different from that used in conventional gravure processes. The primary means for transferring particles from the discretizing elements and the substrate may be gravity with appropriate settings.

[0017] A stationary component, such as a stator, can be utilized to facilitate the use of gravity as a compressive force, thereby depositing particles from the discretization element onto the substrate. While a stator is not required in conventional gravure processes, it can be useful in several ways as described herein. For example, a stator can be used to direct the entry of particles into and exit from the discretization element. In addition, the location of the stator inlet can be optimized to help minimize the amount of particles entering the annular space between the stator and the discretization element. Furthermore, the location of the stator exit can influence how particles are deposited on the substrate and the area of ​​contact of those particles on the substrate. The use of a stator represents a significant departure from conventional gravure printing processes.

[0018] As can be seen from the above description, generally, while utilizing the concept of the gravure process, the inventors have made significant modifications to accommodate such systems for use in non-contact environments with particles.

[0019] Manufacturing process As described above, a process for manufacturing a substrate having particles may have two main elements: a discretizing element 200 and a stator 300. The discretizing element 200 can help to acquire a flow of particles and convert it into discrete particle units. An example of the discretizing element 200 can be seen in Figure 1. The discretizing element 200 can then deliver these discretized particle units to the substrate. This function can be achieved, for example, by including a pocket 210 on the discretizing element 200 for receiving particles.

[0020] The discretization element 200 may have one or more pockets 210. The pockets may be fixed to the discretization element, i.e., the pockets do not move away from the discretization element. The number of pockets 210 can be optimized based on the desired and / or operable size of the discretization element 200. They can also be optimized based on the desired delivery of particles onto the substrate. For example, the pockets may be side by side or from top to bottom to allow for the delivery of multiple particle loads simultaneously. These particle loads may be the same or different. The discretization element may include, for example, about 1 to about 20 pockets, about 2 to about 20 pockets, about 3 to about 20 pockets, about 5 to about 18 pockets, about 6 to about 16, about 8 to about 16, about 8 to about 12, or any combination thereof.

[0021] The locations of the pockets 210 on the discretization element 200 can be equidistant, for example, around the circumference of the discretization element. When operating at a fixed speed, non-equal distances between pockets can result in a periodic and / or non-constant motion profile relative to the discretization element, which can be difficult to control and adjust at high operating speeds; therefore, equidistant pocket locations on the discretization element are preferable. They can also cause timing problems for the entry and / or exit of particles from the pockets.

[0022] The pockets 210 on the discretization element 200 can be sized as required for the desired dose. This may include dimensions in the transverse direction, mechanical direction, and depth. The transverse direction aligns with the axis of rotation of the discretization element. With respect to the transverse direction, this can contribute to the width of the particle contact area when the particles are placed on the substrate. The wider the pocket in the transverse direction, the wider the contact area of ​​the particles on the substrate. The transverse dimensions can also affect the entry and exit of particles from the pockets. Larger transverse dimensions allow for faster release of particles onto the substrate and entry of particles into the pockets. These may be important parameters to consider when assembling a particle delivery system. Desired transverse dimensions of the pockets may be, for example, about 1 mm to about 100 mm, about 3 mm to about 95 mm, about 10 mm to about 90 mm, about 20 mm to about 50 mm, about 25 mm to about 40 mm, or any combination thereof.

[0023] The machine direction is perpendicular to the transverse direction. The dimensions of the pocket in the machine direction can also contribute to the contact area of ​​the particles on the substrate. The longer the machine direction dimension, the greater the potential contact area of ​​the particles on the substrate. Therefore, the machine direction dimension can be limited based on the desired particle contact area. The machine direction dimension can also affect the entry of particles into and exit of the pockets. Desired machine direction dimensions of the pockets may be, for example, about 1 mm to about 100 mm, about 3 mm to about 95 mm, about 10 mm to about 90 mm, about 20 mm to about 50 mm, about 25 mm to about 40 mm, about 10 mm to about 15 mm, about 8 mm to about 12 mm, or any combination thereof.

[0024] There are additional considerations regarding the machine direction dimensions. The machine direction dimensions, combined with the stator inlet size, help define the pocket exposure time for particle feeding. For a given discretization unit rotation speed, an increase in the machine direction dimensions allows the pockets to "fill for more time" with particles. Therefore, this is a balance between machine direction dimensions that are long enough to properly fill with particles and machine direction dimensions that are small enough not to contribute to unnecessarily long dosing times.

[0025] The pockets also have depth. The depth can be optimized to allow particles to enter and exit. The depth of the pockets can also be optimized considering particle entry and air release from the pockets. The minimum depth is preferably such that particles can be contained within the pockets and particle shearing on the stator is minimized. For example, the pockets may have a depth of about 1 to about 25 mm, preferably about 2 to about 15 mm, or about 3 to about 10 mm. Particle shearing can cause sanitary problems in the system and can lead to malfunction over time.

[0026] The pockets may also have a certain shape. The shape can be any shape that satisfies the need for the desired particle delivery. For example, a pocket may be a rectangular prism, cube, cone, pyramid, concave "v", divot, or cylindrical, and may have a triangular cross-section, a rectangular cross-section, or any combination thereof. For example, a grid of depressions may be a repeating pattern on the circumference of the discretized elements. In this pattern, for example, a 5x5 grid may be a unit dose, and each unit dose may replace a single pocket. If the pockets are depressions, the number of pockets may be much larger than those mentioned above, for example, there may be several hundred to several thousand depressions. For elongated particles such as prills, a preferred shape may be a concave "v". In addition, the interior of the pockets may be textured.

[0027] The discretization element 200 can also have the function of a metering device. In this configuration, the pocket 210 or set of pockets that are used together to create a unit dose on the discretization element 200 is the exact volume of the target dose of particles. If the discretization element 200 is not also metering, the pocket 210 is likely to be oversized relative to the target dose, and a separate metering device such as a weigh feeder can be utilized to meter the flow of particles into the pocket 210 of the discretization element 200. The target dose of the discretization element pocket can be by weight or by volume. Using particles can be more accurate because the density of the particles can vary from particle to particle. The target dose in weight can be, for example, from about 0.1 g to about 15 g, from about 0.2 g to about 15 g, from about 0.3 g to about 10 g, from about 0.4 g to about 8 g, from about 0.1 g to about 4.0 g. The target dose with respect to volume can be, for example, from about 0.1 cm 3 to about 8 cm 3 , from about 0.1 cm 3 to about 7 cm 3 , from about 0.1 cm 3 to about 6 cm 3 , from about 0.1 cm 3 to about 5 cm 3 and from about 0.1 cm 3 to about 4.0 cm 3 , or any combination thereof.

[0028] The discretizing element is movable and preferably rotates. The discretizing element may rotate at a speed of, for example, about 10 rpm to about 100 rpm. The discretizing element 200 may be a rotor. The rotor can generally be described as a rotating assembly. It is generally a driven element controlled by a motor. The rotor can be rotated at a desired speed. The speed may be uniform or variable. The speed contributes to the residence time of the pockets while particles enter them. When utilizing non-uniform speeds, the discretizing element may be decelerated to allow particles to enter from the stator inlet and then accelerated to pass through the portion of the discretizing element without pockets. Similarly, the discretizing element may be accelerated to capture fewer particles at the stator inlet and then decelerated to pass through the portion of the discretizing element without pockets. The same applies to the exit of the discretizing element from the pockets. The discretizing elements may be accelerated or decelerated at the particle exit point to correspond to a desired particle placement area on the substrate, or to facilitate timing coordination of the dose on the substrate.

[0029] The rotor can be uniform or non-uniform depending on the desired configuration. The advantage of a highly uniform rotor is that it allows the process to operate at a set speed to achieve the desired unit target per minute. It also allows for better control of the annular space between the discretization element and the stator. Rotors with varying pocket spacings can also be utilized, including their motion profiles with respect to rotational speed.

[0030] The following elements for the particle delivery system may include a stator 300. An example of a stator can be seen in Figure 2, and an exploded view of the stator 300 and discretization element 200 can be seen in Figure 3. The stator 300 may include one or more particle inlets 310. The stator 300 can control the flow of particles from the discretization element 200 into the pockets 210. This can be done, for example, by the design of the particle inlets 310. The dimensions, shape, and location of the inlets 310 on the circumference of the stator 300 may affect the efficiency of filling the discretization element pockets 210 with particles. For example, as mentioned above, increasing the stator inlet opening increases the ability to fill the pockets at higher rotational speeds. For example, by changing the length of the stator inlet opening from 6 mm (in the rotational direction) to about 17 mm, the maximum rate of total pocket dose administration increased from about 2 doses / second to 8 doses / second without any other changes.

[0031] The stator 300 may be a housing for the discretization elements 200 and may be positioned around the discretization elements 200 (see Figures 3 and 4). The position of the stator relative to the discretization elements also contributes to another parameter—the annular space between the discretization elements and the stator. The specifications and tolerances of this component can ensure minimal particle movement into this annular space, which may then contribute to particle shearing / breakage, surface contamination, and / or clogging. Additional mechanisms may be added to help prevent or minimize particle entry into the annular space, for example, by utilizing mechanical sealing or blades to prevent particles from entering the gap between the discretization elements and the stator.

[0032] The annular space between the discretization element and the stator can be adjusted as needed, for example, depending on the size of the particles deposited on the substrate, machining constraints, cost, and feasibility of assembly. The annular space may be, for example, about 10 μm to about 125 μm, about 20 μm to about 100 μm, about 20 μm to about 90 μm, about 30 μm to about 80 μm, about 40 μm to about 80 μm, about 50 μm to about 75 μm, or any combination thereof.

[0033] Another way to minimize the amount of particles entering the annular space is to minimize contact between the particles and the annular space. This can be done by positioning the stator inlet so that it delivers particles to a discretizing element descending from a pinch point. The location of the pinch point is determined by the stator inlet wall and the rotational direction of the discretizing element. A visualization of this concept can be seen in Figure 6, which shows a cross-section of the stator and the discretizing element that deposits particles on the substrate 700. The pinch point is shown on the left-hand representation, and the right-hand representation shows how moving the stator inlet to the descending position minimizes the impact of particles on the pinch point (i.e., the annular space). This minimization helps to keep the integrity of the particles intact, which is especially important for particles that benefit upon rupture, such as fragrance microcapsules. Minimization also helps to prevent the generation of fine particles through a shearing process that alters the particle size distribution of the particles deposited on the substrate.

[0034] Additional features of the stator 300 may include the dimensions and location of the outlet 320 along the circumference of the stator. The outlet design, combined with the pocket geometry of the discretized elements, can primarily contribute to the laydown of particles on the substrate. For example, slight modifications to the stator outlet design can dramatically increase or decrease the particle discharge time from the gravure process, which, when combined with the moving substrate, directly leads to a modification of the particle laydown footprint on the substrate. In particular, a stator opening at approximately 45 degrees from the horizontal provides the optimal minimum discharge time for most particles, as can be seen in Figure 5. It is also beneficial to design the stator outlet so that the final portion of particles exiting the stator outlet has a trajectory that is not primarily downward but rather in the mechanical direction of the substrate. The net effect is that it provides the economic advantage of reducing the overall particle footprint, speeding up the process, and allowing for a better footprint on the substrate.

[0035] These discretization elements and stators can be incorporated into processes for producing non-fibrous, water-soluble products, as described below.

[0036] Method for producing a non-fibrous, water-soluble product containing particles A process for producing a non-fibrous water-soluble product may first include producing a non-fibrous water-soluble substrate. The substrate may be continuous or discontinuous. A description of a process for producing a water-soluble non-fibrous substrate can be found, for example, in U.S. Patent No. 10,683,618, which is incorporated herein by reference.

[0037] Once a substrate is formed, it can be supplied to the process. A single substrate may be supplied, multiple substrates, or even a parent substrate that is cut into multiple substrates during the manufacturing process. Whether starting with two substrates, a single substrate, or a parent substrate that is separated into multiple distinct substrates, particles can be added to the substrate using a discretizing element 200 and a stator 300. The particles are supplied to a hopper 400, where they are supplied to the stator 300. At least a portion of the particles pass through the stator inlet 310 into the discretizing element pocket 210. The discretizing element pocket 210 can be fully or partially filled with particles. The discretizing element pocket can be sized to measure a dose. In this implementation, the discretizing element pocket dimensions determine the volume of the dose. This dose volume can be changed, for example, by changing the discretizing element to one with pockets of different sizes, or, for example, by adding pocket inserts to adjust to a desired volume. The dose can also be measured upstream of the discretizing element, for example, by a weighing device. In this execution, the discretized element pocket may be oversized and then filled to a target dose, as controlled by a metering device.

[0038] The substrate may have a target area for particle application and / or laydown. The target area is the portion of the substrate to which particle application is desired. The configuration of the gravure apparatus may affect the skill with which delivered particles are applied to and remain within the target area. The gravure process 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 deposited particles delivered from the pocket to remain within the target area after exiting a discretization unit, e.g., the pocket opening, 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.

[0039] As can be seen in Figures 6 and 7, the discretizing element rotates to bring the particles to the stator exit. The discretizing element may rotate in either the same direction as the substrate (preferably) or in the opposite direction to the substrate. The particles exit the discretizing element pocket, pass through the stator exit, and are deposited on the substrate. The substrate may be stationary or in motion during the deposition process. For example, the substrate may be moving at a speed of about 15 meters per minute or more, about 20 meters per minute or more, about 25 meters per minute or more, about 30 meters per minute or more, or preferably about 30 m / min to about 60 m / min. Gravity may help the particles exit the discretizing element pocket and deposit on the substrate located beneath the discretizing element.

[0040] The substrate can be at any reasonable distance from the stator outlet. Generally, this distance is kept to a minimum to reduce particle velocity and, therefore, the bounce of particles when they come into contact with the substrate. The distance from the stator outlet to the substrate should not be too close, otherwise it may scrape the substrate. In one example, a target distance of about 1 cm from the stator outlet to the substrate surface is used. In addition, an airflow through the substrate, a vacuum through the substrate, or an air curtain can be used to help contain the bounce or movement of particles when they come into contact with the substrate. Furthermore, the substrate may be at least partially coated with a material to help the particles adhere to the substrate and / or to minimize the bounce of particles when applied to the substrate. This may include any material that makes the substrate itself sticky, such as water or any material that partially wets the particles and makes the particles themselves sticky. These materials may be other liquid active substances such as fragrances or silicones (e.g., defoamers). This substrate may also be an adhesive, for example. 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 random.

[0041] Once the particles are positioned on the substrate, a second portion of the substrate or a second substrate is positioned on the first substrate on which the particles are deposited. Once one or more substrates are positioned as desired, they can be bonded to each other, for example, by thermal bonding. Thermal bonding may be practical if one or more of the layers contain thermoplastic powder, optionally, a water-soluble thermoplastic material. Thermal bonding may also be practical if the fibers constituting one or more of the substrates are thermoplastic. The substrates may optionally be bonded by calendering, point bonding, ultrasonic bonding, infrared bonding, air bonding, needle punching, water flow entanglement, melt bonding, adhesive bonding, or any other known technical method for bonding layers of material.

[0042] The water-soluble products 5 can be separated from each other by a die cutter 160, and optionally by a rotary die cutter 160. The rotary die cutter 160 comprises a die roll and an anvil roll, the die roll and anvil rotating in opposite directions to each other.

[0043] Substrates can be joined together and die-cut in a single process using a reciprocating joiner and die-cutting apparatus, or a single rotary joiner and die-cutting apparatus. In a rotary joiner and die-cutting apparatus that combines joining and die-cutting, the die is shaped to provide a die-cut that grips the material to be cut between the knife edge of the die and the smooth surface of the anvil. Furthermore, the die is shaped to compress together parts of a product or continuous substrate, and their layers, to join them together. The die may be a patterned die that provides cutting and joining patterns to plies, continuous ply substrates, and their layers. Optionally, the die can be heated, which may be practical for thermal bonding.

[0044] For economic viability, the manufacturing process can have a target minimum number of non-fibrous water-soluble products per second. This could be, for example, about 6 water-soluble product doses per second. The manufacturing process can have a target of about 100 to 1000 doses per minute per lane.

[0045] Non-fibrous water-soluble products Non-fibrous water-soluble products may include water-soluble non-fibrous substrates. The substrates may be continuous or individual, as shown in Figures 1 and 2. Non-fibrous water-soluble substrates can be used to form non-fibrous water-soluble products, which will be discussed in more detail below.

[0046] Non-fibrous water-soluble products may contain one or more layers. These layers may be stacked on top of each other. The layers may be placed directly on top of each other, may have particles between the layers, or may be a combination thereof. The layers of the non-fibrous water-soluble product may contain a non-fibrous water-soluble substrate, particles, or a combination thereof.

[0047] Non-fibrous, water-soluble unit-dose articles may contain 50% or more bio-derived materials, for example, 50% to 95% bio-derived materials. Some of the individual components of non-fibrous, water-soluble unit-dose articles may be entirely bio-derived in order to produce articles with a total bio-derived content of more than 50%.

[0048] These non-fibrous, water-soluble unit-dose articles can dissolve under various washing conditions, such as low temperature, low water volume, and / or short wash cycles, or cycles in which consumers overload washing machines with items that have particularly high water absorption capacity, while simultaneously delivering sufficient activators to the target consumer substrate to exert the intended effect (with performance similar to today's liquid products).

[0049] The surface of a non-fibrous, water-soluble unit-dose article may include a printed area. The printed area may cover approximately 10% to approximately 100% of the article's surface. The printed area may include inks, pigments, dyes, bluers, or mixtures thereof. The printed area may be opaque, translucent, or transparent. The printed area may include one color or multiple colors. The printed area may be present on two or more sides of the article and may include explanatory text, diagrams, etc. The surface of a water-soluble unit-dose article may contain an aversive agent, such as a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octaacetic acid, 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 more specifically, 100 to 2500 ppm, or more specifically, 250 to 2000 ppm.

[0050] Non-fibrous water-soluble unit-dose articles may have thicknesses of, for example, more than 0.01 mm and / or more than 0.05 mm and / or more than 0.1 mm and / or about 100 mm or less and / or about 50 mm or less and / or about 20 mm or less and / or about 10 mm or less and / or about 5 mm or less and / or about 2 mm or less and / or about 0.5 mm or less and / or about 0.3 mm or less.

[0051] The non-fibrous, water-soluble unit dose article is approximately 500 grams / m². 2 ~Approximately 5,000 grams / m 2 , or approximately 1,000 grams / m 2 ~Approximately 4,000 grams / m 2 , or approximately 1,500 grams / m 2 ~Approximately 3,500 grams / m 2 , or approximately 2,000 grams / m 2 ~Approximately 3,000 grams / m 2 It may have basis weights of any combination thereof.

[0052] Non-fibrous water-soluble unit-dose articles may exhibit different regions, such as different basis weights, densities, calipers, and / or wettability characteristics. Non-fibrous water-soluble unit-dose articles may be compressed at end sealing points. Non-fibrous water-soluble unit-dose articles may have weaves on one or more of their surfaces. The surfaces of non-fibrous water-soluble unit-dose articles may have patterns, such as non-random repeating patterns. Non-fibrous water-soluble unit-dose articles may have openings. Non-fibrous water-soluble unit-dose articles may include non-fibrous structures having separate regions of non-fibrous elements distinct from other regions of non-fibrous elements in the structure. Non-fibrous water-soluble unit-dose articles may be used as is or coated with one or more activators.

[0053] A non-fibrous water-soluble unit-dose article may contain one or more prisms. A non-fibrous water-soluble unit-dose article may contain at least two, and / or at least three, and / or at least four, and / or at least five prisms. A non-fibrous ply may be a non-fibrous structure. Each ply may contain one or more layers, e.g., 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 layers and non-fibrous element / particle mixture layers may be sealed to prevent particle leakage. A water-soluble unit-dose article may contain multiple prisms, each ply containing two layers, one of which is a non-fibrous element layer and the other is a non-fibrous element / particle mixture layer, and the multiple prisms may be sealed together (e.g., at the edges). Sealing may help the unit-dose article maintain its original structure in addition to preventing particle leakage. However, when a water-soluble unit dose substance is added to water, the unit dose substance dissolves and releases particles into the washing solution.

[0054] Non-fibrous water-soluble unit doses can take the form of any three-dimensional structure. Non-fibrous water-soluble unit dose articles can be perforated. Articles can also be cut or shaped into various sizes for different purposes of use. For example, water-soluble unit doses may take the form of squares, rounded squares, kites, rectangles, triangles, circles, ellipses, and mixtures thereof.

[0055] Non-fibrous water-soluble unit doses may contain fewer than 10 components. Water-soluble unit doses may contain 3 to 9 components, such as 4, 5, 6, 7, or 8 components.

[0056] The non-fibrous water-soluble unit-dose articles disclosed herein comprise a water-soluble non-fibrous structure and one or more particles. The non-fibrous substrate may be, for example, a water-soluble film, a foam, a nonwoven fabric, or a combination thereof.

[0057] The non-fibrous substrate may be a soluble foam sheet and may contain a polyvinyl alcohol (PVA) polymer or copolymer thereof as a film-forming agent, a carrier for any other optional components such as a structuring agent and a surfactant, 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% by weight, preferably about 10% to about 40% by weight, preferably about 15% to about 30% by weight, and more preferably about 20% to about 25% by weight of the total weight of the non-fibrous foam substrate, and the total amount of PVA present in the non-fibrous substrate is most preferably 25% by weight or less of the total weight of the substrate.

[0058] In this specification, suitable PVA polymers or copolymers are selected to have a weight-average molecular weight in the range of about 50,000 to about 400,000 daltons, preferably about 60,000 to about 300,000 daltons, more preferably about 70,000 to about 200,000 daltons, and most preferably about 80,000 to about 150,000 daltons. The weight-average molecular weight is calculated by adding the average molecular weights of each polymer raw material and multiplying by the respective relative weight percentages of the total weight of the polymer present in the porous solid.

[0059] Non-fibrous foam substrates are preferably prepared by first forming a wet premix containing PVA, a surfactant, and other optional active ingredients, then molding the wet premix into a sheet, and then drying the sheet of such wet premix to form a solid non-fibrous substrate. Accordingly, the weight-average molecular weight of the PVA polymer or copolymer may 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 may affect the viscosity of the wet premix, which in turn may affect various physical properties of the resulting non-fibrous substrate.

[0060] The PVA polymer or copolymer may further be characterized by a degree of hydrolysis ranging from about 40% to about 100%, preferably about 50% to about 95%, more preferably about 70% to about 92%, and most preferably about 80% to about 90%.

[0061] PVA copolymers 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):

[0062] [ka] In the formula, R1, R2, and R3 are each independently H or methyl, and n is an integer from 0 to 3. The above-mentioned anionic monomer units, if present, are preferably in an amount ranging from about 0.5 to about 5 mol%.

[0063] Commercially available polyvinyl alcohol may include, but is not limited to, products marketed as CELVOL by Celanese Corporation (Texas, USA), such as CELVOL 523, CELVOL 530, CELVOL 540, CELVOL 518, CELVOL 513, CELVOL 508, CELVOL 504, products marketed as Mowiol (registered trademark) and POVAL (trademark) by Kuraray Europe GmbH (Frankfurt, Germany), and PVA 1788 (also known as PVA BP17) from various suppliers including Lubon Vinylon Co. (Nanjing, China), as well as combinations thereof. In one embodiment, the non-fibrous substrate comprises 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%, in an amount of about 10% to about 25% by weight, more preferably about 15% to about 23% by weight, of the total weight of such article.

[0064] 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 to provide a non-fibrous substrate having the necessary 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 preferable that the non-fibrous substrate contains 20% by weight or less 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 starch.

[0065] Non-fibrous substrates can be films. Preferred film materials are polymer materials. Film materials can be obtained, for example, by casting, blow molding, extrusion, or blow-extrusion of polymer materials, as is known in the art. Preferred polymers, copolymers, or derivatives thereof suitable for use herein include polyvinyl alcohol, polyvinylpyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ether, cellulose ester, celluloseamide, polyvinyl acetate, polycarboxylic acids and salts, polyamino acids or peptides, polyamides, polyacrylamide, maleic acid / acrylic acid copolymers, polysaccharides including starch and gelatin, xanthan gum, and natural gums such as cara gum. More preferred polymers are selected from polyacrylates and water-soluble acrylate copolymers, methylcellulose, sodium carboxymethylcellulose, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropyl methylcellulose, maltodextrin, and polymethacrylate, and most preferably from polyvinyl alcohol, polyvinyl alcohol copolymer, and hydroxypropyl methylcellulose (HPMC), or a combination thereof.

[0066] Preferably, the level of polymer in the film, for example, PVA polymer, 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 useful for controlling the mechanical and / or solubility properties of the compartments or film, depending on the application and required conditions. Suitable mixtures include, for example, mixtures in which one polymer has higher water solubility than another polymer, and / or one polymer has higher mechanical strength than another polymer. Furthermore, mixtures of polymers having different weight-average molecular weights are also suitable, for example, a mixture of PVA or its copolymer with a weight-average molecular weight of about 10,000 to 40,000, preferably around 20,000, and PVA or its copolymer with a weight-average molecular weight of about 100,000 to 300,000, preferably around 150,000.

[0067] Also preferred herein are polymer blend compositions containing hydrolyzable, water-soluble polymer blends, such as a polymer blend of polylactide and polyvinyl alcohol, which is obtained by mixing polylactide and polyvinyl alcohol and typically contains 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 hydrolyzed about 60% to about 98%, preferably about 80% to about 90%, to improve the solubility of the material.

[0068] Naturally, different film materials and / or films of different thicknesses may be used in this specification. The advantage of selecting different films is that the resulting products and / or compartments may exhibit different solubility or release characteristics.

[0069] The most preferred film materials are PVA films known as MonoSol trademark numbers M8630, M8900, and H8779, as well as those described in U.S. Patent No. 6,166,117 and U.S. Patent No. 6,787,512, and PVA films with corresponding solubility and deformation properties, which are incorporated herein by reference.

[0070] Furthermore, the film materials of this specification may contain one or more additive-containing components. For example, the addition of plasticizers such as glycerol, ethylene glycol, diethylene glycol, propylene glycol, sorbitol, and mixtures thereof may be beneficial. Other additives include functional detergent additives delivered to the washing water, such as organic polymer dispersants.

[0071] particle The particles can be incorporated into the aforementioned non-fibrous water-soluble product, for example, at levels ranging from approximately 0.1 g to approximately 30 g. The type of particles used can be any that is suitable for the manufacturing system. One parameter that can contribute to the success of particle deposition by this method is the fluidity of the particles. p ) can be defined as the ratio of consolidation stress (cs) to unconstrained yield strength (ys). p The larger f is, the better the particle flow. Generally speaking, p <1 is not liquidity, f p >1, but less than 2 is very cohesive, f p If the value is between 2 and 4, it is considered to be cohesive, p If the value is between 4 and 10, it is considered to be easily liquid, p If the ratio is 10 or higher, it is considered to be free liquidity. In the process described above, if the ratio is approximately 4 or higher, p Particles having a value are preferred. The level of fluidity can be determined by the fluidity methods listed below. The fluidity of the particles may 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, and up to about 1000.

[0072] The particles may be powders, granules, aggregates, inclusions, microcapsules, and / or 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 may be spherical, rod-shaped, dish-shaped, tubular, square-shaped, rectangular, disc-shaped, star-shaped, fibrous, or have a regular or irregular random shape. The particles may have a D50 particle diameter of approximately 100 μm to approximately 1600 μm.

[0073] The particles may include mixtures of chemically different particles such as surfactant particles, including surfactant aggregates, surfactant extruders, surfactant needles, surfactant noodles, and surfactant flakes; phosphate particles; zeolite particles; silicate particles, especially sodium silicate particles; carbonate particles, especially sodium carbonate particles; polymer particles, e.g., carboxylate polymer particles, cellulosic polymer particles, starch particles, polyester particles, polyamine particles, terephthalate polymer particles, polyethylene glycol particles; aesthetic particles, e.g., colored noodles, needles, lamellar particles, and ring particles; enzyme particles, e.g., protease granules, amylase granules, lipase granules, cellulase granules, mannanase granules, pectinate lyase granules, xyloglucanase granules, bleaching enzyme granules, and cogranules of any of these enzymes (these enzyme granules may contain sodium sulfate); bleaching agent particles, e.g., percarbonate particles, especially carbonates, sulfates, silica 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 alkyloxybenzene sulfonate particles; bleach catalyst particles such as transition metal catalyst particles and / or isoquinolinium bleach catalyst particles; preformed peracid particles, in particular coated preformed peracid particles; filler particles, e.g., sulfate particles and chloride particles; clay particles, e.g., montmorillonite particles and clay and silicone particles; flocculant particles, e.g., polyethylene oxide particles; wax particles, e.g., wax aggregates; silicone particles; whitening agent particles; color transfer prevention particles; dye fixing agent particles; fragrance particles such as fragrance microcapsules and starch-encapsulated fragrance accord particles, or pro-perfume particles such as Schiff base reaction product particles; hue dye particles; chelating agent particles, e.g., chelating agent aggregates; and any combination thereof.

[0074] combination 1. A method for producing a non-fibrous water-soluble product containing particles, comprising: a) providing a first continuous water-soluble non-fibrous substrate having a first side surface and moving in a first direction; b) providing a discretization unit having one or more pockets having an opening; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket opening to at least partially fill at least one of the one or more pockets; d) delivering the first particles from the pocket through the opening onto a portion of the first side surface of the first continuous water-soluble non-fibrous substrate; and e) at least partially covering the first side surface of the first continuous water-soluble non-fibrous substrate.

[0075] 2. A method for producing a non-fibrous water-soluble product containing particles, comprising: a) providing a first continuous water-soluble non-fibrous substrate having a first side surface and moving in a first direction; b) providing a discretization unit having one or more pockets having openings; c) providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket openings; d) intermittently delivering the first particles from the pocket openings onto a portion of the first side surface of the first continuous water-soluble non-fibrous substrate; e) measuring the first particles to a target dose; and f) at least partially covering the first side surface of the first continuous water-soluble non-fibrous substrate.

[0076] 3. The method according to 1 or 2, further comprising sealing a first continuous water-soluble non-fibrous substrate and a cover, and trapping at least a portion of the first particles between the first water-soluble substrate and the cover, wherein the cover comprises a second non-fibrous water-soluble substrate.

[0077] 4. The method according to 3, wherein a unit dose is formed by sealing a first continuous water-soluble non-fibrous substrate onto a second continuous water-soluble non-fibrous substrate to confine at least a portion of the particles.

[0078] 5. The method according to any one of 1 to 4, wherein first particles are delivered to a target area on a first side surface of a first continuous water-soluble substrate, and at least 75%, about 80%, about 85%, about 90%, about 95%, or most preferably about 97% or more of the first particles remain on the target area when they leave the discretization unit.

[0079] 6. The method according to any one of 1 to 5, wherein the discretization unit comprises a rotor.

[0080] 7. The method according to 6, wherein the rotor comprises one or more pockets, and particles are contained within at least one of the one or more pockets of the rotor before being delivered onto a portion of the first side surface of a first continuous substrate.

[0081] 8. The method according to any one of 1 to 7, wherein the size of the pocket measures the amount of first particles delivered to a portion of the first side surface of a first continuous substrate.

[0082] 9. The method according to any one of 1 to 8, wherein a first continuous water-soluble non-fibrous substrate is moving in a first direction at a speed of approximately 5 m / min to approximately 100 m / min.

[0083] 10. The method according to any one of 1 to 9, wherein the first particle is delivered intermittently from one or more pockets of a discretization unit.

[0084] 11. The method according to any one of 1 to 10, wherein the particles have a fluidity of about 4 or more, preferably about 4 to about 1000.

[0085] 12. The particles are separated from the discretization unit and spread approximately 20 mm from the first continuous substrate so as to form a unit dose. 2 ~approximately 6000mm 2 The method according to any one of 1 to 11, wherein one or more unit doses are delivered to an area and formed on a first continuous substrate.

[0086] 13. The method according to any one of 1 to 12, wherein a discretization unit discretizes a continuous flow of first particles into one or more individual doses.

[0087] 14. The method according to any one of 1 to 13, further comprising: a) providing a third continuous water-soluble non-fibrous substrate having a first side and a second side that moves in a first direction; b) providing a supply of second particles to a second discretization unit; c) delivering the second particles from the discretization unit onto a portion of the second side of the second continuous water-soluble substrate; and d) positioning the first side of the third continuous substrate on top of the second particles.

[0088] 15. The method according to any one of 1 to 14, further comprising supplying a second particle to a discretization unit, wherein the first particle and the second particle are the same or different.

[0089] 16. A method according to any one of 1 to 15, wherein the discretization unit moves at a constant speed.

[0090] 17. A method according to any one of 1 to 16, wherein the discretization unit moves at a variable speed.

[0091] 18. The method according to any one of 1 to 17, wherein at least one pocket of the discretization unit progresses in synchronous with the first continuous water-soluble non-fibrous substrate during the deposition of particles onto the first continuous water-soluble non-fibrous substrate.

[0092] 19. The method according to any one of 1 to 18, wherein the particles include powder, granules, aggregates, encapsulated materials, microcapsules, prills, or a combination thereof.

[0093] 20. The method according to any one of 1 to 19, wherein the first particle has a fluidity of approximately 4 or more.

[0094] 21. A particle applicator device, A stator having an inlet and an outlet, A rotating discretization unit for receiving and delivering particles, comprising one or more pockets, recesses, or combinations thereof, A particle applicator device in which a stator and a rotary discretization unit are operably connected.

[0095] 22. The particle applicator apparatus described in 21, wherein the rotating discretization unit rotates at a variable speed.

[0096] 23. The particle applicator apparatus according to 21 or 22, wherein the rotating discretization unit comprises pockets, preferably equally spaced pockets.

[0097] 24. A particle applicator device according to any one of 21 to 23, wherein the rotating discretization unit comprises approximately 1 to approximately 20 pockets, approximately 2 to approximately 20 pockets, approximately 3 to approximately 20 pockets, approximately 5 to approximately 18 pockets, approximately 6 to approximately 16 pockets, approximately 8 to approximately 16 pockets, or approximately 8 to approximately 12 pockets.

[0098] 25. A particle applicator device according to any one of 21 to 24, wherein the rotating discretization unit comprises pockets having transverse dimensions of approximately 1 mm to approximately 100 mm, approximately 3 mm to approximately 95 mm, approximately 10 mm to approximately 90 mm, approximately 20 mm to approximately 50 mm, or approximately 25 mm to approximately 40 mm.

[0099] 26. A particle applicator apparatus according to any one of 21 to 25, wherein the rotating discretization unit comprises pockets having mechanical dimensions of approximately 1 mm to 100 mm, approximately 3 mm to 95 mm, approximately 10 mm to 90 mm, approximately 20 mm to 50 mm, approximately 25 mm to 40 mm, approximately 10 mm to 15 mm, or approximately 8 mm to 12 mm.

[0100] 27. A particle applicator device according to any one of 21 to 26, wherein the rotating discretization unit comprises pockets having depths of approximately 1 mm to 100 mm, approximately 3 mm to 95 mm, approximately 10 mm to 90 mm, approximately 20 mm to 50 mm, approximately 25 mm to 40 mm, approximately 10 mm to 15 mm, or approximately 8 mm to 12 mm.

[0101] 28. A particle applicator device according to any one of 21 to 27, wherein the rotational discretization unit comprises pockets having the shape of a right-angle prism, a cube, a cone, a pyramid, a concave "v", a divot, a cylinder, any shape having a triangular cross-section, any shape having a rectangular cross-section, or any combination thereof.

[0102] 29. A particle applicator device according to any one of 21 to 28, wherein the discretization unit measures a target dose of particles.

[0103] 30. A particle applicator apparatus according to any one of 21 to 29, wherein the rotating discretization unit comprises a pocket, the pocket having a volume of a target dose of particles.

[0104] 31. A particle applicator device according to any one of 21 to 30, wherein the target dose of particles for the rotational discretization unit is approximately 0.1g to approximately 15g, approximately 0.2g to approximately 15g, approximately 0.3g to approximately 10g, approximately 0.4g to approximately 8g, or approximately 0.1g to approximately 4.0g. 3 ~about 8cm 3 , about 0.1cm 3 ~about 7cm 3 , about 0.1cm 3 ~approximately 6cm 3 , about 0.1cm 3 ~about 5cm 3 , and approximately 0.1 cm 3 ~about 4.0cm 3 , or any combination thereof.

[0105] 32. A particle applicator apparatus according to any one of 21 to 31, wherein the rotating discretization unit comprises a rotor.

[0106] 33. A particle applicator apparatus according to any one of 21 to 32, wherein the stator comprises a housing.

[0107] 34. The particle applicator apparatus according to 33, wherein the rotating discretization unit is at least partially located inside the stator housing.

[0108] 35. The particle applicator apparatus according to 34, wherein an annular space exists between the stator housing and the rotating discretization unit.

[0109] 36. The particle applicator apparatus according to 35, wherein the annular space is approximately 10 μm to approximately 125 μm, approximately 20 μm to approximately 100 μm, approximately 20 μm to approximately 90 μm, approximately 30 μm to approximately 80 μm, approximately 40 μm to approximately 80 μm, approximately 50 μm to approximately 75 μm, or any combination thereof.

[0110] 37. A particle applicator according to any one of 21 to 36, wherein the stator inlet is positioned to receive particles when the particle-receiving portion of the rotating discretization unit is moving in a downward orbit.

[0111] 38. A particle applicator as described in any one of 21-37, wherein the stator outlet is located at approximately 45° from the horizontal.

[0112] 39. A particle applicator according to any one of 21 to 38, wherein the particle applicator applies particles to a non-fibrous substrate.

[0113] liquidity method The following comparative tests are conducted to demonstrate the fluidity of particles at ambient temperature and humidity.

[0114] The device adapted for this test is the commercially available fluidity testing system, FloDex® (Teledyne Hanson Research, Chatsworth, Calif., USA), which houses a flat-bottomed cylindrical hopper with a removable bottom and a set of interchangeable bottom discs containing orifices of different sizes. Furthermore, additional bottom discs with smaller orifices (having diameters less than 4 mm) are manufactured 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 through 34 mm.

[0115] The FloDex® instrument includes a funnel for loading particulate test samples into a stainless steel flat-bottom cylindrical hopper having a diameter of approximately 5.7 cm. The hopper has a removable bottom defined by a removal bottom disc having an orifice of a specific size inside. As described above, multiple removal bottom discs with orifices of different sizes are provided, which can be interchangeably mounted on the bottom of the hopper in place of the discs, thereby defining bottom orifices of different sizes. The discharge gate is located directly below the orifice and above the receiver. When flow measurement is initiated, the discharge gate is moved to expose the bottom orifice, allowing the particulate test samples to flow from the hopper through the bottom orifice to the receiver.

[0116] To test the fluidity of a specific test sample, follow these steps: a. Fill the hopper by pouring approximately 75 ml of the test sample through a funnel. This corresponds to a powder layer of approximately 1 inch (25 mm) in the cylindrical hopper. b. After the sample has stabilized for 30 seconds, open the spring-loaded discharge gate to allow the sample to flow through the orifice to the receiver. c. Steps (a) and (b) are repeated for the same test specimen using different bottom disks with orifices of progressively increasing orifice sizes. Initially, when a bottom disk with a relatively small orifice is used, the flow of the test specimen typically stops at a certain point due to clogging, i.e., it cannot pass through the orifice due to the small orifice size. Once the flow of the test specimen stops, 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 iteration of steps (a) and (b). When the test specimen can flow completely through a particular size of orifice three consecutive times without clogging, such an orifice size is recorded as the FloDex® blocking parameter, where B refers to the diameter of the orifice in the flow disk used in the test. The smaller the FloDex® blocking parameter, the better the flowability of the test specimen (i.e., it can flow through smaller orifices without clogging).

[0117] Liquidity is calculated according to the following equation:

[0118]

number

[0119]

number

[0120] The dimensions and values ​​disclosed herein should not be understood as strictly limited to the exact numerical values ​​listed. Instead, unless otherwise indicated, each such dimension is intended to mean both the listed value and the functionally equivalent range encompassing that value. For example, a dimension disclosed as "40 mm" is intended to mean "approximately 40 mm."

[0121] All documents referenced herein, including any patents or patent applications that are cross-referenced or related, and any patent applications or patents on which this application claims priority or benefit thereof, are incorporated herein by reference in their entirety unless explicitly stated to be excluded or limited. No reference to any document shall be deemed prior art to any invention disclosed or claimed herein, nor shall it be deemed to teach, suggest or disclose any such invention, either alone or in combination with any one or more other references. Furthermore, in the event of any conflict between any meaning or definition of a term in this document and any meaning or definition of the same term in any document incorporated by reference, the meaning or definition given to the term in this document shall prevail.

[0122] While specific embodiments of the present invention have been illustrated and described, it will be apparent 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. Therefore, it is intended that all such changes and modifications within the scope of the invention be covered in the appended claims. The various aspects of this disclosure are summarized below as an appendix. (Note 1) A method for producing a non-fibrous, water-soluble product containing particles, a) To provide a first continuous water-soluble non-fibrous substrate that includes a first side surface and moves in a first direction, b) To provide a discretization unit having one or more pockets with openings, c) Providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket opening, and at least partially filling the at least one of the one or more pockets, d) Delivering the first particles from the pocket through the opening onto a portion of the first side surface of the first continuous water-soluble non-fibrous substrate, e) A method comprising at least partially covering the first side surface of the first continuous water-soluble non-fibrous substrate. (Note 2) The method according to Appendix 1, further comprising sealing the first continuous water-soluble non-fibrous substrate and the cover, and trapping at least a portion of the first particles between the first water-soluble substrate and the cover, wherein the cover comprises a second non-fibrous water-soluble substrate. (Note 3) The method according to Appendix 1 or 2, wherein the first particles are delivered to a target area on the first side surface of the first continuous water-soluble non-fibrous 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 when they leave the discretization unit. (Note 4) The method according to any one of the appendices 1 to 3, wherein the discretization unit comprises a rotor. (Note 5) The method according to Appendix 4, wherein the rotor comprises one or more pockets, and the particles are contained in at least one of the one or more pockets of the rotor before being delivered onto a portion of the first side surface of the first continuous water-soluble non-fibrous substrate. (Note 6) The method according to any one of the appendices 1 to 5, wherein the size of the pocket is used to measure the amount of the first particles delivered to the portion of the first side surface of the first continuous substrate. (Note 7) The method according to any one of the appendices 1 to 6, wherein the discretization unit discretizes the continuous flow of the first particles into one or more individual doses. (Note 8) The method according to any one of the appendices 1 to 7, wherein the first particles are delivered intermittently from one or more pockets of the discretization unit. (Note 9) The method according to any one of the appendices 1 to 8, wherein the particles preferably have a fluidity of about 4 or more, as measured according to a fluidity method. (Note 10) The particles are dispersed from the discretization unit into the first continuous water-soluble non-fibrous substrate for approximately 20 mm so as to form a unit dose. 2 ~approximately 6000mm 2 The method according to any one of the appendices 1 to 9, wherein one or more unit doses are delivered to an area and formed on the first continuous water-soluble non-fibrous substrate. (Note 11) The method according to any one of the appendices 1 to 10, wherein at least one pocket of the discretization unit advances in synchronous with the first continuous water-soluble non-fibrous substrate during the deposition of the particles onto the first continuous water-soluble non-fibrous substrate. (Note 12) The method according to any one of the appendices 1 to 11, wherein the discretization unit moves at a constant speed. (Note 13) The method according to any one of the appendices 1 to 11, wherein the discretization unit moves at a variable speed. (Note 14) The method according to any one of the appendices 1 to 13, further comprising supplying a second particle to the discretization unit, wherein the first particle and the second particle are the same or different. (Note 15) a) To provide a third continuous water-soluble non-fibrous substrate having a first side surface and a second side surface, and moving in the first direction, b) supplying a second particle to a second discretization unit, c) Delivering the second particles from the discretization unit onto a portion of the second side surface of the second continuous water-soluble non-fibrous substrate, d) The method according to any one of the appendices 1 to 13, further comprising placing the first side of the third continuous water-soluble non-fibrous substrate on the second particles.

Claims

1. A method for producing a non-fibrous, water-soluble product containing particles, a) To provide a first continuous water-soluble non-fibrous substrate that includes a first side surface and moves in a first direction, b) To provide a discretization unit having one or more pockets with openings, c) Providing a continuous supply of first particles to at least one of the one or more pockets of the discretization unit through the pocket opening, and at least partially filling the at least one of the one or more pockets, d) Delivering the first particles from the pocket through the opening onto a portion of the first side surface of the first continuous water-soluble non-fibrous substrate, e) including at least partially covering the first side surface of the first continuous water-soluble non-fibrous substrate, A method comprising delivering the first particles to a target area on the first side surface of the first continuous water-soluble non-fibrous substrate, wherein at least 75% of the first particles remain on the target area as they exit the discretization unit.

2. The method according to claim 1, further comprising sealing the first continuous water-soluble non-fibrous substrate and the cover, and trapping at least a portion of the first particles between the first water-soluble substrate and the cover, wherein the cover comprises a second non-fibrous water-soluble substrate.

3. The method according to claim 1, wherein the discretization unit comprises a rotor.

4. The method according to claim 3, wherein the rotor comprises one or more pockets, and the particles are contained in at least one of the one or more pockets of the rotor before being delivered onto a portion of the first side surface of the first continuous water-soluble non-fibrous substrate.

5. The method according to claim 1, wherein the size of the pocket is used to measure the amount of the first particles delivered to the portion of the first side surface of the first continuous substrate.

6. The method according to claim 1, wherein the discretization unit discretizes the continuous flow of the first particles into one or more individual doses.

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

8. The method according to claim 1, wherein the particles have a fluidity of about 4 or more, as measured according to a fluidity method.

9. The particles are dispersed from the discretization unit into the first continuous water-soluble non-fibrous substrate for approximately 20 mm so as to form a unit dose. ２ ~approximately 6000mm ２ The method according to claim 1, wherein one or more unit doses are delivered to the area and formed on the first continuous water-soluble non-fibrous substrate.

10. The method according to claim 1, wherein at least one pocket of the discretization unit moves in synchronous with the first continuous water-soluble non-fibrous substrate during the deposition of the particles onto the first continuous water-soluble non-fibrous substrate.

11. The method according to claim 1, wherein the discretization unit moves at a constant speed.

12. The method according to claim 1, wherein the discretization unit moves at a variable speed.

13. The method according to claim 1, further comprising supplying a second particle to the discretization unit, wherein the first particle and the second particle are the same or different.

14. a) To provide a third continuous water-soluble non-fibrous substrate having a first side surface and a second side surface, and moving in the first direction, b) Providing a supply of second particles to the second discretization unit, c) Delivering the second particles from the discretization unit onto a portion of the second side surface of the second continuous water-soluble non-fibrous substrate, d) The method according to claim 1, further comprising placing the first side surface of the third continuous water-soluble non-fibrous substrate on the second particles.

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