Method for thermoforming a film for the production of water soluble dosage elements

Abstract

The present disclosure provides a method for thermoforming a film (2, 20, 20a, 20b, 320, 420, 422, 40, 435) for the production of a water-soluble dosage element (475), and an apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465) for thermoforming a film (2, 20, 20a, 20b, 320, 420, 422, 40, 435) for the production of a water-soluble dosage element (475). The method comprises heating and aligning a film (2, 20, 20a, 20b, 320, 420, 422, 40, 435) with an array of cavities (4, 40, 40a, 340, 41, 440, 540); moving the film (2, 20, 20a, 20b, 320, 420, 422, 40, 435) and the array of cavities (4, 40, 40a, 340, 41, 440, 540) through a punching module (100, 200, 310, 410, 510, 120), the punching module (100, 200, 310, 410, 510, 120) comprising at least one punch (120, 220, 330, 430) that is moveable into the cavities (4, 40, 40a, 340, 41, 440, 540) of the array; and operating the punching module (100, 200, 310, 410, 510, 120) to push the film (2, 20, 20a, 20b, 320, 420, 422, 40, 435) into the cavities (4, 40, 40a, 340, 41, 440, 540) with the punch (120, 220, 330, 430) as each cavity (40c, 41, 42) from the array moves through the punching module (100, 200, 310, 410, 510, 120). The present disclosure also provides the use of the apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465) for performing the method, a method of making the apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465), and a kit (500) for use in the method of making the apparatus (1, 10, 60, 300, 360, 400, 460, 425, 435, 455, 511, 20, 80, 422, 445, 465).

Description

[0001] METHOD FOR THERMOFORMING A FILM FOR THE PRODUCTION OF WATER SOLUBLE DOSAGE ELEMENTS

[0002] Field of the Invention

[0003] The present disclosure relates to a method for thermoforming a film for the production of a water-soluble dosage element, and to an apparatus for thermoforming a film for the production of a water-soluble dosage element. The present disclosure also relates to the use of the apparatus for performing the method, to a method of making the apparatus, and to a kit for use in the method of making the apparatus.

[0004] Background

[0005] Thermoforming is a well-known technique for preparing articles from a polymer. It generally comprises heating a polymeric material to above its softening temperature and thermally deforming the composition in a mould.

[0006] It is also known to package chemical treatment agents into water-soluble dosage elements, by thermoforming water-soluble films and encapsulating the treatment agents therein. Water soluble dosage elements dissolve or disintegrate in water to release the treatment agent. Dosage elements commonly find use as dishwasher or detergent tablets. Examples can be found in international patent application number WO 00 / 55045 A1 and European patent number EP 0 507 404 B.

[0007] Water-soluble dosage elements are made using a wide range of apparatus and methods. One particular apparatus 1 is shown in Figures 1 a and 1 b. In Figure 1 a a film 2 of a water-soluble polymer is heated by a heated roller 6 and drawn over an array of cavities 4. As shown in Figure 1 b, a vacuum is applied to the cavities by vacuum source 5 to pull film 2 into the cavities to adopt the shape of the cavities. The array of cavities 4 is then withdrawn vertically downwards from the thermoformed film and another length of film 2 is then drawn over the array of cavities 4. The array of cavities 4 returns to its original position and a further length of film is thermoformed. A treatment agent (not shown) may then be applied to the thermoformed film 2 and a layer of another film (not shown) applied to seal the treatment agent inside, forming a dosage element.

[0008] The present invention aims to provide improvements generally over the prior art methods and apparatus. The present invention may optionally seek to provide one or more of the following advantages: i) improve the quality of encapsulation by the film, ii) improve the visual appearance of the dosage elements, iii) improve the burst resistance of the dosage elements, iv) provide apparatus that can provide improve dosage elements at high throughput, v) provide low complexity apparatus for producing dosage elements, vi) provide apparatus that is retrofittable to existing apparatus.

[0009] Summary of the Invention

[0010] In a first aspect of the present disclosure there is a method for thermoforming a film for the production of a water-soluble dosage element, the method comprising the steps of: i) in any order or concurrently, heating and aligning a film with an array of cavities; ii) moving the film and the array of cavities through a punching module, the punching module comprising at least one punch that is moveable into the cavities of the array; and iii) operating the punching module to push the film into the cavities with the punch as each cavity from the array moves through the punching module.

[0011] In a second aspect of the present disclosure, there is an apparatus for thermoforming a film for the production of a water-soluble dosage element, the apparatus comprising: i) a moveable array of cavities; ii) film feeding apparatus to align a film with the array of cavities and move the film therewith; iii) a heat source to heat the film; and iv) a punching module comprising a punch to push the film into the cavities as the cavities and film move through the punching module.

[0012] Aspects of the present disclosure provide a thermoformed dosage element having improved distribution of the film thickness throughout the dosage element. This leads to more even tension throughout the dosage element giving an improved visual appearance amongst other improvements. The present disclosure also allows for high throughput production of dosage elements with low-complexity apparatus, amongst other benefits.

[0013] Thermoforming, as used herein in reference to the film, is the process of heating the film, shaping it (e.g. in the cavity), and then allowing the film to cool, whereupon the film will hold its shape, e.g. the shape of the cavity.

[0014] Film

[0015] In some embodiments, the film comprises a water-soluble polymer.

[0016] The water-soluble polymer may be selected from the group consisting of polyvinyl alcohol, polyacrylamide, poly(acrylic acid), poly(methacrylic acid), polyvinylpyrrolidone, quaternary ammonium polymers, cellulose ethers, polyethylene oxide, starch, polyacrylamide, polyacrylonitrile, polyvinyl methyl ether-maleic anhydride, polymaleic anhydride, styrene maleic anhydride, hydroxyethylcellulose, methylcellulose, polyethylene glycols, carboxymethylcellulose, polyacrylic acid salts, alginates, acrylamide copolymers, guar gum, casein, ethylene-maleic anhydride resins, polyethyleneimine, ethyl hydroxyethylcellulose, ethyl methylcellulose, hydroxyethyl methylcellulose and any mixture of any of the foregoing. In some embodiments, the film comprises a polyvinyl alcohol (PVOH) film. The polyvinyl alcohol may comprise a modified or an un-modified polyvinyl alcohol.

[0017] In some embodiments, the film has a thickness not exceeding 300 pm, or 260 pm, or 240 pm, or 220 pm, or 200 pm, or 180 pm, or 160 pm, or 140 pm, or 120 pm, or 100 pm or 80 pm. In some embodiments, the film has a thickness greater than 40 pm, or 60 pm, or 80 pm, or 100 pm, or 120 pm, or 140 pm, or 160 pm, or 180 pm. Optionally the film has a thickness between 100 pm and 240 pm, or between 120 pm and 220 pm, or between 140 pm and 180 pm, or between 150 pm and 170 pm, or any range made from any of the previously stated values. Film thickness may be measured prior to thermoforming. In some embodiments, the film has an areal weight between 80 and 300 g / m2, or between 100 and 280 g / m2, or between 120 and 260 g / m2, or between 140 and 240 g / m2, or between 160 and 220 g / m2, or between 180 and 200 g / m2, or any range made from any of these endpoints.

[0018] The film may be formed through solvent casting, blow-moulding, extrusion or blown extrusion. Processes for the solvent casting of the film are well-known in the art.

[0019] Some embodiments may use a first and a second film. In such embodiments, the first film is the film that is pushed into the cavities. The first and second films may be formed from any film as described herein.

[0020] Heating

[0021] Heating the film may comprise applying heat from a heat source to raise the temperature of the film. The temperature of the film may be raised the closer the film gets to the punching module. The term “heat source” may refer to a single heat source or may refer to a plurality of individual heat sources. A plurality of heat sources may be distributed throughout the apparatus. In some embodiments, the film is heated to a temperature of 70 to 220 degrees C, or from 85 to 190 degrees C, or from 100 to 170 degrees C, or from 115 to 150 degrees C, or from 130 to 135 degrees C, or any range made from any of these endpoints. The temperature of the film is preferably measured on the surface furthest from the cavities using an IR temperature sensor. Preferably the temperature of the film is measured prior to and adjacent to the film entering the punching module. The term “prior” in this context may refer to the direction of travel of the film in the apparatus, i.e. the machine direction. The term “prior” in relation to a part of the apparatus thus may refer to another part or other parts of the apparatus encountered by the film as it is processed through the apparatus in the machine direction before it reaches the aforesaid part. Conversely after may refer to a subsequent part or other parts of the apparatus encountered by the film as it is processed through the apparatus in the machine direction.

[0022] The heat source may be configured to heat the film. Configured, in this context may refer to the apparatus being positioned, orientated or otherwise arranged to direct sufficient thermal energy to soften the film. The heat source may be located in contact with or adjacent to the film. The heat source may comprise one or more of: a hot air source, a radiation heater (optionally an infrared heater), piezoelectric elements, and / or resistive heating elements. The resistive heating elements may optionally be incorporated into one or more rollers, one or more static plates, the cavities and / or the punch. The film may be heated directly, or indirectly for example by heating a surface or applying a hot item onto the film.

[0023] In some embodiments, the film is heated prior to the punch. Thus, in some embodiments, a heat source for heating the film may be located adjacent to and prior to the punch. The heat source may be a radiation heater or a hot air source, when the heat source for heating the film is located adjacent to and prior to the punching module. The heat source or part thereof may be positioned before the film feeding apparatus, as part of the film feeding apparatus, and / or after the film feeding apparatus. Thus heating may occur before alignment of the film with the cavities, during alignment or after alignment.

[0024] In some embodiments, the heat source comprises a heated roller and a radiation heater. The heated roller may also be all or part of the film feeding apparatus and may serve to align the film whilst also heating it. The radiation heater may be positioned between the heated roller and the punching module. The heated roller may heat the film to an intermediate temperature between the ambient temperature and the thermoforming temperature. The radiation heater may then heat the film from the intermediate temperature to the thermoforming temperature.

[0025] In some embodiments, the film is aligned with the array of cavities by one or more rollers prior to the punching module, and at least one of the one or more rollers prior to the punching module is heated. One or more rollers may be heated to a temperature of from 50 to 170 degrees C, or from 60 to 160 degrees C, or from 70 to 130 degrees C, or from 70 to 90 degrees C, or any range made from any of these endpoints. Optionally, the roller may be heated with a resistive element within the roller, or the roller may be heated indirectly by an external heat source. In some embodiments, the cavities of the array of cavities are heated to a temperature of from 50 to 170 degrees C, from 60 to 160 degrees C, or from 70 to 130 degrees C, or from 70 to 90 degrees C, or any range made from any of these endpoints. In some embodiments, the apparatus comprises a heat source to heat the cavities. The heat source may be comprised within the cavities or may be external thereto. The cavities may control the rate of cooling of the film after thermoforming. The cavities may partially heat the film after thermoforming to slow the rate of cooling of the film.

[0026] The film may be heated prior to alignment by the film feeding apparatus. For example, a heat source may be located before the film feeding apparatus. Alternatively, the film may be heated after alignment by the film feeding apparatus. For example, a heat source may be after the film feeding apparatus and before the punching module. The film may also be heated during alignment by a heat source comprised as part of the film feeding apparatus Embodiments may comprise any combination of heating before, after or during alignment.

[0027] Array of cavities

[0028] The array of cavities may comprise a plurality of individual cavities connected together. The cavities may confer their shape onto the thermoformed film. Thus the cavities may optionally be considered as female moulds for thermoforming the heated film within.

[0029] The cavities, in which the film is thermoformed can have any shape, length, width and depth, depending on the required dimensions of the dosage elements. The cavities can also vary in size and shape from one to another, if desirable.

[0030] In some embodiments, the array of cavities comprises the cavities arranged as an endless loop. The endless loop may be arranged as a continuous belt, or circular wheel comprising the cavities on the outer radius. Adjacent cavities may be joined by flexible or articulated linkages or any other mechanical connection that permits the cavities to move from a starting point, follow a predetermined path and return to the starting point. Alternatively, the cavities may be individually mounted to a chain, belt or similar.

[0031] In embodiments comprising an endless loop, the cavities may move in a first direction from a starting point (e.g. the machine direction), invert around an endpoint and return to the start point via a second direction, where the second direction is parallel to the first direction and the reverse thereof. Such an arrangement may comprise rollers, gears or wheels to drive and guide the motion of the cavities. The cavities may comprise a body having an internal and an external surface. The internal surface may partially enclose an internal volume. In some embodiments, the cavities have an internal volume of from 5 cm3to 30 cm3, or from 10 cm3to 25 cm3, or from 15 cm3to 30 cm3, or any range made from any of these endpoints. The internal volume may refer to the maximum volume of liquid the cavity can accommodate internally. The shape of the internal volume may be the shape conferred on the dosage element during thermoforming. The body of the cavity may define the perimeter of the opening. The opening may therefore be defined as the upper bound of the internal volume. The punch may move into the cavity perpendicular to the plane of the opening.

[0032] In some embodiments, the cavities have an internal depth from 5 mm to 30 mm, or from 10 mm to 25 mm, or from 15 mm to 20 mm, or any range made from any of these endpoints. Internal depth is measured internally in the depth direction from the opening to the deepest part of the cavity. The depth direction is perpendicular to the opening of the cavity. Where a cavity is aligned with the opening in the horizontal plane, the depth direction will be aligned in the vertical direction.

[0033] The opening of the cavity may be surrounded by a flange. The flange may be a planar surface, which may extend parallel to the opening. In some embodiments, the film may be aligned so that it is in contact with the flange. A flange may improve the seal between the cavity and the film.

[0034] The cavity may comprise an internal radius less than 10 mm, or 9 mm, or 8 mm, or 7.5 mm, or 7 mm, or 6.5 mm, or 6 mm, or 5.5 mm, or 5 mm, or 4.5 mm, or 4 mm, or 3.5 mm, or 3 mm. The cavity may comprise an internal radius greater than 0.1 mm, or 0.25 mm, or 0.5 mm, or 0.75 mm, or 1 mm, or 1 .25 mm, or 1 .5 mm, or 1 .75 mm, or 2 mm, or 2.25 mm, or 2.5mm.

[0035] The dosage element may comprise an external radius corresponding to the internal radius of the cavity. The external radius of the dosage element may be smaller than the internal radius of the cavity: the external radius of the dosage element may be between 10 and 0.01% less, or between 5% and 0.1% less, or between 2% and 0.05% than the internal radius of the cavity, or by any range formed from any of these endpoints. The dosage elements may comprise an external radius less than 10 mm, or 9 mm, or 8 mm, or 7.5 mm, or 7 mm, or 6.5 mm, or 6 mm, or 5.5 mm, or 5 mm, or 4.5 mm, or 4 mm, or 3.5 mm, or 3 mm. The dosage element may comprise an external radius greater than 0.1 mm, or 0.25 mm, or 0.5 mm, or 0.75 mm, or 1 mm, or 1 .25 mm, or 1 .5 mm, or 1 .75 mm, or 2 mm, or 2.25 mm, or 2.5mm. The radius may be determined by applying a radius gauge to the radius to be measured.

[0036] In some embodiments, the cavities may comprise 1 , 2, 3, 4 or more compartments within each cavity. The compartments may be separate or distinct sections in the bottom of the cavity that result in separate cavities in the final dosage element.

[0037] The array of cavities may comprise at least 2 cavities, at least 10 cavities, at least 40 cavities, at least 100 cavities, at least 200 cavities, or at least 400 cavities. The array of cavities may comprise less than 100,000 cavities, 50,000 cavities, 10,000 cavities, 5000 cavities, 1000 cavities, or 500 cavities.

[0038] The cavities of the array of cavities may also be arranged in parallel, that is, a plurality of cavities may aligned perpendicular to the direction of movement of the array of cavities (i.e. perpendicular to the machine direction). For example, if the array of cavities comprises four cavities arranged perpendicular to the direction of movement, as the array moves, the cavities will pass through the punching modules in sets of four, where each cavity of a set passes through the punching module simultaneously. The array of cavities may comprise at least one cavity, at least 2 cavities, at least 4 cavities, at least 8 cavities, at least 12 cavities, or at least 20 cavities or at least 40 cavities that are aligned perpendicular to the direction of movement of the array of cavities.

[0039] The array of cavities and film may move perpendicular to the direction of movement of the punch into and out of the cavities. Thus if the punch moves vertically, the cavities and film may move horizontally, or visa vera. The direction of movement of the cavities and film may be referred to as the machine direction, the punch may therefore move perpendicular to the machine direction when moving into and out of the cavities.

[0040] Aligning

[0041] Aligning in the context of the present disclosure refers to bringing the film together with the array of cavities so that the film is in a position from which it can be pushed into the cavities. In some embodiments, the film may be brought into contact with the cavity so that a seal is formed between the film and the cavity around the perimeter of the opening, sufficient for a vacuum applied to the cavity to pull the film into the cavity. Where the cavity comprises a flange, the film may be aligned to be in contact with the flange. Once aligned the film and cavities move together at the same speed. The apparatus comprises a film feeding apparatus to align the film. Film feeding apparatus may comprise web handling apparatus used to convey films. The film feeding apparatus may comprise one or more rollers. Thus, in some embodiments, the film may be aligned with the array of cavities by one or more rollers. Rollers may include live shaft and dead shaft / idler rollers, or dancer rollers. Rollers may be arranged as roller pairs e.g. nip rollers, and s-wrap rollers. Alternatively, the film feeding apparatus may comprise a single roller, or the film feeding apparatus may comprise a spindle to accommodate a roll and the film may be unwound directly from the roll to be aligned with the array of cavities. Accordingly, the film feeding apparatus may comprise one or more additional rollers. Optionally one or more additional rollers may align the film prior to the punching module and / or one or more additional rollers may align the film after the punching module.

[0042] The film may be under tension prior to step ii). Optionally the tension may be applied during alignment of the film with the cavities and maintained by contact between the film and cavities. Tension may be applied by moving the array cavities faster than the film feeding apparatus so that the film is partially stretched before contact with the cavities. In some embodiments, the tension of the film prior to step ii) is greater than 1 N, or 5N, or 10N, or 15N, or 20N or 25N, and not exceeding 45N, or40N, or 35N, or 30N, or 25N, or 20N or 15N. Tension may be within any range made from any of these endpoints.

[0043] In some embodiments, the film and cavities move together at a speed from 4 m / min to 18 m / min, or from 6 m / min to 16 m / min, or from 8 m / min to 14 m / min, or from 10m / min to 12 m / min, or any range made from any of these endpoints. Thus in some embodiments, the moveable array of cavities and film feeding apparatus are configured to move the film and array of cavities film together at a speed from 4 m / min to 18 m / min, or from 6 m / min to 16 m / min, or from 8 m / min to 14 m / min, or from 10m / min to 12 m / min, or any range made from any of these endpoints. The speed of the array of cavities may be continuous. Alternatively, the array of cavities may pause as cavities pass through the punching module, prior to the punch entering a cavity and resume movement once the punch has withdrawn from the cavity.

[0044] Punching module

[0045] The punching module may comprise a housing and one or more actuators configured to move one or more punches in a reciprocating motion into and out of the cavity. The actuator may be configured to move the punch(s) as the cavities pass through the module.

[0046] Alternatively, the punch(s) may move in the machine direction at the same or similar rate to the array of cavities. Thus the punches may track the cavities as they move. For example, the punching module may comprise a plurality of punches mounted on a rotary body. The rotation of the body may correspond to the speed of the array of cavities. Alternatively, the punching module may comprise a plurality of actuated punches that track the movement of the cavities, e.g. the punches may be mounted on an endless loop such as a belt.

[0047] The method may comprise the punch module moving the punch at the same speed as the array of cavities, whilst the punch enters and withdraws from a cavity. The punch module may move the punch parallel to the machine direction. Thus, the punching module may comprise one or more actuators to move the punch parallel to the machine direction at the same speed as the array of cavities. The punching module may move the punch in the machine direction, tracking a cavity, from the insertion of the punch into the cavity until the punch has withdrawn from the cavity. After the punch has withdrawn from the cavity, the punching module may move the punch in the reverse direction to the machine direction to restore the punch to its starting position. The punching module may then move the punch to the next cavity, restarting the process. The punching module may comprise a plurality of punches mounted on a rotary body. The rotation of the body may correspond to the speed of the array of cavities. Alternatively, the punching module may comprise a plurality of actuated punches that track the movement of the cavities, e.g. the punches may be mounted on an endless loop such as a belt.

[0048] In some embodiments where the punch module moves the punch at the same speed as the cavities, the heat source may move adjacent to the punch. Optionally, the heat source may be mounted to the punch and / or the punch module. Optionally, the heat source may move parallel to the machine direction.

[0049] The shape of the punch may be the same as the internal volume of the cavity, or it may be shaped geometrically similar and smaller to the cavity.

[0050] In some embodiments the punch comprises a material with a coefficient of thermal expansion of less than 100, less than 75, less than 60, less than 50, less than 45, less than 40, less than 35, less than 30, or less than 25 um / mK. The punch may comprise a material with a coefficient of thermal expansion greater than 1 , or greater than 5, or greater than 10, or greater than 15, or greaterthan 20, orgreaterthan 25, or greaterthan 30 um / mK. In some embodiments, where the punch is heated, and / or comprises part of the heat source, the punch may comprise a material with a coefficient of thermal expansion of from 15 to 400, or from 50 to 300, or from 100 to 250 W / m K or any range made from any of these endpoints. In some embodiments where the punch is not heated, and / or does not comprise part of the heat source, the punch may comprise a material with a coefficient of thermal expansion of from 0.01 to 20, or from 0.1 to 15, or from 0.2 to 10 W / m K or any range made from any of these endpoints. The punch may be made from metal including but not limited to aluminium, titanium, stainless steel and alloys thereof, or from polymers including but not limited to thermosets and thermoplastic polymers such as polyolefins polyamides, and polyesters amongst others. The polymers may optionally be composites, comprising fillers, fibres or other reinforcement material. The punch may be solid, hollow, or foamed, and in particular, may comprise a syntatctic foam. The punch may alternatively be made from ceramics or wood.

[0051] In some embodiments, the punch is heated to a surface temperature of from 20 to 170 degrees C, or from 50 to 170 degrees C, or from 60 to 120 degrees C, or from 70 to 130 degrees C, or from 70 to 90 degrees C, or from 80 to 100 degrees C, or any range made from any of these endpoints. In some embodiments, wherein the heat source comprises a heated punch, the punch may configured to be heated to a surface temperature of from 20 to 170 degrees C, or from 50 to 170 degrees C, or from 60 to 120 degrees C, or from 70 to 130 degrees C, or from 70 to 90 degrees C, or from 80 to 100 degrees C. Heating the punch may help to maintain the film at or above the softening temperature and may help improve the distribution of the film.

[0052] In some embodiments, the punch moves into the cavity at a rate from 10 m / s to 500 m / s, or from 50 m / s to 400 m / s, or from 75 m / s to 300 m / s, or from 100 m / s to 200 m / s, or from 125 m / s to 175 m / s, or any range made from any of these endpoints. Thus the punching module may be configured to move the punch into the cavity at a rate from 10 m / s to 500 m / s, or from 50 m / s to 400 m / s, or from 75 m / s to 300 m / s, or from 100 m / s to 200 m / s, or from 125 m / s to 175 m / s, or any range made from any of these endpoints.

[0053] In some embodiments, the mean distance between the punch and the sides of the cavities from or from 0.1 mm to 6 mm, or from 0.3 mm to 3 mm, or from 0.35 mm to 1.5 mm, or from 0.4 mm to 0.9 mm, or from 0.5 mm to 0.75 mm, or from any range formed from any of these endpoints. The mean distance may be measured perpendicular to the machine direction when the punch is in the cavity. The sides of the cavity may be the surface bounding the internal volume of the cavity adjacent to the opening of the cavity.

[0054] In some embodiments, the mean distance between the bottom of the punch and the bottom of the cavities, when the punch is at the maximum depth in the cavity does not exceed 10 mm, or 8 mm, or 6 mm, or 4 mm, or 2 mm, or 1 mm, or 0.75 mm, or 0.5 mm or 0.25 mm, or 0.1 mm, or 0.05 mm. Optionally the mean distance between the bottom of the punch and the bottom of the cavities, when the punch is at the maximum depth in the cavity is greater than or equal to 0 pm, or 10 pm of 50 pm or 75 pm or 0.1 mm or 0.125 mm or 0.15 mm or 0.175 mm or 0.2 mm or 0.5 mm, or 1 mm, or 2 mm, or 5 mm. Optionally the mean distance between the bottom of the punch and the bottom of the cavities, when the punch is at the maximum depth in the cavity is the same as the thickness of the film. The mean distance between the bottom of the punch and the bottom of the cavities may measured parallel to the depth direction when the punch is at the deepest part of the cavity during punching.

[0055] In some embodiments, the punch enters the cavity for a duration between 0 and 4000 ms, or between 250 and 3500, or between 500 and 3000 ms, or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500 or any range made from any of these endpoints. Thus, in some embodiments, the punch is configured to enter the cavity when pushing the film into the cavities, for a duration between 0 and 4000 ms, ore between 250 and 3500 or between 500 and 3000 ms or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500 or any range made from any of these endpoints.

[0056] In some embodiments, the punch enters the cavity up to 100%, or 99.99%, or 99.75%, or 99.5%, or 99.25%, or 99%, or 97.5%, or 95% of the total depth of the cavity; and optionally more than 50%, or 70%, or 80%, or 90%, or 95%, or 97.5% of the total depth of the cavity, or any range made from any of these values.

[0057] The film feeding apparatus and the punching module may be separated by distance from 0 to 400 cm, or from 1 to 300 cm, or from 60 cm to 240 cm, or from 120 cm to 180 cm, or any range made from any of these endpoints.

[0058] Dosage Element

[0059] The dosage element may be water soluble to release a treatment agent. The term “water soluble” may optionally refer to the dosage element comprising a water-soluble film encasing the treatment agent. The water-soluble film may dissolve or otherwise degrade in the presence of water to release the treatment agent into the water.

[0060] The dosage element may comprise one, two, three or more compartments. A compartment may be the void or region within the dosage element where a treatment agent is contained. In some embodiments, the dosage element may comprise a different treatment agent in adjacent compartments. Adjacent compartments may be separated by film, preventing the movement of treatment agents between compartments. The compartments of multi-compartment dosage articles may be of the same or different size(s) and / or volume(s). In some embodiments, the second and / or third and / or subsequent compartments may be superimposed on the first compartment.

[0061] The dosage elements may have a length less than 250mm, 100 mm, 50 mm, 40 mm or 35 mm. Where the length is the longest linear measurement of the exterior of the dosage element, measured parallel to an edge of the dosage element. The dosage elements may have a length greater than 20 mm, 30 mm, 40 mm or 50 mm.

[0062] The dosage elements may have a depth of less than 50 mm, 40 mm, 30 mm, 25 mm or 15 mm. The dosage elements may have a depth of greater than 5 mm, 10 mm, 20 mm, 25 mm or 30 mm. Depth may be measured perpendicular to the length and width of the dosage element, and parallel to an external edge of the dosage element.

[0063] The dosage elements may have a width of less than 50 mm, 40 mm, 30 mm, 25 mm or 15 mm. The dosage elements may have a width of greater than 5 mm, 10 mm, 20 mm, 25 mm or 30 mm. Width may be measured perpendicular to the length and depth of the dosage element, and parallel to an external edge of the dosage element. The width of the dosage element may be greater than the depth.

[0064] Treatment agents

[0065] The dosage element may comprise a single dose of a treatment agent. The treatment agent may comprise any active chemical agent affected by water. In some embodiments, the treatment agent comprises a detergent, optionally wherein the detergent is a laundry detergent or a dishwasher detergent. Such detergent compositions may comprise a surfactant, a bleach, an enzyme, a perfume, a rinse aid, a dye or colourant, a solvent and combinations thereof. The treatment agent may alternatively comprise, amongst others, detergents for hand washing and / or machine washing; hard surface cleaning compositions, fabric enhancers, detergent gels commonly used for laundry, bleach and laundry additives, shaving creams, skincare, hair care compositions (e.g. shampoos and conditioners), and body washes, amongst others. The treatment agent may be in the form of powders, gels, pastes, mulls, liquids, solids, tablets (e.g. pressed tablets) or any combination thereof.

[0066] The dosage elements of be of any size suitable for providing a single dose. The single dose may be sized to provide a single dose for a single treatment cycle of a domestic apparatus, such as a washing machine or dishwasher. The size of the single unit dose will depend on the end application. In some embodiments, the volume of the treatment agent of the final dosage elements may be from 1 ml to 200 ml, or from 5 ml to 100 ml, or from 10 ml to 50 ml or any range formed from any combination of these endpoints3

[0067] Filling

[0068] In some embodiments, the method may comprise filling the film in the cavities with one or more treatment agents. Accordingly, in some embodiments, the apparatus may comprise a filling apparatus to fill the film in the cavities with one or more treatment agents.

[0069] The filling apparatus may comprise a nozzle for filling the cavity with flowable materials e.g. liquids gels and flowable powders. The filing apparatus may comprise a placement apparatus to place tablets and other solid treatment agent forms. These may be gravity-fed and may comprise valves to regulate the supply of treatment agents into the cavities. The cavities may be filled by flood dosing. In this process, the cavities pass under a fixed dosing unit which doses a set amount or volume of treatment agent per time unit. Another well-known process of filing is known as continuous motion inline filling. This process uses a dispensing unit having a plurality of nozzles positioned above the cavities. The dispensing unit rotates in continuous motion. The nozzles move at the same speed as the cavities and in the same direction, such that each cavity is under the same nozzle or nozzles for the duration of the dispensing step. After the filling step, the nozzle rotates to start another filling step. Another process for filling the cavities is a reciprocating-motion-filling method. This process uses a moving filling station which typically includes a series of nozzles. The nozzles each move at the same speed as the cavities and in the same direction as the treatment agent is dispensed into the cavities. Then, when each cavity is full, the nozzle stops moving with the pouch and returns to its original position above a new set of open pouches as the process is repeated.

[0070] In an alternative embodiment, the treatment agent may be brought into contact with the film prior to the punching module, and the punch of the punching module is operated to push the treatment agent into the cavity. Thus the shape and size of the punch and cavity are configured to account for the shape of the treatment agent. This alternative embodiment is of particular relevance when the treatment agent is a discrete solid, for example, a tablet.

[0071] Lid and sealing

[0072] In some embodiments, the method may comprise applying a film lid to the filled film in the cavities and sealing the film lid to the film to form the dosage elements. Accordingly, in some embodiments, the apparatus may comprise means to apply a film lid to the film in the cavities, and / or apparatus to seal the film lid to the film in the cavities to form dosage elements. The means to apply a film lid may comprise a second film feeding apparatus. The second film feeding apparatus may comprise any apparatus as defined for the film feeding apparatus (i.e. the first film feeding apparatus). The film lid may comprise the same or different material to the film. A dosage element may therefore comprise two different films or two pieces of the same film.

[0073] Sealing of the film lid to the film in the cavities may include heat sealing, solvent welding, solvent or wet sealing, and combinations thereof, amongst others. Typically, only the area which is to form the seal is treated with heat or solvent. The heat or solvent can be applied by any known method, typically on the closing material, and typically only on the areas which are to form the seal. Thus the apparatus to seal the film lid may comprise heat sealing means, solvent welding means or wet sealing. Such means comprise any applicable equipment known in the art. A heat sealing means may comprise a heat seal element that comes into contact with the second film lid to melt bond it to the first film in the cavity. A heat seal element may be any heated member appropriately shaped for the desired seal pattern.

[0074] One suitable heat seal means may comprise a heated roller having depressions corresponding to the cavities. The roller is continuously rolled over the array of cavities. As a result, the heated roller only contacts the predetermined sealing surfaces on the perimeter of the opening of the cavities. Alternatively, a moveable, returnable sealing device may be used to seal each surface for a period of time before moving to a new location to seal a new set of pouches.

[0075] Before the lid and the film are pressed together, one or both may be wetted to render them tacky to improve the bond between the film and the lid. The film and the lid may then be sealed together, for example by heat sealing across the flange of the cavity. A suitable heat sealing temperature is, for example, 50° C to 300° C depending on the film material and other characteristics of the sealing process. A suitable sealing pressure is, for example, from 250 kPa to 800 kPa, which is likewise dependent on the film material and other characteristics of the sealing process. Other methods of sealing the films together may be used, for example infrared, radio frequency, ultrasonic or laser solvent, vibration, electromagnetic, hot gas, hot plate, insert bonding, fraction sealing or spin welding. An adhesive such as water or an aqueous solution of PVOH may also be used. The adhesive can be applied to the films by spraying, transfer coating, roller coating or otherwise coating, or the film / lid can be passed through a mist of the adhesive. The adhesive may also be a solvent. The seal desirably is also water-soluble.

[0076] Removing from cavities In some embodiments, the method may comprise removing the dosage elements from the cavities. Accordingly, in some embodiments, the apparatus may comprise apparatus to remove the dosage elements from the cavities. The apparatus to remove the dosage elements from the cavities may comprise lifting means to lift the dosage elements from the cavities. Removal of the dosage elements may be facilitated by applying air under pressure to cavities through vacuum ports, or the cavities may comprise mechanical ejection means, such as springs, for example.

[0077] Cutting

[0078] In some embodiments, the method may comprise cutting or perforating the film between adjacent dosage elements. Accordingly, in some embodiments, the apparatus may comprise a cutting apparatus configured to cut or perforate the film between adjacent cavities to form individual dosage elements. Cutting or perforating can be accomplished using any known method. It may be preferred that the cutting is also done in a continuous manner, preferably with constant speed and preferably while the film is aligned in a generally horizontal orientation. The cutting apparatus, for example, may comprise a sharp item, a hot item, or a laser, whereby in the latter cases, the hot item or laser ‘burns’ through the film / sealing area. The cutting apparatus may comprise one device to cut or perforate in the machine direction and a second device to cut in the cross direction (perpendicular to the machine direction).

[0079] Superimposed compartments

[0080] In some embodiments, the dosage element may comprise an internal film dividing the dosage into multiple compartments. Thus the method may comprise placing an additional film over the cavity after the first treatment agent has been placed in the cavity. The additional film is then heated and a second punching module pushes the additional film into the cavity and into contact with the first treatment agent. A second treatment agent may then be placed on top of the additional film, and a lid applied to the dosage element. Thus the apparatus may additionally comprise an additional film feeding apparatus, a second punching module and a second filling apparatus.

[0081] Additional assistance for thermoforming

[0082] In some embodiments, the method may comprise applying negative pressure to the cavities of the array before and / or after and / or during step iii) (i.e. pushing the film into the vanity with the punch). Accordingly, in some embodiments, the apparatus may comprise one or more than one vacuum source to apply negative pressure to individual cavities of the array of cavities. Negative pressure refers to negative pressure compared to ambient pressure and may comprise a partial or complete vacuum. The application of negative pressure may partially or completely pull the film into the cavity. The negative pressure may be applied prior to, after or during the entry of the punch into the cavity. The negative pressure may be applied after partial or complete entry of the punch into the cavity. The negative pressure may assist with the thermoforming by the punch and may further improve the distribution of the film by the punch. When negative pressure is exerted in this manner, the negative pressure should ideally comprise pressure difference to ambient pressure of no greater than 0.9 Bar, or no greater than 0.6 Bar, for no greater than 0.3 Bar, and optionally no less than 0.05 Bar, 0.1 Bar or 0.2 Bar. The cavity may comprise one more vacuum port in the bottom portion of the cavity which fluidly connects to a vacuum source. Fluid connection to a vacuum source may occur when the array of cavities has aligned a cavity adjacent to the fluid source, or the cavities may comprise a flexible connection to a static vacuum source. Alternatively, each individual cavity may comprise a vacuum source that moves with the array of cavities. To enable negative pressure to pull the film into the cavity the film feeding apparatus may align the film to be in contact with the cavities so that the film surrounds the openings of the cavities forming a seal between. A cavity comprising a flange around the opening of the cavity may improve contact between the film and the cavity.

[0083] In an alternative embodiment of the invention, the film is forced away from the cavity by blowing air against it, i.e. using positive pressure in the cavity relative to the ambient. Typically the pressure of the blown air will be less than 5 Bar, preferably less than 3 Bar. Blowing air may occur when the punch is brought into contact with the film or when the punch has moved partially into the cavity. Air under pressure may move through the vacuum ports to lift the film. In this configuration, the blown air may stretch the film in the region between the punch and the perimeter of the cavity. The apparatus may comprise a clamp or other retaining means to keep the film against the cavity, particularly the flange thereof. After the film is blown with positive pressure, negative pressure may be applied to the cavity to pull the film off the punch into the cavity.

[0084] Plasticisation

[0085] In some embodiments, a wetting agent may be applied to the film prior to thermoforming (i.e. step Hi)), or prior to the punching module. A wetting agent may be added to the film to make the film material softer, more flexible, and easier to process. The term wetting agent as used herein includes aqueous and non-aqueous wetting agents that may have a plasticisation effect on the film. A wetting agent may optionally be partially or entirely water, a solution of the film composition, a plasticizer for the film composition, or any combination of the foregoing. The wetting agent may be applied to the film prior to step iii), prior to heating the film, or prior to aligning the film with the array of cavities. In some embodiments, the apparatus may comprise a liquid application device to apply the wetting agent to the film, optionally this may be located prior to the punching module, and / or prior to aligning the film with the array of cavities, and / or prior to the heat source. A liquid application device may comprise a spray device, which may optionally comprise one or more nozzles. The spray device may be positioned to spray a wetting agent directly onto the film or indirectly onto a surface or object that contacts the film. A liquid application may alternatively comprise a medium for transferring water by nonspraying means, e.g. a wicking material or a gravure roller for example.

[0086] Use

[0087] In a third aspect of the present disclosure, there is the use of an apparatus according to the second aspect, or the use of the method according to the first aspect, wherein the use is for producing a dosage element. The dosage element may be any dosage element as described herein.

[0088] Retrofitting

[0089] In a fourth aspect, there is a method of making an apparatus according to the second aspect comprising: providing an apparatus comprising: i) a moveable array of cavities, and ii) a film feeding apparatus to align a film with the array of cavities; retrofitting to the apparatus: iii) a heat source to heat the film, and iv) a punching module comprising a punch to push the film into the cavities.

[0090] Retrofitting in this context may refer to the modification of the apparatus to enable it to perform the method of the first aspect. The apparatus in the fourth aspect may not comprise a punching module and / or heat source prior to the method of the fourth aspect. Specifically, it may comprise integrating the heat source and punching module to the apparatus comprising the moveable array of cavities and film feeding apparatus. Integrating may comprise connecting the heat source and punching module to the apparatus, and additionally may comprise configuration of the heat source and punching module to operate with the apparatus. For example, the heat source may be configurable to operate at a temperature appropriate for thermoforming with the punching module. Likewise, the punching module may be capable of operating at a punch rate and depth appropriate for the line speed and depth of the array of cavities. Retrofitting may additionally comprise some configuration of the apparatus, e.g. the speed of the array of cavities, and film feeding apparatus. In some embodiments, the heat source is retrofitted after the film feeding apparatus, and the punching module is retrofitted after the heat source.

[0091] In a fifth aspect of the present disclosure, there is a kit for use in the method according to the fourth aspect comprising: a heat source to heat the film, and a punching module comprising a punch to push the film into the cavities; wherein 1) and 2) are retrofittable to an apparatus comprising: i) a moveable array of cavities, and ii) a film feeding apparatus to align a film with the array of cavities.

[0092] The apparatus of the fifth aspect may not comprise a punching module and / or heat source. Retrofittable in this context may refer to the punching module and heat source being capable of integrating with the apparatus. Thus the heat source and punching module may be configured to be connected with the apparatus. For example, the heat source and punching module may comprise connections such as bolt holes, brackets flanges etc. that may facilitate a mechanical connection to the apparatus. Similarly, the heat source and punching module may be configured to allow operation with the apparatus. For example, the punching module or heat source may comprise an accessible interface that permits the configuration of operating temperature, punching rate and punching depth.

[0093] The present disclosure provides a method and an apparatus as disclosed herein for thermoforming a film for the production of a dosage element, the use of the apparatus, a method of making said apparatus and a kit for use in the method of making said apparatus. The apparatus, method, use thereof, and method of making the apparatus and kit may implement any feature of any preceding embodiment or another embodiment disclosed herein.

[0094] The preceding summary is provided for the purposes of summarizing some embodiments to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding embodiments may be combined in any suitable combination to provide further embodiments. Features described in one aspect of the disclosure are to be construed as applicable to other aspects of the disclosure. For example, the apparatus described herein is to be construed as applicable for performing the function of the apparatus in the method, and visa versa. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims. The present invention conclusively focuses on a plurality of aspects as described above, which are disclosed in the following again in the form of certain listed embodiments:

[0095] Herein, the invention focuses on a method for thermoforming a film forthe production of water- soluble dosage elements, the method comprising the steps of: i) in any order or concurrently, heating and aligning a film with an array of cavities; ii) moving the film and the array of cavities through a punching module, the punching module comprising at least one punch that is moveable into the cavities of the array; and iii) operating the punching module to push the film into the cavities with the punch as each cavity from the array moves through the punching module.

[0096] In a preferred embodiment thereof, the method further comprises filling the film in the cavities with one or more treatment agents; wherein preferably the method further comprises applying a film lid to the film in the cavities and sealing to form water-soluble dosage elements.

[0097] In a more preferred embodiment thereof, the method further comprises removing the dosage elements from the cavities and / or the method further comprises cutting or perforating the film between adjacent dosage elements.

[0098] In an embodiment, the method further comprises applying negative pressure to the cavities of the array before and / or after and / or during step iii).

[0099] In an embodiment, the film is aligned with the array of cavities by one or more rollers.

[0100] In an embodiment, the array of cavities comprises the cavities arranged as an endless loop, optionally wherein the endless loop is a continuous belt.

[0101] In an embodiment, the punch is heated to a surface temperature of from 20 to 170 degrees C, or from 50 to 170 degrees C, or from 60 to 120 degrees C, or from 70 to 130 degrees C, or from 70 to 90 degrees C, or from 80 to 100 degrees C.

[0102] In an embodiment, the method further comprises applying a wetting agent to the film prior to step iii).

[0103] In an embodiment, the film is heated priorto the punch by the heat source, and the heat source is located adjacent to and priorto the punch, and optionally wherein the heat source comprises one or more of a hot air source, a radiation heater, piezoelectric elements, and / or resistive heating elements.

[0104] In an embodiment, the film is aligned with the array of cavities by one or more rollers prior to the punching module, and at least one of the one or more rollers prior to the punching module is heated to a temperature of from 70 to 220 degrees C, or from 85 to 190 degrees C or from 100 to 170 degrees C, or from 115 to 150 degrees C, or 130 to 135 degrees C.

[0105] In an embodiment, the punch moves into the cavity at a rate of from 10 m / s to 500 m / s, or from 50 m / s to 400 m / s, or from 75 m / s to 300 m / s, or from 100 m / s to 200 m / s, or from 125 m / s to 175 m / s.

[0106] In an embodiment, the film and the array of cavities move together at a speed from 4 m / min to 18 m / min, or from 6 m / min to 16 m / min, or from 8 m / min to 14 m / min, or from 10m / min to 12 m / min.

[0107] In an embodiment, the cavities have a depth from 5 mm to 30 mm, or from 10 mm to 25 mm, or from 15 mm to 20 mm.

[0108] In an embodiment, the mean distance between the punch and the sides of the cavities from or from 0.1 mm to 6 mm, or from 0.3 mm to 3 mm, or from 0.35 mm to 1.5 mm, or from 0.4 mm to 0.9 mm, or from 0.5 mm to 0.75 mm.

[0109] In an embodiment, the punch enters the cavity for a duration between 0 and 4000 ms, or between 250 and 3500, or between 500 and 3000 ms, or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500.

[0110] In an embodiment, the punch enters the cavity up to 100%, or 99.99%, or 99.75%, or 99.5%, or 99.25% or 99%, or 97.5%, or 95% of the total depth of the cavity; and optionally more than 50%, or 70%, or 80%, or 90% or 95% or 97.5% of the total depth of the cavity.

[0111] In an embodiment, the punch module moves the punch in the machine direction at the same speed as the array of cavities, whilst the punch enters and withdraws from a cavity.

[0112] In an embodiment, the cavities of the array of cavities are heated to a temperature of from 70 to 220 degrees C, or from 85 to 190 degrees C or from 100 to 170 degrees C, or from 115 to 150 degrees C, or 130 to 135 degrees C. In an embodiment, the film is heated to a temperature of 70 to 220 degrees C, or from 85 to 190 degrees C, or from 100 to 170 degrees C, or from 115 to 150 degrees C, or from 130 to 135 degrees C.

[0113] In an embodiment, the tension of the film prior to step ii) is greater than 1 N, or 5N, or 10N, or 15N, or 20N or 25N, and not exceeding 45N, or 40N, or 35N, or 30N, or 25N, or 20N or 15N.

[0114] The invention focuses also on an apparatus for thermoforming a film for the production of a dosage element, comprising: i) a moveable array of cavities, ii) film feeding apparatus to align the film with the array of cavities, iii) a heat source to heat the film, iv) a punching module comprising a punch to push the film into the cavities as the cavities and film move together through the punching module.

[0115] In a preferred embodiment thereof, the apparatus further comprises a filling apparatus to fill the film in the cavities with one or more treatment agents.

[0116] In one embodiment, the apparatus further comprises means to apply a film lid to the film in the cavities, and / or apparatus to seal the film lid to the film in the cavities to form dosage elements.

[0117] In a preferred embodiment thereof, the apparatus further comprises apparatus to remove the dosage elements from the cavities; and / or the apparatus further comprises a cutting apparatus configured to cut or perforate the film between adjacent cavities to form individual dosage elements.

[0118] In one embodiment, the apparatus further comprises one or more than one vacuum source to apply negative pressure to the cavities of the array of cavities.

[0119] In one embodiment, the film feeding apparatus comprises one or more rollers.

[0120] In one embodiment, the array of cavities comprises cavities arranged as a continuous belt.

[0121] In one embodiment, the heat source comprises a heated punch, wherein the punch is heated to a surface temperature of from 20 to 170 degrees C, or from 50 to 170 degrees C, or from 60 to 120 degrees C, or from 70 to 130 degrees C, or from 70 to 90 degrees C, or from 80 to 100 degrees C. In one embodiment, the apparatus further comprises a liquid application device to apply a wetting agent to the film prior to the punching module.

[0122] In one embodiment, the heat source comprises a radiation heater, resistive element or a hot air source located adjacent to and prior to the punching module.

[0123] In one embodiment, the apparatus comprises at least one roller prior to the punching module, wherein the at least one roller is heated to a temperature of 70 to 220 degrees C, or from 85 to 190 degrees C or from 100 to 170 degrees C, or from 115 to 150 degrees C, or 130 to 135 degrees C.

[0124] In one embodiment, the punching module is configured to move the punch into the cavity at a rate of from 10 m / s to 500 m / s, or from 50 m / s to 400 m / s, or from 75 m / s to 300 m / s, or from 100 m / s to 200 m / s, or from 125 m / s to 175 m / s.

[0125] In one embodiment, the moveable array cavities and film feeding apparatus are configured to move the film and array of cavities film together at a speed from 4 m / min to 18 m / min, or from 6 m / min to 16 m / min, or from 8 m / min to 14 m / min, or from 10m / min to 12 m / min.

[0126] In one embodiment, the cavities have a depth from 5 mm to 30 mm, or from 10 mm to 25 mm, or from 15 mm to 20 mm.

[0127] In one embodiment, the mean distance between the punch and the sides of the cavities from or from 0.1 mm to 6 mm, or from 0.3 mm to 3 mm, or from 0.35 mm to 1.5 mm, or from 0.4 mm to 0.9 mm, or from 0.5 mm to 0.75 mm.

[0128] In one embodiment, the punch is configured to enter the cavity for a duration between 0 and 4000 ms, ore between 250 and 3500 or between 500 and 3000 ms or between 700 and 2500 ms, or between 900 and 2000 ms, or between 1000 and 1500 when pushing the film into the cavities.

[0129] In one embodiment, the punch is configured to enter the cavity up to 100%, or 99.99%, or 99.75%, or 99.5%, or 99.25%, or 99%, or 97.5%, or 95% of the total depth of the cavity; and optionally more than 50%, or 70%, or 80%, or 90%, or 95%, or 97.5% of the total depth of the cavity. In one embodiment, the punching module may comprise one or more actuators to move the punch parallel to the machine direction at the same speed as the array of cavities.

[0130] In one embodiment, the apparatus comprises a heat source to heat the cavities of the array of cavities.

[0131] In one embodiment of the method or apparatus, the dosage element is water soluble to release a treatment agent.

[0132] In one embodiment of the method or apparatus, the dosage element comprises two or more compartments, optionally wherein a different treatment agent is contained within each compartment.

[0133] In one embodiment of the method or apparatus, the treatment agent comprises a detergent, optionally wherein the detergent is a laundry detergent or a dishwasher detergent.

[0134] In one embodiment of the method or apparatus, the film comprises a water-soluble polymer; wherein the film preferably comprises a PVOH film.

[0135] In one embodiment of the method or apparatus, the film has a thickness between 100 pm and 240 pm, or between 120 pm and 220 pm, or between 140 pm and 180 pm, or between 150 pm and 170 pm.

[0136] The invention is also directed to the use of such an apparatus or of such a method for producing dosage elements.

[0137] The invention is further directed to a method of making such an apparatus comprising: providing an apparatus comprising: i) a moveable array of cavities, and ii) film feeding apparatus to align a film with the array of cavities; retrofitting to the apparatus: iii) a heat source to heat the film, and iv) a punching module comprising a punch to push the film into the cavities.

[0138] The invention is further directed to a kit for use in such a method of making such an apparatus, comprising: a heat source to heat the film, and a punching module comprising a punch to push the film into the cavities; wherein 1) and 2) are retrofittable to an apparatus comprising: i) a moveable array of cavities, and ii) a film feeding apparatus to align a film with the array of cavities.

[0139] Brief description of the Drawings

[0140] Aspects, features and advantages of embodiments of the present disclosure will become apparent from the following description of embodiments in reference to the appended drawings in which like numerals denote like elements.

[0141] Figures 1a and 1 b are schematic illustrations of an apparatus of the prior art for the production of dosage elements.

[0142] Figure 2a is a schematic illustration of an apparatus of the present disclosure.

[0143] Figure 2b is a schematic illustration of an alternative apparatus of the present disclosure.

[0144] Figure 3a is a schematic illustration of an alternative apparatus of the present disclosure.

[0145] Figure 3b is a schematic illustration of a cavity according to Figure 3a.

[0146] Figure 3c is a schematic illustration of a top-down view of a section of the array of cavities according to Figure 3a.

[0147] Figure 4 is a schematic illustration of an alternative apparatus of the present disclosure. Figure 5 is a schematic illustration of a kit according to an aspect of the present disclosure.

[0148] Detailed Description of the Invention

[0149] Before describing several embodiments of the apparatus, it is to be understood that the apparatus is not limited to the details of construction or process steps set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the embodied apparatuses are capable of being practised or being carried out in various ways, in particular, the below embodiments may be combined with any other disclosure described herein.

[0150] Figure 2a shows apparatus 10 according to the second aspect. Apparatus 10 is useable for performing a method according to the first aspect. Apparatus 10 comprises a moveable array of cavities 40, a film feeding apparatus 60, a heat source 80 and a punching module 100 comprising punch 120. The array of cavities 40 is formed from a plurality of individual cavities (40a, 40b, 40c) arranged on an endless loop, the endless loop is shown in part in Figure 2. The array of cavities 40 continuously moves to sequentially move the individual cavities (40a, 40b, 40c) through the punching module 100. The film feeding apparatus 60 shown in Figure 2a is a pair of rollers. The film feeding apparatus 60 functions to align a film 20 with the array of cavities 40 and move the film 20 therewith, thus the feeding apparatus 60 brings the film 20 into contact with the array of cavities 40 and moves the film 20 at the same or a similar speed to the individual cavities (40a, 40b, 40c). The movement of film 20 (i.e. the machine direction) is shown by arrow A.

[0151] Heat source 80 shown in Figure 2a is an infrared heat source. The heat source 80 heats the film 20 to a softening temperature. The heat-softened film 20a is then conveyed along with the array of cavities 40 to the punching module 100. The punching module 100 comprises a punch 120. The punch 120 is configured to move into and out each of the cavities (40a, 40b, 40c) as the cavities (40a, 40b, 40c) pass through the punching module 100. The punch 120 does not move laterally at the cavities pass. 40a is an empty cavity moving towards the film feeding apparatus 60. 40b is a cavity with the film 20 aligned with it being heated to a softening temperature by the heat source 80. Cavity 40c is moving away from film feeding apparatus 60 towards the punching module 100. The movement of punch 120 into the cavities pushes the softened film 20a into the cavities, thermoforming the film 20b to the shape of the cavities. 40c shows a cavity with the softened film 20b pushed into the cavity by punch 120.

[0152] A single infrared heat source 80 is shown in Figure 2a, however as stated above, it is within the scope of the present disclosure for the heat source to comprise additional sources or alternative sources of heat to the heat source 80 illustrated in Figure 2a. A pair of rollers is shown in Figure 2a as the film feeding apparatus 60, however, it is within the scope of the disclosure for the film feeding apparatus to comprise an alternative apparatus to that shown in Figure 2a e.g. a single roller or any other film handling apparatus.

[0153] Figure 2b shows the same apparatus as Figure 2a, with an alternative punching module 200. The punch module comprises actuators to move the punch 220 linearly parallel with the machine direction A. The punch module 200 starts with the punch in position B and moves the punch 220 at the same speed as an adjacent cavity. Punch 220 then enters the cavity pushing the film inside. Punch 220 retracts from the cavity and the punch module 200 moves the punch 220 back to the start position B at high speed. The punch module 200 then tracks the next cavity with the punch 220, repeating the process.

[0154] Figure 3a shows an alternative apparatus 300 according to the second aspect. Apparatus 300 is useable for performing a method according to the first aspect. Apparatus 300 comprises a moveable array of cavities 340, a film feeding apparatus 360, a heat source 380 a punching module 310 comprising punch 330 and a vacuum source 350. The array of cavities 340 is formed from a plurality of individual cavities 41 arranged on an endless loop, shown in part in Figure 3a. The array of cavities 340 continuously moves to sequentially move the individual cavities through the punching module 310. Film 320 is aligned with the array of cavities by film feeding apparatus 360. The film feeding apparatus 360 is a roller that guides the film into contact with the array of cavities 340. The film feeding apparatus 360 also comprises a heat source 380 which heats the surface of the roller. Contact between the film and the roller heats the film to a softening temperature. The softened film then moves with the array of cavities 340 to the punching module 310 and vacuum source 350. The punch 330 of the punching module 310 then moves into the cavity pushing the film to a partial or full depth of the cavity. The vacuum source 350 applies negative pressure to the bottom part of a cavity partially additionally pulling the softened film into the cavity. The vacuum source 350 may be applied before during or after the punch 330 enters the cavity.

[0155] Figure 3b shows an enlarged view of cavity 41 according to Figure 3a and corresponding punch 330. The cavity 41 is formed from a solid body 43 and encloses an internal volume 44. The internal volume 44 is bounded at the upper surface by an opening illustrated with line 48 in Figure 3b. Cavity 41 has an internal depth 47 measured perpendicular to the opening 48, from the opening 48 to the deepest part of cavity 41 , illustrated with line 47 in Figure 3b. The cavity 41 in Figure 3b also comprises two separate compartments 46 in the bottom of the cavity 41. The cavity has an internal radius between the bottom and the sides of the cavity illustrated with R in Figure 3b. The cavity has a flat surface surrounding the opening which may be shaped as a flange 42 which the film 20 may contact. Vacuum ports 45 in the bottom of cavity 41 allow a vacuum to be applied to the cavity from a vacuum source 350.

[0156] Figure 3c shows a top-down view of a section of the array of cavities 340 according to Figure 3a. The cavities 41 are aligned 4-abreast. Adjacent rows of cavities are joined by linkages 49. Optionally, the linkages may be flexible or articulated. That is there are four cavities 41 aligned perpendicular to the direction of movement of the array of cavities 340. The direction of movement (i.e. the machine direction) is shown by arrow A. The array of cavities 340 moves towards the punching module 310 which comprises four punches 330. As each row of four cavities 41 enters the punching module, each of the four punches pushes the film simultaneously into the cavities 41 .

[0157] Figure 4 shows an alternative apparatus 400 according to the second aspect. Apparatus 400 is useable for performing a method according to the first aspect. Apparatus 400 comprises the same features as the apparatus of Figure 2: a moveable array of cavities 440, a film feeding apparatus 460, a heat source 480 and a punching module 410 comprising punch 430. After punching module 410, apparatus 400 additionally comprises a filling apparatus 425 to place a treatment agent 475 onto the film 420 in the cavities 41 . A second film feeding apparatus 435 places a second film 422 over the first film 420. The second film 422 is then sealed to the first film 420 by heat sealing means 445. A cutting apparatus 455 then cuts out individual dosage elements 485 from adjacent dosage elements. Apparatus for removing dosage elements 465 then removes the dosage elements 485 from their cavities. The Apparatus 400 is shown with a heat source, film feeding apparatus and punching module arrangement the same as Figure 2, however, all other arrangements within the scope of the disclosure are applicable to the embodiment shown in Figure 4.

[0158] Figure 5 shows a kit 500 according to the fifth aspect and a separate apparatus 511 useable with the kit 500. The Kit 500 comprises a punching module 510 and a heat source 580. The Apparatus 511 comprises at least a film feeding apparatus and an array of cavities 540. Kit 500 can be fitted to apparatus 511 to form an apparatus according to the present disclosure. Apparatus 511 may already incorporate a heat source, e.g. a heated roller, where the heat source can be adapted to achieve a temperature sufficient to operate with a punching module, the kit may comprise the punching module alone. Alternatively, the heat source 580 may be applied to apparatus 511 in addition to the preexisting heat source of the apparatus 511.

[0159] As used in this specification, any formulation used of the style “at least one of A, B or C”, and the formulation “at least one of A, B and C” use a disjunctive “or” and a disjunctive “and” such that those formulations comprise any and all joint and several permutations of A, B, C, that is, A alone, B alone, C alone, A and B in any order, A and C in any order, B and C in any order and A, B, C in any order. There may be more or less than three features used in such formulations.

[0160] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word ‘comprising’ does not exclude the presence of other elements or steps than those listed in a claim. Furthermore, the terms “a” or “an,” as used herein, are defined as one or more than one. Also, the use of introductory phrases such as “at least one” and “one or more” in the claims should not be construed to imply that the introduction of another claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an." The same holds true for the use of definite articles. Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to advantage.

[0161] Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, example or claims prevent such a combination, the features of the foregoing embodiments and examples, and of the following claims may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit and instead may arise from an “ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of the example(s), embodiment(s), or dependency of the claim(s). Moreover, this also applies to the phrases “in one embodiment”, “according to an embodiment” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to ‘an’, ‘one’ or ‘some’ embodiment(s) may be a reference to any one or more, and / or all embodiments, or combination(s) thereof, disclosed. Similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment.

[0162] The preceding description of one or more implementations provides illustration and description but is not intended to be exhaustive or to limit the scope of the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from the practice of various implementations of the present disclosure.

[0163] List of References

[0164] 10, 300, 400 Apparatus

[0165] 20, 320, 420 Film

[0166] 20a softened film

[0167] 20b thermoformed film

[0168] 40, 340, 440, 540 Moveable array of cavities 40a, 40b, 40c individual cavities

[0169] 41 cavity

[0170] 42 flange

[0171] 43 solid body

[0172] 44 internal volume

[0173] 45 vacuum ports

[0174] 46 compartments

[0175] 47 cavity internal depth

[0176] 48 opening

[0177] 49 linkages

[0178] 60, 360, 460, 560 Film feeding apparatus

[0179] 80, 380, 480, 580 heat source

[0180] 100, 200, 310, 410, 510 punching module

[0181] 120, 220, 330, 430 punch.

[0182] 350 vacuum source

[0183] 425 filling apparatus

[0184] 422 second film

[0185] 435 second film feeding apparatus

[0186] 445 heat sealing means

[0187] 455 cutting apparatus

[0188] 465 apparatus for removing dosage elements

[0189] 485 Dosage element

[0190] 475 Treatment agent

[0191] 500 Kit

Claims

Claims1. A method for thermoforming a film for the production of water-soluble dosage elements, the method comprising the steps of: i) in any order or concurrently, heating and aligning a film with an array of cavities; ii) moving the film and the array of cavities through a punching module, the punching module comprising at least one punch that is moveable into the cavities of the array; and iii) operating the punching module to push the film into the cavities with the punch as each cavity from the array moves through the punching module.

2. A method according to claim 1 , further comprising filling the film in the cavities with one or more treatment agents.

3. A method according to claim 2, further comprising applying a film lid to the film in the cavities and sealing to form water-soluble dosage elements.

4. A method according to any preceding claim, further wherein the array of cavities comprises the cavities arranged as an endless loop, optionally wherein the endless loop is a continuous belt.

5. A method according to any preceding claim, wherein the film is aligned with the array of cavities by one or more rollers prior to the punching module, and at least one of the one or more rollers prior to the punching module is heated to a temperature of from 70 to 220 degrees C, or from 85 to 190 degrees C or from 100 to 170 degrees C, or from 115 to 150 degrees C, or 130 to 135 degrees C.

6. A method according to any preceding claim, wherein the film and the array of cavities move together at a speed from 4 m / min to 18 m / min, or from 6 m / min to 16 m / min, or from 8 m / min to 14 m / min, or from 10m / min to 12 m / min.

7. A method according to any preceding claim, wherein the punch module moves the punch in the machine direction at the same speed as the array of cavities, whilst the punch enters and withdraws from a cavity.

8. A method according to any preceding claim, wherein the film is heated to a temperature of 70 to 220 degrees C, or from 85 to 190 degrees C, or from 100 to 170 degrees C, or from 115 to 150 degrees C, or from 130 to 135 degrees C.

9. Apparatus for thermoforming a film for the production of a dosage element, comprising: i) a moveable array of cavities, ii) film feeding apparatus to align the film with the array of cavities, iii) a heat source to heat the film, iv) a punching module comprising a punch to push the film into the cavities as the cavities and film move together through the punching module.

10. Apparatus according to claim 9, further comprising a filling apparatus to fill the film in the cavities with one or more treatment agents.11 . Apparatus according to claim 9 or claim 10, further comprising means to apply a film lid to the film in the cavities, and / or apparatus to seal the film lid to the film in the cavities to form dosage elements.

12. Apparatus according to any of claims 9 to 11 , wherein the array of cavities comprises cavities arranged as a continuous belt.

13. Apparatus according to any of claims 9 to 12, wherein the punching module is configured to move the punch into the cavity at a rate of from 10 m / s to 500 m / s, or from 50 m / s to 400 m / s, or from 75 m / s to 300 m / s, or from 100 m / s to 200 m / s, or from 125 m / s to 175 m / s.

14. Apparatus according to any of claims 9 to 13, wherein the moveable array cavities and film feeding apparatus are configured to move the film and array of cavities film together at a speed from 4 m / min to 18 m / min, or from 6 m / min to 16 m / min, or from 8 m / min to 14 m / min, or from 10m / min to 12 m / min.

15. Apparatus according to any of claims 9 to 14, wherein the punching module may comprise one or more actuators to move the punch parallel to the machine direction at the same speed as the array of cavities.

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