Process for making a sachet

Abstract

A method for forming a thermoformed sachet involves stacking a first and a second flexible sheet, deforming the sheets using heat to conform to compatible shapes within a mold system, and sealing the sheets together along an edge. The sachet envelope comprises a first and a second flexible sheet, each having a thermoformed concave or convex shape, arranged in a nested stack and partially sealed along an edge to form separable interior portions. The sachet includes a pocket formed by sealing the sheets along an edge, filled with material, and may feature a planar top and bottom surface and curvatures with angles between 45 and 90 degrees. The sachet may also have an insert for controlled dispensing, allowing the sachet to collapse without venting. The material within the sachet can be a fabric and homecare product, such as liquid laundry detergent.

Description

[0001] PROCESS FOR MAKING A SACHET

[0002] TECHNICAL FIELD

[0003] The present disclosure is directed to methods of thermoforming sachets and the resulting sachet therefrom.

[0004] BACKGROUND

[0005] Thermoforming refers to the process of heating a plastic sheet until it becomes pliable, then forming it into a specific shape using a mold, and, in some cases, trimming it to create a usable product. This technique is widely used in packaging, automotive parts, and consumer products. Thermoformed products can range from simple trays and containers to complex automotive panels and medical device components. The process can involve several steps, including for example heating, forming, and cooling, and can be performed using various methods such as vacuum forming, pressure forming, and mechanical forming. EP0019005A1 discloses forming cavities for preparation of suppositories. CH437102A discloses forming a packaging cavity and filling the formed cavity. EP0750547A1 discloses deep-drawn half shells to form a volume of a package of fluid.

[0006] BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0008] Fig. 1 A-B are block diagrams of example methods of manufacturing a thermoformed sachet according to the present disclosure.

[0009] Fig. 1C-F are schematics of example first and second flexible sheets positioned during an example method of manufacturing a thermoformed sachet according to the present invention.

[0010] Fig. 2A-B are block diagrams of example methods of manufacturing a thermoformed sachet according to the present invention.

[0011] Fig. 3A is a block diagram of an example method of manufacturing a thermoformed sachet according to the present invention. Fig. 3B-3D are schematics of example folding configurations of example first and second flexible sheets according to some embodiments of the present invention.

[0012] Fig.4A-B are block diagrams of example methods of manufacturing a thermoformed sachet according to the present invention.

[0013] Fig. 5 is a schematic of an example thermoformed sachet envelope according to the present invention.

[0014] Fig. 6 is a perspective of an example multi-layer laminate for a first and second flexible sheet accordingto some embodiments of the present invention.

[0015] Fig.7A-E are comparisons of example thermoformed sachet envelopes and example thermoformed sachets accordingto the present invention.

[0016] Fig. 8 and 9 are schematic views of an example edge seal of a thermoformed sachet accordingto some embodiments of the present invention.

[0017] Fig. 10 is a perspective of an example thermoformed sachet received within an enclosure of a compartment according to the present invention.

[0018] DETAILED DESCRIPTION

[0019] Thermoforming is a manufacturing process used to shape thermoplastic materials into various three-dimensional forms. It involves heating a thermoplastic sheet to a specific temperature below its meltingtemperature, then (orwhile) usinga mold ortoolto shape the softened sheet, for example with a vacuum or assisted by a stamp, into a desired shape, and subsequently fixing the shape by cooling the thermoplastic. In the packaging industry, thermoforming aims to create containers that are both functional and efficient in terms of space utilization. The goal is to maximize the volume of the contents while minimizing the material used and the space occupied by the packaging. This is particularly important for products that need to be shipped and stored in large quantities. Efficient packaging can lead to significant cost savings in transportation and storage, as well as reduced environmental impact due to lower material usage.

[0020] One of the main challenges in thermoforming is achieving a high level of space efficiency while maximizing the amount of material to be contained in the thermoformed container. Thermoformed containers often require additional headspace to accommodate the filling process, which reduces the overall efficiency of the packaging. Additionally, these containers may be semi-rigid, a semi-rigid or self sustainable cavity or volume being formed prior to the filling of such cavity of volume, making them susceptible to damage and leakage while making shipping more difficult given the large footprint of each container. The need for venting and labelling further complicates the design and manufacturing process, adding to the cost and reducing the overall efficiency of the packaging solution.

[0021] Thermoforming techniques can involve heating a relatively thick and relatively rigid plastic sheet and forming it into a shape using a mold. This method typically results in a semi-rigid structure that requires additional headspace for filling and venting.

[0022] A sachet should be understood as a structure obtained from two flat substrates, or from a single flat substrate folded onto itself, which may be sealed on all edges or partially sealed on one or more edges. As will be explained below, a sachet according to this disclosure is a thermoformed sachet, such that one or more of the flat substrates will eventually not maintain a flat structure. A sachet may be used to contain and dispense products such as powders, liquids, or gels.

[0023] In contrast, other film forming or sachet forming techniques can involve sealing two flat, thin, flexible substrates all edges, forming a flexible pillow shape. While these sachets are more flexible and can be filled with minimal headspace, they suffer from deformation during filling. As the sachet is filled, the sachet dimensions increase in a first direction, which compress the sachet in an opposing dimension, leading to irregular shaped pillows. This reduces the space efficiency especially when incorporating such sachets into a predetermined space.

[0024] There is thus a need for a packaging solution that combines the flexibility and minimal headspace of sachets with the structural integrity and space efficiency of thermoformed containers while allowing for independent control of the shape and depth of individual pockets or compartments within the packaging. This solution should address the shortcomings of conventional thermoforming and sachet techniques, providing a more efficient and reliable packaging option forvarious applications.

[0025] The present disclosure addresses the aforementioned needs by providing a thermoforming process and resultingthermoformed sachet with improved space efficiency, reduced or absent venting requirement, reduced or absent deformation, and the ability to be efficiently stacked and shipped. Method of manufacturing

[0026] Referringto Fig. 1 A, the present disclosure relates to a method 100 of thermoforming a sachet, comprising block 101 of stacking a first and a second flexible sheet, block 102 of heating said first and second flexible sheets to deform them into compatible shapes, and block 103 of sealing the first and second flexible sheets about an edge thereof.

[0027] Flexible refers to the ability of a material or structure to bend or be bent easily without breaking. In the context of the patent application, it describes the characteristic of the sachet material that allows it to conform to different shapes, withstand deformation during filling, and collapse without venting, thereby enhancing space efficiency and reducing the risk of damage or leakage. A flexible sheet according to this disclosure should be understood as a sheet which, when integrated into a sachet as hereby described, would bend or collapse under its own weight (i.e. not be self-sustainable). It is important to note that such flexibility provides the advantage of collapsing without venting.

[0028] In block 101, the method involves stacking the first and second flexible sheets. Stacking may be understood as placing the first and the second sheet on top of each other, such that at least a significant portion of the first and second sheets overlap each other. As seen in Fig. 1B, the first and second flexible sheets are individual sheets which may be stacked on top of each other. In some embodiments, the first and second sheets are stacked directly on top of each other. In some other embodiments, intermediate sheets or other elements are present between the first and second flexible sheets.

[0029] As shown in Fig. 1A, the stacking step may occur before any subsequent heating or deforming steps. In other embodiments, as shown in Fig. 1B, the first and second flexible sheets may first be deformed (as detailed below) then stacked in a nested configuration.

[0030] The first and second flexible sheets may be made of the same or different materials having the same or different thicknesses as seen in Fig. 1 C-1 F. One or more of the first and second flexible sheets are formed of a non-water soluble polymeric material. In some examples, both the first and second flexible sheets are formed from a non-water soluble polymeric material. Non-water soluble refers to a material's characteristic of not dissolving or breaking down when exposed to water such that a non-water soluble polymer should be understood to describe a polymer that does not readily dissolve or disperse in solvents or water. In the context of the patent application, it describes the property of the flexible sheets used in the thermoformed sachet, ensuring that the sachet maintains its structural integrity and does not degrade or dissolve when in contact with water or aqueous solutions. This property is of relevance to applications where the sachet may be exposed to moisture or liquid contents.

[0031] In some embodiments, the first and second flexible sheet are formed of the same polymeric, non-water soluble flexible films. Examples of polymeric, non-water soluble flexible films include polyethylene, polypropylene, bi-oriented polypropylene, polyvinyl chloride, polyethylene terephthalate, polyamide, or polystyrene. In some examples, a monomaterial is used for the sachet envelope to facilitate recycling. In some examples, the monomaterial is a polyethylene. In other embodiments, the first and second flexible sheet are formed of different non-water soluble flexible films.

[0032] In using non-water soluble films, the sachet envelope can maintain structural integrity and can reduce or prevent degradation or dissolution when in contact with water or aqueous solutions. This property is of relevance for applications where the sachet may be exposed to moisture or liquid contents, such as in fabric and homecare products. The non-water soluble nature of the material ensures that the sachet can securely contain liquids, powders, or gels reducing or suppressing the risk of leakage or material breakdown, thereby enhancing reliability and durability of the packaging. However, some non-water soluble materials, for example laminated or coated papers, cannot solely be used to form the thermoformed sachets as such non-water soluble materials cannot be formed in the described thermoform process herein.

[0033] The use of a non-water soluble material may also contribute to the overall robustness of the sachet, making it suitable for various demanding environments, including high humidity and temperature conditions. This may enhance the shelf life and performance of the packaged product.

[0034] Additionally, the non-water soluble material can allow for the sachet to be used in applications wherein the sachet is used multiple times especially in applications where prolonged exposure to water or other liquids is expected, providing versatility and broadening the range of potential uses for the thermoformed sachet.

[0035] By designing the thermoformed sachet for multiple uses and enabling it to be refilled, the invention can reduce the carbon footprint associated with the thermoformed sachet. This approach may reduce the amount of plastic waste generated, as the same sachet can be reused multiple times, thereby contributing to an extended lifecycle and reducing the need for frequent replacements. This contributes to environmental sustainability by lowering the overall consumption of raw materials and reducing the volume of waste that ends up in landfills.

[0036] The ability to refill the sachet also offers practical benefits for consumers, as it provides a cost-effective and convenient solution for managing household products. Users can purchase refills instead of entirely new sachets, which can be more economical and reduce the frequency of waste disposal. This feature can enhance the user experience by providing a more sustainable and user-friendly packaging option.

[0037] By offering a reusable and refillable option, the invention may also support efforts to reduce the environmental impact of packaging and promotes a circular economy where materials are kept in use for as long as possible. This may benefit the environment and also may enhance the marketability of the product by appealing to environmentally conscious consumers.

[0038] In block 102, the first and second flexible sheets may be heated and deformed to form compatible shapes within one or more molds forming one or more thermoformed cavities. During deforming, the first and second flexible sheets may take the shape of the one or more thermoformed cavities within the one or more molds. “Compatible shape" refers to the specific form or contour that two or more components are designed to have so that they can fit together seamlessly. In the context of thermoforming sachets, it means that the first and second flexible sheets are deformed using heat to conform to shapes that are complementary, allowing them to nest or stack together efficiently and be sealed alongtheir edges to form a cohesive structure. In some embodiments, the first and second flexible sheets are simultaneously or sequentially deformed to achieve the thermoformed shapes. This flexibility in the manufacturing process may allow for the production of sachets with varying shapes and sizes, tailored to specific needs while maintaining the benefits of space efficiency and structural integrity.

[0039] Thermoforming both the first and the second sheet permits reaching higher material filling rates. In some embodiments, regions of one or more of the first or second flexible sheets may be shielded from heat such that only intended regions of the first or second sheet are deformed. This may prevent non-deformed regions of the one or more first or second flexible sheets from adhering to each other. In some embodiments, blown air may be employed between the first and second flexible sheets to maintain separation during deforming. In other embodiments, heat resistant lacquer or coatings may be applied to desired regions of one or more of the first or second flexible sheets in order to prevent undesired heating.

[0040] Example different shapes can be seen in Fig. 1A, 1C-1F, whereby each figure represents, on top, the first and second sheet being stacked. As illustrated, the first and the second sheets may have a same thickness (Figs. 1A and 1C) or may have different thicknesses (Fig. 1D, 1E and 1F). While different thicknesses are represented, other characteristics may be the same or may be different for the first and second sheets. Each of these figures represents, in the middle, deforming the first and second flexible sheets. As illustrated, the deforming may take different shapes, for example with a single flat bottom cavity having oblique edges (Fig. 1A), with a single pointy cavity having oblique edges(Fig.

[0041] 1C), with two pointy cavities (Fig. 1D), with a combination of a flat bottom cavity with right angle edges and of a flat bottom cavity with oblique edges (Fig. 1 E), or with a combination of a flat bottom cavity with right angle edges and of a pointy cavity with oblique edges (Fig. 1 F). Such different deforming configurations are here to illustrate numerous possibilities, many others being possibly used while not illustrated here. Each of these figures represents, at the bottom, a sealing of the first and second flexible sheets along an edge thereof. In Fig. 1 A, the sealing takes place on edges surrounding the cavity. In Fig. 1C, sealing takes place on one edge of the cavity. In Fig. 1D, sealing takes place between the cavities. In Fig. 1E, sealing takes place on edges surrounding both cavities. In Fig. 1F sealing takes place between the cavities and surrounding one of both cavities. Many other sealing configurations may be considered.

[0042] In block 103, the first and second flexible sheets may be sealed about an edge thereof to form the thermoformed sachet. The first and second flexible sheets remain separable about at least a portion of the interior of the sachet while being fixedly adhered to each other about at least a portion of the seal. In some embodiments, the sealing occurs along at least along an exterior edge of the stacked firstand second flexible sheets. In some embodiments, sealingthefirstand second flexible sheets occurs priorto beingpulled into the mold system. In other embodiments, sealing occurs after the first and second sheets are pulled into the mold system but before the first and second sheets are deformed. Sealing may also occur after the first and second sheets are deformed. This flexibility in the manufacturing process allows for the production of sachets with varying 3D shapes and sizes, tailored to specific needs while maintaining the benefits of space efficiency and structural integrity.

[0043] The order of performance of the blocks may differ ensuring that the final product meets specific requirements for various applications. In some embodiments, stacking the first and second flexible sheets occurs before the deforming step (pre-stacked configuration). This may simplify the manufacturing process by allowing the sheets to be handled as a single unit during the thermoforming process. This may reduce the complexity and potential misalignment issues that could arise if the sheets were deformed separately and then aligned for sealing. The pre-stacked configuration can increase the alignment of the first and second flexible sheets when they are deformed, which may lead to a more consistent and reliable final product. This process can also improve control on the dimensions of the flange during forming and later during filling versus conventional sachets as conventional sachets may deform during filling. This is of relevance in applications requiring multiple pockets with varying shapes and volumes.

[0044] This approach may also enhance the structural integrity of the resulting sachet as the sheets deformed together may have a more uniform shape and thickness distribution. Uniformity may minimize the risk of weak points that could lead to leakage or damage, therefore, improving uniformity may make the sachet more durable and suitable for various applications. Additionally, the pre-stacked configuration can allow for more efficient use of the mold system, as both sheets can be deformed simultaneously, the overall cycle time and production efficiency may be improved.

[0045] In other embodiments, the first and second flexible sheets may be stacked after being separately deformed. Stacking the sheets after deforming allows for better integration of pre-printed text and images, as the sheets can be aligned more precisely before sealing. This ensures that the artwork and text are accurately positioned on the final sachet, enhancing the visual appeal and branding of the product. This method also allows for the use of different materials or thicknesses for the first and second flexible sheets, providing greater flexibility in the design and functionality of the sachet. In Fig. 2A, the method 200 includes block 204 of printing one or more of text and images onto one or more of the first and second flexible sheets prior to block 101 or 102. This printing block may allow for the integration of information and branding directly onto the sachet material. This may eliminate the need for additional labelling steps post-formation, which may reduce the manufacturing process and production costs. Additionally, the preprinted information may be well-protected during the thermoforming process, which can maintain legibility and aesthetic quality.

[0046] In some embodiments, printing may be done by flexo or offset printing. This process is possible at least in part due to the flexibility and thickness of the first and second flexible sheets forming the thermoformed sachet. Because of the thickness and flexibility of the first and second flexible sheets, the sheets can be run directly from a reelor spoolthrough a print press to be decorated. The first and second flexible sheets can then be thermoformed in a single continuous process or rewound on the reel or spool to be later processed in a separate production line. This may improve process speed and lower manufacturing costs.

[0047] The thickness of each of the first and second flexible sheets may be between 30 and 400 microns. In some examples, the thickness of each of the first and second flexible sheets may be of less than 350 micron, or less than 300 micron, or less than 250 micron, or of less than 200 micron. A lower thickness may be related to an increased film flexibility which would facilitate nesting and provide a more efficient and reliable packaging solution. In some examples, the thickness of each of the first and second flexible sheets may be between 50 and 350 microns. In some examples, thickness of each of the first and second flexible sheets may be between 70 and 300 microns. In some examples, thickness of each of the first and second flexible sheets may be between 90 and 250 microns. In some examples, thickness of each of the first and second flexible sheets may be between 100 and 200 microns. In some embodiments the first and second flexible sheets may have the same thickness. In other embodiments the thickness of each of the first and second flexible sheets can vary in thickness within the above range. Increasing the thickness of each of the first and second flexible sheets above 400 microns may result in sheets having too rigid a structure to maintain necessary flexibility for the present thermoformed sachet whereas sheets having a thickness below 30 microns may not provide sufficient structural support in forming the thermoformed sachet and may be more likely to rupture or tear. Printing on the flexible sheets before subsequent manufacturing steps may also promote more accurate alignment of the text and / or images with the shape of the sachet. This may prevent or reduce distortion or misalignment that could occur if printing were done after the sachet is formed. Furthermore, this method may allow for the use of reverse printing techniques, where the ink is encapsulated between layers of the film, providing additional protection against environmental factors such as moisture and abrasion. Reverse printing may protect the ink to be printed and may eliminate the need for an additional protective layers. Reducing the number of required layers may reduce process complexity, cost, and improve recyclability.

[0048] One or both of the first and second flexible sheets may be at least partially transparent so as to enable a user to see text / i mage when not printed on an external surface of the sachet. One or both of the first and second flexible sheets being at least partially transparent may also enable the user to see the type and color of contents within the thermoformed sachet.

[0049] Transparent refers to a material's characteristic of allowing light to pass through it such that objects behind the material can be clearly seen. In the context of the patent application, it describes the property of the flexible sheets used in the thermoformed sachet, which may enable visibility of the contents or any printed text and images on the sachet. This transparency can be relevant for consumer products where visual inspection of the contents is desired, or for displaying branding and information directly on the sachet material without the need for additional labels.

[0050] In Fig.2B, the method 200 further includes a block 205 of cooling the first and second flexible sheets. In some embodiments, the cooling step may occur after the deforming step. In other embodiments (not shown) the cooling step may occur after the sealing step. Cooling refers to the removal of heat such that the first and second flexible sheets return to a temperature below their melting point. The cooling step allows the first and second flexible sheets to maintain their deformed shape. In some embodiments, the cooling step is an internal cooling whereby the first and second flexible sheets are cooled by cooling the mold. In some examples, internal cooling is accomplished by extinguishing a heat source used for sealing and / or thermoforming. Internal cooling may also include running cold water through a cooling coil located inside the mold. Other cooling fluids may also be used. In other embodiments, the cooling step is an external cooling whereby the first and second flexible sheets are subjected to blown air or water mist. Method 200 also includes blocks 101, 102, and 103 as described in the context of method 100.

[0051] In Fig.3A, the method 300 includes block 305 wherein the stacking according to block 101 occurs by pulling the first and second flexible sheets from one or more spools or reels of general material and folding the general material to stack the first and second flexible sheets. Method 300 also includes blocks 102 and 103 as described in the context of method 100.

[0052] In Fig. 3B, stacking may occur by folding the general sheet at least once such that a first folded portion forms the first flexible sheet and a second folded portion forms the second flexible sheet. This approach may improve alignment between the two sheets, as they originate from the same general sheet, and can reduce or prevent potential misalignment issues during the thermoforming and sealing steps. This approach may also enable higher machine output by producing an increased number of thermoformed sachets at the same production speed. In Fig. 3B, the general sheet is represented, on the top, prior to thermoforming, in the process of being folded onto itself, and on the bottom, after thermoforming. Fig. 3C demonstrates another embodiment, in which folding the general sheet may occur at least twice. The first fold may originate from a first edge of the general sheet and the second fold may originate from a second, opposing edge of the general sheet such that the first edge and the second, opposing edge may be generally aligned. In this embodiment, the first folded portion and a corresponding non-folded portion may form a first stack and the second folded portion and a corresponding non-folded portion may form a second stack. This approach may allow for multiple thermoforming processes to occur simultaneously from the same general sheet, which can contribute to reduced manufacturing time. In Fig. 3C, the general sheet is represented, on the top, prior to thermoforming, in the process of being folded onto itself on each edge, and on the bottom, after thermoforming.

[0053] Fig. 3D demonstrates yet another embodiment in which folding the general sheet occurs after thermoforming. The general sheet is thermoformed to include at least one pair of compatibly-shaped regions then the general sheet is folded at least once such that the at least one fold occurs at a point between the compatibly-shaped regions of each pair such that the folding aligns the corresponding pair of compatibly-shaped regions. Fig. 3D demonstrates an embodimentwherein onefold occurs, however, in otherembodiments, not shown, the general sheet may be folded more than once to align a plurality of pairs of compatibly-shaped regions formed in the general sheet. In Fig. 3D, the general sheet is represented, on the top, prior to thermoforming, in the middle after thermoforming and before folding, and on the bottom, after folding.

[0054] By pulling a general sheet from a reeland folding it to form the first and second flexible sheets, the method may simplify the manufacturing process by reducing the number of separate materials that need to be handled. This approach can improve alignment between the first and second flexible sheets, as they originate from the same general sheet, and can reduce or prevent potential misalignment issues during the thermoforming and sealing steps. This may lead to a more consistent and reliable final product. This approach may also be beneficial for recyclability as the sheets need not be separated from one another because they can be processed as a whole in the single recycling stream.

[0055] This method can also improve material efficiency by utilizing a single general sheetto create both the first and second flexible sheets. This can reduce waste compared to using separate sheets and can support continuous production, as the general sheet can be fed directly from the reel into the thermoforming process. This may improve production speed and may reduce downtime associated with material changes. Such improvements may lead to cost savings and improved manufacturing efficiency.

[0056] Additionally, the folding process can be adapted to accommodate different thicknesses and material properties, such that the final product can meet specific requirements forvarious applications.

[0057] In some embodiments, not pictured, the method 300 can include the step of blocks 204 and / or 205 as described above.

[0058] In Fig.4A, the method 400 includes blocks 101 , 102 and 103 as described above, and further include a block 406 of drawing the first and second flexible sheets into the mold system comprised in block 102. In block 406, the drawing step may include a deep draw process wherein the deep draw takes place along a direction outside of a plane of the sheet prior to deformation. “Deep draw” refers to a manufacturing process in which a sheet of material, typically metal or plastic, is deformed, or drawn, into a forming die by the mechanical action of a punch or of a vacuum pump. This process can create complex, hollow shapes with significant depth. The material undergoes deformation, allowing it to be shaped into deep forms while reducing or preventing compromise to its structural integrity. Promoting uniform deformation can reduce or prevent distortion of text and / or images preprinted on the general sheet.

[0059] In some embodiments, a vacuum can be used to draw the first and second flexible sheets into the mold system. In other embodiments, the first and second flexible sheets can be drawn into the mold system via pressure or mechanical forces.

[0060] In some embodiments, the first and second flexible sheets may each be deep drawn into the mold system to a depth of between 0.1 to 3 cm from plane P, preferably between 0.5-2 cm from plane P, such that the resulting height of the sachet may be between 0.2-6 cm, preferably between 1-4 cm. In some embodiments, the sachet extends in both directions from the plane P such that the resulting height is the sum of the depths of the first and second flexible sheets. Ensuring this deep draw depth can ensure the resulting sachet has a well-defined shape and consistent depth while reducingthe riskof rupture ortearwhich may be associated with stretching of the first or second flexible sheets beyond this depth. Controlled dimensions of the deep draw and resulting sachet are of relevance in applications in which the thermoformed sachet is to be installed in a housing.

[0061] In some embodiments, both the first and second flexible sheets can be drawn into the same mold system simultaneously and deformed simultaneously. The use of a mold system to deform both sheets simultaneously can promote the resulting sachet having a well-defined shape and substantially consistent depth, which may prevent or reduce deformation during filling. This can lead to a more reliable and aesthetically pleasing product, as the sachet can substantially maintain an intended shape and volume. Controlling the shape and dimension of the thermoformed sachets is of specific relevance in applications wherein the thermoformed sachet is to be installed in a housing.

[0062] In other embodiments, each of the first and second flexible sheets are drawn into separate mold systems. The separate molds may have the same shape or may have compatible shapes, such as compatible male and female, either stacked or hinged to form the first and second flexible sheets into the thermoformed sachet. In some examples, compatible shapes corresponds to shapes formed from, on one end, the deformed first flexible sheet and from, on the other end, the deformed second flexible sheet, such respective shapes sharing a same or similar overall perimeter in a same plane, even if the shapes themselves may be different outside of such plane (or may be the same or similar outside of such plane). Such same plane essentially corresponds to a plane comprisin the sealed edge.

[0063] The one or more mold systems may have a single cavity to impart a single compatible shape on the resulting thermoformed sachets. In other embodiments, the one or more mold systems may comprise one or more molds each including a plurality of cavities having the same or different shapes, configurations, or volumes. In such embodiments, the plurality of cavities may impart a shape on the first or second flexible sheets which may result in a plurality of discrete pockets. A portion of the interior space, cavity or cavities defined between the first and the second deformed flexible sheets may be sealed to promote sealing between such plurality of discrete pockets as shown in Fig. 1 C and 1 E. This flexibility in the manufacturing process allows for the production of sachets with varying 3D shapes and sizes, tailored to specific needs while maintaining the benefits of space efficiency and structural integrity.

[0064] In Fig.4B, the method further includes a block 407 of filling. The filling step may include filling one or more of pockets of the thermoformed sachet with contents including liquid, gels, powders or combinations thereof. In some embodiments, all pockets are filled with the same composition. In other embodiments different pockets may contain different compositions. In some embodiments, filling of all pockets occurs simultaneously. This can improve process efficiency and reduce manufacturing time. In other embodiments, at least some of a plurality of pockets are filled sequentially. This allows for more precise filling and prevents or reduces cross contamination between contents of discrete pockets of the thermoformed sachet.

[0065] The method may further include a block (not shown) of die-cutting or slitting the first and second flexible sheets. In some embodiments, this step may occur after the forming and sealing steps. In other embodiments, this step may occur after the stacking step. The die-cutting or slitting step may be included in any of the above methods including the methods of Fig. 1A, Fig. 2A, Fig. 2B, Fig. 3A, Fig. 4A, and Fig. 4B. In some examples, diecutting is not necessary. Thermoformed Sachet

[0066]

[0067] Fig. 5 represents an example thermoformed sachet envelope. In Fig. 5, the thermoformed sachet envelope comprises the first flexible sheet, 501, and the second flexible sheet, 502, having a thermoformed concave or thermoformed convex shape arranged in a nested stack (depending on the point of view) and at least partially sealed together along an edge of the stacked first and second flexible sheets to form one or more interior portions within which the first and second flexible sheets are separable.

[0068] Concave refers to a shape that curves inward, resembling the interior of a sphere or bowl, creating a hollowed or sunken appearance. Convex refers to a shape that curves outward, resembling the exterior of a sphere or dome, creating a bulging or protruding appearance.

[0069] Separable refers to the characteristic of being able to be divided or disconnected into distinct parts. In the context of the patent application, it describes the ability of the first and second flexible sheets within the sachet envelope to be separated from each other within the interior portions to define one or more cavities while maintaining a sealed portion about an exterior edge of the first and second flexible sheets which cannot be separated from each other.

[0070] By arranging the first and second flexible sheets in a nested stack and sealing them together along an edge, the sachet envelope may achieve a more compact and spaceefficient design. This configuration can allow the sachet to maintain a substantially uniform shape and depth, which is relevant for increasingthe volume of the contents while reducing the overall footprint and material consumption of the packaging. The nested stack arrangement may also enhance the structural integrity of the sachet, reducing or preventing the risk of deformation and leakage during filling and handling.

[0071] The use of thermoformed concave or convex shapes for both the first and second flexible sheets can contribute to the sachet envelope having reduced or minimized headspace. This design also contributes to improved stacking and shipping, as the nested shapes fit more snugly together, and can reduce the amount of wasted space during transport. Additionally, the thermoformed shapes can provide a more aesthetically pleasing and uniform appearance, which is relevant for branding and consumer appeal. The nested stack design can also simplify the manufacturing process, as the sheets can be handled as a single unit during thermoforming and sealing, which may also reduce or prevent the potential for misalignment.

[0072] In some embodiments, as seen in Fig. 6, one or each of the first and second flexible sheets can be formed of multi-layer laminates. In such examples, a first layer may be formed of a polymer selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polystyrene, and combinations thereof and a second polymer layer selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polystyrene, and combinations thereof having a thickness greater than the first layer. The first layer may contain the printed text and / or images. The second layer may impart strength and / or impact resistance to the multi-layer laminate and protect the printed text and / or image from the contents of the thermoformed sachet and / or environmental conditions such as humidity.

[0073] In some embodiments one or more of the first and second layers may be transparent. In other embodiments, one or more of the first andsecond layers may be opaque. Opaque refers to a material's characteristic of not allowing light to pass through it, preventing visibility of objects behind the material. In the context of the patent application, it describes the property of certain layers in the sachet's multi-layer laminate, which may be used to protect contents from light exposure or to conceal the contents from view.

[0074] The first layer and second layer of the multi-layer laminate may be adhered together via adhesive or lamination. In some embodiments, the multi-layer laminate may further include a third layer of a polymer selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polystyrene, and combinations thereof. In some embodiments, the multi-layer laminate may further include a barrier layer, such as ethylene vinyl alcohol, to protect the contents of the thermoformed sachet against external conditions such as humidity, oxygen, oil or perfume loss.

[0075] Materials for forming any of the layers within the first or second flexible sheets can be or comprise virgin, partially recycled plastics, or fully recycled plastics. Virgin plastics should be understood to refer to plastic material that has not been previously used or processed. It is made from raw petrochemical feedstocks, such as natural gas or crude oil, and has not been recycled or reprocessed from existing plastic products. Virgin plastic is typically used in manufacturing to ensure purity and consistency in the final product. Partially recycled plastic refers to plastic material that is composed of a blend of virgin plastic and recycled plastic content. The recycled portion is derived from previously used plastic products that have been reprocessed and incorporated into new plastic materials. This approach helps reduce the reliance on virgin plastic, promoting sustainability by reusing existing materials and minimizing waste. Partially recycled plastic in the context of this invention refers to a blend of recycled and virgin plastic that contains 10-99% recycled plastic. Fully recycled plastic refers to plastic material that has been entirely reprocessed from previously used plastic products, without the addition of virgin plastic.

[0076] In some embodiments, the text and / or images may be printed directly on an interior surface of an exterior layer of the multi-layer laminate. In other embodiments, the text and / or images may be printed on an intermediate layer disposed between the exterior most layers of the multi-layer laminate. In some embodiments, one or both of thefirstand second sheets are formed of a single layer. In some embodiments, one or both of the first and second sheets are printless.

[0077] By printing text and / or images directly on an interior surface of an exterior layer of the multi-layer laminate, the printed information may be well-protected from external environmental factors such as moisture, abrasion, and chemical exposure. This encapsulation between layers can improve legibility and aesthetic quality of the printed content, which can enhance the durability and longevity of the artwork and text. This approach also allows for reverse printing techniques, where the ink is applied to the underside of the top layer, improving the likelihood that the printed content remains intact and visually appealing throughout the lifecycle of the sachet.

[0078] In cases where the text and / or images are printed on an intermediate layer disposed between the exterior most layers of the multi-layer laminate, the method can provide an additional layer of protection for the printed content. This intermediate layer may shield printing fluid from direct contact with the external environment and the contents of the sachet, which may reduce or prevent potential degradation or contamination of the printed information. The respective layers of the multi-layer laminate, or the sheets of flexible material, may be appropriately transparent, at least in part, to enable a user to see the text / images. Both printing methods (printing on an internal layer, or on an intermediate layer) can contribute to a more professional and visually appealing product, which can enhance brand perception and consumer trust. The protected printed content can reduce or prevent distortion of any legal text, branding, and other important information. This is relevant for regulatory compliance and effective communication with consumers. Additionally, this approach can reduce the need for additional labelling steps post-formation and can simplify the manufacturing process and reduce production costs. A method whereby printing takes place on an outer layer (i.e. not exposed to a content of the sachet) may also be considered.

[0079] When at least one of the first and second flexible sheets comprise multi-layer laminates, the overall thickness of the multi-layer laminate may be between 30-400 microns as laid out above. In a specific example, the first layer may comprise a 40 micron reversed printed PE layer laminated to a 140 micron inner layer of PE giving a total thickness of 180 micron. In some other embodiments, the thickness of each of the layers within the multilayer laminate may vary while the overall thickness remains within the range of 30-400 microns.

[0080] Thermoformed Sachet

[0081] Fig. 7A represents a thermoformed sachet of one or more embodiments of the present invention. The top of Fig. 7A shows an empty sachet envelope made according to one of the above-mentioned methods, i.e., by stacking, thermoforming and sealing together two sheets of flexible material. The bottom part of Fig. 7A shows the thermoformed sachet filled with a (not represented) filling material. In Fig. 7A, the thermoformed sachet may comprise a pocket which is a first pocket and further comprising at least one second pocket, separate from the first pocket, so as to form one or more discrete pockets filled with material. In this example, a seal is provided between the pockets. In some embodiments, when the thermoformed sachet envelope is filled with material, the material fills the one or more discrete pockets causing the pockets to pop out such that the one or more discrete pockets have a planar top surface and a planar bottom surface which have been defined when deforming the first and second sheets using heat. This feature may increase the use of available space especially in applications wherein the thermoformed sachets may be utilized in a defined housing. This design may reduce or minimize deformation of the thermoformed sachets during filling, which can prevent or reduce uneven surfaces of the thermoformed sachet. The planar surfaces can provide a shape that may be easier to handle, stack, and store, and can thereby improve overall space efficiency and reduce the risk of damage during transportation and storage.

[0082] The planar top and bottom surfaces can also improve the filling process by reducing or preventing the likelihood of overfilling or underfilling, thereby increasing the precision in the filling amount. This precision in filling not only can increase the reliability of the product but also may reduce or prevent waste, which can contribute to cost savings and environmental benefits. In some examples, the planar top and bottom surfaces are parallel to each other, and parallel to a plane comprisingthe sealed edge.

[0083] Additionally, the planar surfaces can improve the aesthetic appeal of the sachet, making it more attractive to consumers and preventing or reducing any readability issues of any text and / or images printed on the sachet. The planar shape and smooth surface can provide a professional appearance that can enhance brand perception and consumer trust. This is relevant for products displayed on retail shelves, where visual appeal can significantly influence purchasing decisions.

[0084] Due to the design of the present thermoformed sachet, material may fill 60-99% of the volume of each pocket. In some examples, the material may fill 70-99% of the volume of each pocket. In some examples, the material may fill 80-99% of the volume of each pocket. In some examples, the material may fill 90-99% of the volume of each pocket. This fill volume may reduce or minimize wasted space within the pocket and may reduce the amount of headspace. Reduced head space is of relevance in maintaining the structural integrity and stability of the sachet during handling and transportation. Reduced headspace can also reduce or prevent the risk of material movement within the pocket, which can lead to leakage or deformation and can extend the lifetime of the product due to the absence or reduction of air or other gases in the limited headspace.

[0085] This high fill percentage contributes to improved storage capacity efficiency of the thermoformed sachet, such that a substantial amount of material relative to its overall size may be introduced. This may be beneficial for applications where maximizing the volume of the contained material is desired, such as in fabric and homecare products. This improved use of space within the pockets also may contribute to cost savings in terms of material usage and transportation, as more product can be packed into a given volume. Reduced void space can also ensure accurate representation of product capacity which can improve consumer appeal.

[0086] Additionally, the controlled fill volume can contribute to forming sachets with consistent shapes and appearance, which is relevant for branding and consumer appeal. Uniformity in shape and volume can enhance the visual appeal of the sachet, which may make it more attractive to consumers and improve the overall user experience. This uniformity can also facilitate better stacking and storage, as the sachets can be arranged more efficiently with reduced risk of deformation or instability.

[0087] As can be seen in Fig. 7A, each sachet pocket may include at least one curvature having an angle, a. As a pocket is filled, the respective angle a may be between 45 and 90 degrees in relation to a plane defined by a portion of the seal adjacent to the curvature. This plane is represented by element P in Fig. 7A. This defined curvature may allow the sachet to achieve a more efficient use of space within the pocket and can reduce or prevent deformation during filling. As a result of this specific angle range, the footprint of the thermoformed sachet prior to filling with material may be substantially the same as the footprint of the thermoformed sachet after filling with material as shown in Fig. 7A. This specific angle range, at least in part as a result of the deep draw and deformation process, can provide for a more compact and stable structure, which may better withstand internal pressure during filling and handling, thereby reducing the risk of deformation and leakage. This can make the sachet more durable and reliable for various applications, including those requiring high barrier properties. In some examples, a is between 50 and 90 degrees in relation to the plane defined by a portion of the seal adjacent to the curvature. In some examples, a is between 60 and 90 degrees in relation to the plane defined by a portion of the seal adjacent to the curvature. The angle a of a curvature of a pocket should be understood to correspond to a maximum angle between a plane defined by a portion of the seal adjacent to the curvature and a plane tangent to a surface of the curvature. In the specific case of a flat top or flat bottom pocket, see for example Fig. 7A, such angle a should correspond to the angle between a plane P parallel to the flat top or flat bottom, and a plane P2 tangent to a point of the curvature corresponding to an inflexion point IP of the curvature between the plane defined by a portion of the seal adjacentto the curvature and the plane corresponding to the flat top or flat bottom. As can be seen in Fig. 7A, the thermoformed sachet may comprise a plurality of discrete pockets. Each of the plurality of discrete pockets may have a height, h, in relation to plane P, plane P comprising in this example seals between the first and the second sheet, such seals pertaining to a same plane. In some embodiments, the height of all of the plurality of pockets - when filled - may be the same. In some example, a same height should be understood as a same height within a 5% amount. When the height varies across a pocket, the height of the pocket should correspond to the maximum height of the pocket. By ensuring that the height of all the plurality of discrete pockets is the same, the sachet can achieve a substantially uniform shape, which can enhance the overall structural integrity and stability of the sachet. This uniformity can reduce or prevent deformation during filling and handling, increasing the likelihood that the sachet will maintain its intended shape and volume. This is relevant for applications where precise dosing and minimal waste are important, as it can ensure that each pocket can contain a specific amount of material with reduced risk of overfilling or underfilling.

[0088] The uniform height of the discrete pockets can also improve space efficiency of the sachet and can allow for better stacking and storage. This can reduce the amount of wasted space during transportation and storage and can lead to cost savings and reduced environmental impact. Additionally, the uniform height can facilitate a more controlled and predictable filling process wherein the thermoformed sachet contains a precise amount of material intended. This can enhance the reliability and performance of the product.

[0089] The uniform height of the pockets can also contribute to a more aesthetically pleasing appearance, which can enhance brand perception and consumer appeal. The uniform shape and planar top and bottom surface provide a professional appearance that can significantly influence purchasing decisions, particularly for products displayed on retail shelves.

[0090] Furthermore, due to the advantageous design of the present invention, the length of the thermoformed sachet prior to filling, L1 , can be substantially the same as the length of the thermoformed sachet after filling with material, L2. This promotes space efficiency and predictable storage capabilities as the thermoform sachet does not substantially reduce in length as it is filled. The length L1 or L2 may be measured in a plane comprising one or more seals between the first and the second sheet. The length of a thermoformed sachet should be understood as the maximum length of the sachet in this plane comprising one or more seals between the first and the second sheet. In some examples, a variation between such length prior to filing and after filling is of less than 10%.

[0091] In some embodiments, as illustrated in Fig. 7B, a single one of the first and second flexible sheets is thermoformed. In other embodiments, both of the first and second flexible sheets are thermoformed. In some embodiments, one or more of the pockets may not have a planartop or bottom surface, as illustrated in Fig. 7C. In some embodiments, the pockets may be symmetrical as illustrated in Fig. 7C and Fig. 7D. Symmetrical should be understood to refer to the pockets being balanced and proportionate, such that one side is a mirror image of the other. It describes the arrangement of pockets within the thermoformed sachet that are mirror images of each other about the plane P within a 5% deviation, ensuring uniformity and balance in the structure. In some embodiments, as illustrated by Fig. 7D, at least some pockets of the thermoformed sachet may have different shapes. In other embodiments, the shape of all pockets within the thermoformed sachet are the same.

[0092] In some embodiments, as illustrated in Fig. 7E, the pockets may be asymmetrical about the plane P. Asymmetrical should be understood to refer to the pockets not mirroring each other about the plane resulting in different shapes or configurations in each of the first and second flexible sheets which form the thermoformed sachet. Additionally, as shown in Fig. 7E, at least some pockets may have different heights.

[0093] Fig. 8 shows the sealing edge of a thermoformed sachet according to some embodiments of the present disclosure. In one embodiment, the edge region of each of the first and second flexible sheets to be sealed are not deformed. As such, the thickness of the general sheet, T1 , maybe maintained along the edge region. The thickness of the deformed interior space of each of the first and second flexible sheets, T2, may be 30-95% of the thickness of the edge region, T1 , due to a stretching effect in this region as a consequence of the thermoforming. In other words, the first flexible sheet and the second flexible sheet each have a thickness T1 at the edge and a thickness T2 in a region of the at least one curvature, wherein for both the first and second flexible sheets, the thickness at the edge is greater than the thickness in the region of the at least one curvature. In some examples, T2 may be 40-95% of the thickness of the edge region T1. In some examples, T2 may be 60-95% of the thickness of the edge region T1. While illustrated in a case of sheets having a same thickness, such stretching would also take place, for each sheet, even if their thicknesses were different at the edge.

[0094] By ensuring the first and second flexible sheets maintain thickness T2 in relation to T1 as laid out above may prevent damage to the thermoformed sachet when filled. If the thickness T2 is reduced belowthe disclosed range, there may be an increased riskof tearing or rupture due to decreased structural integrity of the first and second flexible sheets forming the thermoformed sachet. Conversely, If thickness T2isgreaterin relation toT1 than the disclosed range, this may indicate the first and second flexible sheets were not sufficiently deformed to a desired shape in the manufacturing process.

[0095] Fig.9 shows an embodiment of the present thermoformed sachet including an insert, 900, placed between the first and second flexible sheets. The insert may be disposed between the first and second flexible sheets about the edge and sealed therebetween. The insert may comprise a conduit to allow the thermoformed sachet to be filled with material and may allow for dispensing of such material so as to evacuate substantially all material with reduced or absent need for venting. Reduced or absent need for venting simplifies the filling process as no air needs to be evacuated duringthe filling operation. This also prevents the formation of foam during filling and can enable a desired controlled fill level with reduced or no headspace. Reduced to no headspace may help to extend the product shelf life and product lifetime during use due to reduced degradation of the contents in the thermoformed sachet due to reduced interaction with air or gas within the sachet.

[0096] The insert may provide a reliable and user-friendly mechanism for dispensing the material, which may enhance the overall functionality of the sachet. This is relevant for applications where precise dosing is desired, such as in fabric and homecare products. The ability to dispense the material with reduced or absent venting requirements may also simplify the design and manufacturing process, reducing the need for additional components, such as an air-intake valve, and potential failure points.

[0097] The insert may allow for more controlled filling of material within the thermoformed sachet and more controlled dispensing during use. This contributes to the reduced or absent venting requirement as the sachet collapses during dispensing at least in part because of the flexibility of the sachet. This feature can reduce or eliminate complexities associated with venting systems, such as potential leakage, blockage, and interrupted flow during dispensing which could occur if air attempts to enter the sachet while contents are being evacuated.

[0098] The ability of the sachet to collapse with reduced or absent venting du ring dispensing can also improve space efficiency and reduce waste. As the sachet collapses, the residual volume of the material left inside is reduced, increasing usage of the contents by promoting substantially all contents to be dispensed. The sachet may then return to substantially its pre-filled nested shape. This is relevant for applications where precise dosing and minimal waste are desired, such as in fabric and homecare products.

[0099] Additionally, the sealed insert can provide a robust and reliable connection point for dispensing mechanisms, which can be designed to interface the sachet. This can enhance the user experience by providing a way to dispense the product with reduced risk of spills or contamination.

[0100] Fig. 10 demonstrates in a plan view an example use for a thermoformed sachet according to at least some of the present embodiments wherein the thermoformed sachet, 1000, may be installed into an enclosure, 1001. In some embodiments, the thermoformed sachet includes the plurality of discrete pockets, for example p1 , p2, and p3 (as indicated by sealed boundaries between pockets in Fig. 10) installed within the enclosure. In some embodiments, (not shown), the thermoformed sachet may comprise more or less discrete pockets, including a single pocket, installed within the enclosure. The enclosure may be semi-rigid or rigid to house the thermoformed sachet.

[0101] Semi-rigid refers to a material or structure that possesses a degree of stiffness and resistance to deformation, but is not completely inflexible. In the context of the patent application, it describes the characteristic of the enclosure that allows it to maintain a certain shape and structural integrity while still having some flexibility.

[0102] Rigid refers to a material or structure that is inflexible and resistant to deformation under normal conditions. In the context of the patent application, it describes the characteristic of the enclosure that maintains a fixed shape and does not bend or flex easily. Rigid materials provide strong structural integrity and protection for the contents. In some embodiments, a volume of the sachet occupies, when full, 50-100% of a volume of the enclosure. The volume of the sachet being 50-100% of the volume of the enclosure can improve use of available space within the compartment. The volume capacity of the thermoformed sachet may be between 5mL and lOOOOmL depending on the desired application. This can contribute to a snug fit of the sachet within the enclosure, which may reduce wasted space and improving overall space efficiency and may prevent substantial movement of the sachet within the enclosure after installation. In some examples, volume of the sachet occupies, when full, 60-100% of a volume of the enclosure. In some examples, volume of the sachet occupies, when full, 70-100% of a volume of the enclosure. In some examples, volume of the sachet occupies, when full, 80-100% of a volume of the enclosure. In some examples, volume of the sachet occupies, when full, 90-100% of a volume of the enclosure.

[0103] For use in fabric and homecare

[0104] In some embodiments, the material within the thermoformed sachet may be a fabric and homecare product selected from the group consisting of liquid, powder, gel or a combination thereof. The fabric and homecare product may be a liquid laundry detergent. A fabric and homecare product refers to any product designed for the care, cleaning, or maintenance of fabrics and household surfaces. This includes items such as liquid laundry detergents, air-care products, fabric softeners, stain removers, household cleaners, and other similar products that are used to maintain the cleanliness and condition of fabrics and home environments.

[0105] By ensuring that the material within the sachet is a fabric and homecare product, such as liquid laundry detergent, the sachet can be tailored for specific applications that require precise dosing and minimal waste. The thermoformed sachet's design can allow for improved use of space and material such that the liquid laundry detergent may be contained securely and dispensed effectively. This can reduce the risk of spillage and contamination, which can enhance the user experience.

[0106] The use of a thermoformed sachet for liquid laundry detergent can also leverage the airless nature of the sachet, which reduces headspace and can prevent airfrom entering the sachet during dispensing. This feature is relevant for liquid products, as it helps maintain the product's quality and extends its shelf life by reducing oxidation and contamination risks. Additionally, the collapsible nature of the sachet during dispensing can increase the dispensing of substantially all liquid contained therein, minimizing waste and providing cost savings for the consumer. The use of a thermoformed sachet for liquid laundry detergent also improves space efficiency compared to other packaging. The sachet can be filled with reduced headspace, in turn increasing the volume of the detergent while reducing the overall footprint of the packaging. This is relevant for storage and transportation, as more units can be packed into a given space, leading to cost savings and reduced environmental impact due to lower material usage and improved logistics.

[0107] Additionally, the sachet's ability to collapse with reduced or absent venting during dispensing can promote efficient use of liquid laundry detergent therein with reduced waste. This feature is relevant for consumers, as it allows for substantially all material use within the sachet, which can reduce the amount of residual product left in the packaging. This not only can provide better value for the consumer but also can contributes to sustainability by reducing product waste.

[0108] Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0109] For the purposes of defining the present technology, the transitional phrase “consisting of” may be introduced in the claims as a closed preamble term limiting the scope of the claims to the recited components or steps and any naturally occurring impurities. For the purposes of defining the present technology, the transitional phrase “consisting essentially of” may be introduced in the claims to limit the scope of one or more claims to the recited elements, components, materials, or method steps as well as any nonrecited elements, components, materials, or method steps that do not materially affect the novel characteristics of the claimed subject matter. The transitional phrases “consisting of” and “consisting essentially of” may be interpreted to be subsets of the open-ended transitional phrases, such as “comprising” and “including,” such that any use of an open ended phrase to introduce a recitation of a series of elements, components, materials, or steps should be interpreted to also disclose recitation of the series of elements, components, materials, or steps using the closed terms “consisting of” and “consisting essentially of.” For example, the recitation of a composition “comprising” components A, B, and C should be interpreted as also disclosing a composition “consisting of” components A, B, and C as well as a composition “consisting essentially of” components A, B, and C. Any quantitative value expressed in the present application may be considered to include open-ended embodiments consistent with the transitional phrases “comprising” or“including” as well as closed or partially closed embodiments consistent with the transitional phrases “consisting of” and “consisting essentially of.”

[0110] As used in the Specification and appended Claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly indicates otherwise. The verb “comprises” and its conjugated forms should be interpreted as referring to elements, components or steps in a non-exclusive manner. The referenced elements, components or steps may be present, utilized or combined with other elements, components or steps not expressly referenced.

[0111] It should be understood that any two quantitative values assigned to a property may constitute a range of that property, and all combinations of ranges formed from all stated quantitative values of a given property are contemplated in this disclosure. The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

[0112] The subject matter of the present disclosure has been described in detail and by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to the particular embodiment or to any other embodiment.

[0113] It should be apparent to those skilled in the art that various modifications and variations may be made to the embodiments described within without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described within provided such modifications and variations come within the scope of the appended claims and their equivalents. Unless otherwise stated within the application, all tests, properties, and experiments are conducted at room temperature and atmospheric pressure.

[0114] Having described the subject matter of the present disclosure in detail and by reference to specific embodiments thereof, it is noted that the various details disclosed within should not be taken to imply that these details relate to elements that are essential components of the various embodiments described within, even in cases where a particular element is illustrated in each of the drawings thataccompany the present description. Further, it should be apparent that modifications and variations are possible without departing from the scope of the present disclosure, including, but not limited to, embodiments defined in the appended claims. More specifically, although some aspects of the present disclosure are identified as particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

Claims

CLAIMSWhat is claimed is:

1. A method for forming a thermoformed sachet comprising:stacking a first and a second flexible sheet, wherein the first and second flexible sheets comprise a non-water-soluble film;deforming the first and second flexible sheets using heat to conform each of the first and second flexible sheets to compatible shapes using a mold system; and sealing the first and second flexible sheets together along an edge thereof.

2. The method of claim 1 , wherein the stacking occurs before the deforming.

3. The method of any of claims 1 to 2, further comprising printing one or more of text and images onto one or more of the first and second flexible sheets prior to the stacking or the deforming.

4. The method of any of claims 1 to 3, wherein stacking the first and second flexible sheets further comprises:pulling a general sheet from a reel and folding said general sheet such that a first folded portion of the general sheet forms the first flexible sheet and a second folded portion of the general sheet forms the second flexible sheet.

5. A sachet envelope comprising:a first and a second flexible sheet each having a thermoformed concave or thermoformed convex shape,wherein the first and the second flexible sheets comprise a non-water-soluble film and are arranged in a nested stack and at least partially sealed together along an edge of the stacked first and second flexible sheets to form one or more interior portions within which the first and second flexible sheets are separable.

6. The sachet envelope of claim 5, wherein one or more of the first and second flexible sheets are multi-layer sheets.

7. A sachet comprising:a first and a second flexible sheet each having a thermoformed concave or thermoformed convex shape,wherein the first and second flexible sheets comprise a non-water-soluble film and are sealed together along an edge thereof to form a pocket therein; anda material filling the pocket.

8. The sachet of claim 7, wherein the pocket has a planar top surface and a planar bottom surface.

9. The sachet of any of claims 7 to 8, wherein the material fills 60-99% of the volume of the pocket.

10. The sachet of any of claim 7 to 9, wherein the pocket is formed to include at least one curvature, an angle of the at least one curvature in relation to a plane defined by a portion of the seal adjacent to the curvature being between 45 and 90 degrees.

11. The sachet of any of claims 7 to 10, wherein the sachet comprises a plurality of discrete pockets and wherein a height of all of the plurality of discrete pockets is the same.

12. The sachet of claim 11, the first flexible sheet and the second flexible sheet each having a thickness at the edge and a thickness in a region of the at least one curvature, wherein for both the first and second flexible sheets, the thickness at the edge is greater than the thickness in the region of the at least one curvature.

13. The sachet of any of claims 7 to 12, further comprising an insert sealed between the first and the second flexible sheet along the edge, wherein the insert allows the material to be dispensed from the sachet, wherein during dispensing, the sachet collapses without venting.

14. The sachet of any of claims 7 to 13, wherein the material is a fabric and homecare product selected from the list consisting of liquid, powder, gel, and a combination thereof.

15. The sachet of claim 14, wherein the fabric and homecare product is liquid laundry detergent.

16. A compartment and a sachet of any of claims 7 to 13, wherein the sachet is within an enclosure of the compartment and wherein a volume of the sachet is 50-90% of a volume of the enclosure.

17. A kit comprising a sachet envelope of any of claims 5 to 6 and a sachet of any of claims 7 to 13, both the sachet envelope and the sachet beingformed in a same mold system and according to a method of any of claims 1 to 4, wherein the sachet envelope and sachet have a similar footprint.

Images