Multi-compartment Water-soluble Capsule with Domed Partition Seal
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Solution Overview
Problem
Existing multi-compartment water-soluble detergent capsules with flat seal areas are prone to folding, leading to handling issues and leakage, and require complex manufacturing processes, while thermoformed capsules with polyvinyl alcohol film struggle to effectively segregate sensitive ingredients.
Innovation Solution
A multi-compartment capsule design using two sheets of water-soluble film with a continuous rectangular partition seal, forming a larger outer compartment and a smaller inner compartment, preventing folding and ensuring effective segregation of ingredients, and utilizing a thermoforming process with a semi-circular mould for uniform cross-section and efficient film draw.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multi-compartment capsules use flat seal areas to separate compartments, then compartment separation is achieved, but the capsule becomes floppy and prone to folding along the seal
Solution Approach 1:
The patent replaces the flat seal area with a domed or curved seal structure. This curvature prevents the capsule from folding along the seal line while maintaining effective compartment separation. The domed shape provides structural rigidity that eliminates the floppy handling issues associated with flat seals.
2Ease of manufacture
If multi-compartment capsules are manufactured by thermoforming with vacuum, then compartment formation is achieved, but the capsule deforms after release from the mould
Solution Approach 1:
The domed seal structure is integrated into the thermoforming process, allowing the capsule to maintain its curved profile after mould release. The curvature distributes stress more evenly during vacuum release, preventing the rectangular profile deformation that occurs with flat-sealed capsules.
3Duration of action of moving object
If thin film is used in multi-compartment capsules, then dissolution performance is improved, but leakage occurs due to pin-holing during manufacture
Solution Approach 1:
The domed seal structure distributes manufacturing stress more evenly across the film, reducing the formation of pin-holes during thermoforming. This allows the use of thinner films for improved dissolution while maintaining leakage prevention, as the curved geometry eliminates stress concentration points that cause pin-hole formation.
4Stability of the object's composition
If multiple compartments are used for ingredient segregation, then ingredient stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the capsule into multiple compartments separated by domed seals, allowing sensitive ingredients to be segregated for improved stability. The segmentation is achieved through a standardized domed seal process that can be integrated into existing thermoforming lines, managing manufacturing complexity while enabling effective ingredient separation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances handling and stability, prevents leakage, and ensures effective segregation of ingredients, allowing for efficient dispensing in washing machines even with minimal water exposure, while reducing manufacturing complexity and waste.
Implementation Method 1
Multi-compartment water-soluble capsules comprising at least two compartments made from water-soluble film
Implementation Method 2
The process involves heating the film to soften it
Implementation Method 3
the application of vacuum to hold the film in the moulds
Data Source
AI summary
A multi-compartment water-soluble capsule thermoformed from two sheets of water-soluble film, the capsule comprising a least two compartments with a different part of a detergent composition in each compartment, the two sheets of film being sealed together to form seal areas around each compartment, all the seal areas lying substantially in a first plane; —the capsule having at least one larger volume outer compartment and at least one smaller volume inner compartment generally enclosed in the first plane by the outer compartment(s), the outer compartment(s) being separated from the inner compartment(s) by a continuous partition seal area which is substantially rectangular and lies in the first plane, —the outer compartment(s) having a generally rectangular outer perimeter with rounded corners and a substantially uniform cross-section taken along a plane perpendicular to the first plane and perpendicular to the inner seal separating the inner and outer compartments.