Dust Extraction Conduct for Zeolite-Safe Detergent Sealing
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Solution Overview
Problem
Existing water-soluble unit dose articles face issues with detergent leakage during storage due to inappropriate air permeability of the fibrous non-woven sheet, and zeolite particles cause damage to sealing jaws, leading to manufacturing failures.
Innovation Solution
A dust extraction system is implemented to manage air flow and extract abrasive particles, maintaining suitable air permeability (5-200 m3/m2/min) of the fibrous non-woven sheet to prevent leakage and protect sealing jaws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air permeability of the water-soluble fibrous non-woven sheet is increased to allow dissolution during washing, then the detergent can dissolve satisfactorily, but granular laundry detergent leaks out during storage
Solution Approach 1:
The patent applies parameter changes by precisely controlling the air permeability of the water-soluble fibrous non-woven sheet within a specific range (5-200 m3/m2/min). This parameter optimization allows the sheet to maintain sufficient structural integrity during storage to prevent detergent leakage, while simultaneously enabling adequate water penetration and dissolution during the washing process. The specific permeability range represents a balanced parameter setting that resolves the contradiction between dissolution performance and leakage prevention.
2Reliability
If zeolite particles are used in the granular laundry detergent for effective washing, then laundry washing performance is improved, but abrasive particles damage sealing jaws during manufacturing
Solution Approach 1:
The patent applies the extraction principle by introducing a dust extraction system that removes abrasive zeolite particles from the air stream during the sealing process. The extraction system captures particles that would otherwise escape from the internal compartment through the non-woven sheet and damage the sealing jaws. This allows the manufacturing process to continue uninterrupted with zeolite-containing detergent formulations, maintaining both washing performance and manufacturing ease.
Solution Approach 2:
The dust extraction system acts as an intermediary between the granular detergent containing zeolite particles and the sealing jaws. By positioning the extraction system in the air path between these two elements, it intercepts and removes abrasive particles before they can contact and damage the sealing surfaces, thus protecting the manufacturing equipment while allowing zeolite-based formulations to be used.
3Loss of substance
If the air permeability of the non-woven sheet is too low to prevent leakage, then detergent leakage is reduced, but dissolution during washing becomes difficult
Solution Approach 1:
The patent resolves this contradiction through parameter changes by establishing an optimal air permeability range (5-200 m3/m2/min) for the water-soluble fibrous non-woven sheet. Within this range, the sheet maintains sufficient porosity to allow water penetration and dissolution during washing, while simultaneously providing adequate structural integrity to prevent detergent leakage during storage and handling. The specific numerical range represents a optimized parameter setting that balances both requirements.
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 solution ensures satisfactory dissolution of the unit dose article during washing, reduces detergent leakage, and increases the lifespan of sealing jaws by preventing damage from abrasive particles.
Implementation Method 1
a dust extraction conduct which directs a gas flow away from an area surrounding a top section of the sealing jaws
Implementation Method 2
The water-soluble fibrous non-woven sheet and the granular laundry detergent dissolve
Implementation Method 3
with a suitable air permeability of the water-soluble fibrous non-woven sheet, few particles of granular laundry detergent can leak out
Data Source
AI summary
An example system comprises a water-soluble unit dose article comprising a water-soluble fibrous non-woven sheet and a granular laundry detergent. The water-soluble fibrous non-woven sheet is shaped to form a partially sealed internal compartment and has an air permeability comprised between 5 m3/m2/min and 200 m3/m2/min. The granular laundry detergent is comprised within said internal compartment and comprises a plurality of particles, wherein the plurality of particles comprises zeolite particles. The system comprises sealing jaws, wherein at least one of the sealing jaws is a heated sealing jaw, wherein a bottom seal of the internal compartment is sandwiched between the jaws. The jaws comprise a non-stick coating in contact with the bottom seal and a first dust extraction conduct to direct a gas flow away from an area surrounding a top section of the sealing jaws or away from a bottom section of the internal compartment.