Heated Sealing Jaws for Dissolvable Nonwoven Detergent Pods
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Solution Overview
Problem
Existing water-soluble unit dose articles with granular laundry detergent face issues of seal defects due to perfume particles, leading to leakage and reduced seal reliability, while also experiencing delayed detergent dissolution during laundry cycles.
Innovation Solution
The use of specific sealing jaws with protruding portions and controlled heating to create a mechanically reliable seal that dissolves rapidly, combined with a water-soluble fibrous non-woven sheet, ensures the integrity of the compartment and efficient detergent release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing jaws are used to seal water-soluble unit dose articles containing granular laundry detergent with perfume particles, then the sealing process is simple, but seal defects occur leading to leakage and reduced seal reliability
Solution Approach 1:
The sealing jaw is divided into multiple independent heating zones with separate temperature control. Each zone can be independently adjusted to optimize sealing temperature for different areas, preventing perfume particles from causing seal defects while maintaining reliable sealing
Solution Approach 2:
Different regions of the sealing jaw surface are designed with varying thermal properties and contact pressures to accommodate the presence of perfume particles. The sealing surface includes textured regions that can accommodate particulate matter without compromising seal integrity
2Reliability
If a robust internal compartment is used to prevent detergent leakage, then seal reliability improves, but dilution time increases during laundry cycles
Solution Approach 1:
The seal structure incorporates varying thickness and density parameters along its length. The seal is thinner and less dense at regions designed for rapid dissolution while maintaining sufficient thickness and density in regions requiring leak prevention, achieving both reliability and fast dilution
Solution Approach 2:
The sealing compartment uses a composite structure combining water-soluble materials with different dissolution rates. The seal includes a barrier layer for leakage prevention and a dissolvable layer for rapid dissolution, creating a multi-functional sealing system
3Ease of manufacture
If perfume particles are present in the sealing area, then product fragrance is achieved, but powder-like accumulation occurs leading to seal defects and jaw deterioration
Solution Approach 1:
A non-stick coating layer is applied to the sealing jaw surface acting as an intermediary between the perfume particles and the jaw material. This coating prevents perfume oil from bonding to the jaw, eliminating jaw deterioration while allowing the sealing process to proceed normally
Solution Approach 2:
The sealing jaw incorporates a replaceable non-stick coating layer that can be easily renewed or replaced when deteriorated. This disposable coating element protects the expensive jaw structure from perfume particle damage while maintaining sealing effectiveness
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 provides a seal that prevents leakage during storage and transportation while ensuring rapid dissolution during laundry, maintaining seal reliability and effective detergent distribution.
Implementation Method 1
controlled heating to create a mechanically reliable seal that dissolves rapidly
Data Source
Figure 1~2
Figure 3A~3F
Figure 4
AI summary
An example system comprises a water-soluble unit dose article comprising a fibrous non-woven sheet shaped to form a sealed internal compartment and a granular laundry detergent comprised within the internal compartment. The sheet comprises fibres which comprise polyvinyl alcohol polymer. The granular laundry detergent comprises perfume particles. The system also comprises sealing jaws, whereby at least one of the sealing jaws is a heated sealing jaw. A top seal of the internal compartment is sandwiched between the jaws. A first of said jaws comprises a protruding portion along a longitudinal direction of the seal. The protruding portion has a base along a direction perpendicular to the longitudinal direction of the seal. The base has a dimension of more than 3 times and of less than 20 times a thickness of the water-soluble fibrous non-woven sheet.