Multilayer Dissolvable Solid Articles for Leak-Resistant Particle Loading
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Solution Overview
Problem
Challenges exist in creating multi-layer dissolvable sheets with solid particles, particularly bleaching agents, due to sealing issues and potential powder leakage, which affect the integrity and performance of the product.
Innovation Solution
A coating composition comprising a non-aqueous liquid carrier, a thickening agent, and solid particles is applied on the surfaces of adjacent layers of flexible, porous dissolvable sheets to enhance stability and sealing, using a non-aqueous liquid carrier, a thickening agent, and solid particles, including a source of available oxygen and a bleach activator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If solid particles are incorporated between layers of foam sheets, then the loading capability and active ingredient delivery are improved, but sealing reliability deteriorates due to insufficient contact area and particle interference
Solution Approach 1:
A coating composition serving as an intermediary substance is applied between the foam sheets and solid particles. This coating material fills gaps and creates a bonding matrix that ensures reliable sealing around particles, preventing powder leakage while maintaining the ability to deliver active ingredients. The coating acts as a mediator that reconciles the conflicting needs of particle loading and sealing integrity.
Solution Approach 2:
The invention uses a composite structure combining foam sheets, coating material, and solid particles. The multi-component composite system allows each material to fulfill its specific function: foam sheets provide the dissolvable matrix, coating material provides sealing and bonding, and solid particles provide active ingredients. This composite approach resolves the contradiction by integrating multiple materials with complementary properties.
2Productivity
If multiple layers of dissolvable sheets are assembled into a unitary article, then the delivery efficiency and product concentration are improved, but manufacturing complexity increases
Solution Approach 1:
Multiple dissolvable sheets are merged into a single unitary multi-layer article through the coating composition that bonds layers together. This merging maintains the advantages of multiple layers (enhanced delivery efficiency and concentration) while creating an integrated structure that simplifies handling and manufacturing compared to separate components.
Solution Approach 2:
The dissolvable sheets function as flexible thin films that can be layered and bonded together. The flexibility of these films allows for easy assembly into multi-layer configurations, and the thin-film nature enables high concentration of active ingredients in a compact form factor, improving delivery efficiency without excessive manufacturing complexity.
3Object-generated harmful factors
If solid particles are sealed between foam layers, then powder leakage is reduced, but the contact area between layers decreases affecting dissolution profile
Solution Approach 1:
The foam sheets inherently possess a porous structure that allows water penetration and maintains good dissolution profile. The coating composition is applied in a manner that seals particles within these pores rather than creating a dense barrier, thus preventing powder leakage while preserving the open-celled foam structure necessary for rapid dissolution when the article is activated.
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 improved stability, reduced leakage, and enhanced loading capability for moisture-sensitive active ingredients, ensuring effective delivery and prevention of premature reactions, while maintaining a balanced dissolution profile.
Implementation Method 1
solid particles dispersed in a non-aqueous liquid carrier applied on one or both contacting surfaces of adjacent layers
Implementation Method 2
a coating composition comprising a non-aqueous liquid carrier, a thickening agent, and solid particles
Implementation Method 3
porous sheets with open-celled foam (OCF) structures characterized by a Percent Open Cell Content of from about 80% to 100%
Implementation Method 4
the porous structure of the multi-layer dissolvable solid article allows air or moisture to enter
Data Source
AI summary
A dissolvable solid article which can include multiple layers of flexible, dissolvable, porous sheets, in which a coating composition including solid particles is present on at least one internal surface of at least one sheet in the solid articles and a process for making such solid articles.