Water-Soluble Core Substrate for Stable Unit Dose Cleaning Pouches
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional water-soluble pouches for cleaning formulations have an unpleasant feel, stability issues due to incompatible ingredients, and complex, costly manufacturing processes, limiting their practicality and effectiveness.
Innovation Solution
The development of single unit dose (SUD) articles with a water-soluble core substrate made from polyvinyl alcohol (PVOH) based polymers and starch derivatives, which are biodegradable and recyclable, enclosed in a water-soluble nonwoven, foam, or film material, allowing for precise dosing and easy handling, and containing a carrier solvent with active cleaning formulations that dissolve quickly without residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional water-soluble pouches are used for cleaning formulations, then dosing accuracy is improved, but handling pleasure deteriorates due to unpleasant rubbery or plastic-like feel
Solution Approach 1:
The patent uses composite materials consisting of a water-soluble film layer combined with a water-soluble polymer coating layer. This composite structure provides both the dosing accuracy of traditional pouches and a more pleasant, less rubbery feel by combining the benefits of different material properties in a single integrated structure.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the water-soluble material by controlling the molecular weight, hydrolysis degree, and composition of the polyvinyl alcohol and starch derivatives. These parameter changes result in a material that maintains dosing accuracy while improving the tactile feel and reducing the unpleasant rubbery sensation.
2Quantity of substance
If bulk or concentrated detergents are used, then formulation effectiveness is improved, but chemical stability deteriorates due to incompatible ingredients
Solution Approach 1:
The patent segments the detergent formulation into separate compartments or layers within the pouch, allowing each ingredient to remain stable individually while maintaining overall effectiveness. This segmentation prevents incompatible ingredients from contacting each other until the pouch dissolves and mixes in the washing machine.
Solution Approach 2:
The water-soluble film and polymer coating act as intermediaries that protect the detergent ingredients from each other and from the washing environment until dissolution occurs. This intermediary layer maintains chemical stability during storage and transport while allowing all ingredients to work together effectively during the washing cycle.
3Measurement precision
If traditional film-based unit dose construction is used, then dosing accuracy is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the water-soluble film and the polymer coating into a single integrated layer or structure, eliminating the need for separate manufacturing steps for each component. This merging simplifies the manufacturing process while maintaining dosing accuracy through the combined functionality of the integrated structure.
Solution Approach 2:
The water-soluble polymer coating serves multiple functions simultaneously: it provides the water-soluble characteristic, improves handling properties, maintains chemical stability, and ensures dosing accuracy. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process.
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 SUD articles provide a stable, easily manufacturable, and pleasant-to-handle solution for cleaning formulations, ensuring chemical stability during storage and quick dissolution in washing cycles, while maintaining the effectiveness of active agents like enzymes.
Implementation Method 1
water-soluble core construction that dissolves quickly without leaving undesired residue
Implementation Method 2
The SUD articles provide a stable, easily manufacturable, and pleasant-to-handle solution for cleaning formulations, ensuring chemical stability during storage
Data Source
AI summary
A single unit dose article includes a water-soluble core substrate comprising a water-soluble resin. The water-soluble core substrate contains a carrier solvent with an active cleaning formulation, wherein upon contact of the carrier solvent with the water-soluble core substrate, the water-soluble core substrate exhibits shrinkage or swelling. Also disclosed are methods of making the single unit dose article.