Dual-Layer Water-Soluble Packets With Vacuum-Compacted Powder Boundaries

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Solution Overview

Problem

Conventional water soluble packets lack distinct boundaries between different colored powders, leading to blending and a loose, pliable feel, which affects cosmetic appeal and product integrity.

Innovation Solution

The formation of dual layer water soluble packets involves creating openings in a base film using a laser, water mist, or mechanical piercing to deposit and compact layers of powder under vacuum, ensuring a firmer feel and clearer boundaries between colors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional water soluble packets are formed using drums, flat-bed platen, or belt systems with rows of cavities, then the packets can be produced efficiently in continuous rows, but the packets exhibit a loose, pliable feel with no distinct boundary between different colored powders

Engineering Contradiction:

Improvecontinuous production of packetsVSAvoidboundary definition between powder layers

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The packet forming assembly is divided into multiple independent cavities arranged in rows, with each cavity acting as a separate molding chamber. This segmentation allows continuous production while maintaining precise control over powder layer boundaries in each individual packet, preventing blending between different colored powders.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies localized vacuum suction at the base of each cavity to compact the powder layers precisely where needed. This local quality approach ensures that each powder layer is firmly packed with distinct boundaries without affecting the entire packet structure, resolving the issue of loose, pliable packets while maintaining continuous production capability.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If powder layers are deposited without vacuum compaction, then the deposition process is simpler and faster, but the resulting packets have a loose feel and poor cosmetic appearance

Engineering Contradiction:

Improvepowder deposition processVSAvoidfirmness and compactness of powder layers

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The invention uses vacuum pneumatic suction applied through the base of each cavity to compact the powder layers during deposition. This pneumatic approach firmly packs the powder layers to achieve the desired firmness and cosmetic appearance while maintaining a relatively simple and fast deposition process, avoiding complex mechanical compaction mechanisms.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Adaptability or versatility

If multiple layers of colored powder are deposited sequentially, then the cosmetic appeal and product differentiation are enhanced, but the layers blend together without distinct boundaries

Engineering Contradiction:

Improvemulti-layer colored powder structureVSAvoidseparation and boundary definition between layers

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The invention applies vacuum compaction after each powder layer is deposited, before the next layer is added. This preliminary action firmly packs each layer and creates a stable boundary that prevents blending with subsequent layers, enabling the production of multi-layer colored packets with distinct boundaries and enhanced cosmetic appeal.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Localized vacuum suction at the base of each cavity compactsthe powder layers in situ, creating firm boundaries between different colored layers. This local quality approach maintains the stability of each layer's composition and position, preventing blending while allowing versatile multi-layer color configurations for product differentiation.

Inventive Principle:

Principle #3Local quality

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 method results in water soluble packets with defined boundaries between layers, preventing blending and providing a firmer, more compact structure, enhancing cosmetic appeal and product integrity.

Implementation Method 1

The vacuum generally holds the powder in position

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

forming openings in a base layer of the film with a laser

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 3

forming openings in a base layer of the film with water mist

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentUS20250223067A1Systems and methods for forming dual layer water soluble packets

Publication Date: 2025.07.10 NEW SPS POD LLC

AI summary

A method of forming dual layer water soluble packets includes drawing a base film into a cavity of a mold, drawing air through openings in the base film, metering an amount of a first product of a first color onto the base film in the cavity, metering an amount of a second product of a second color onto the amount of the first product, and, sealing a lid film to the base film.