Water-Soluble Sheet Structured Surface Pattern Formation

Solution Overview

Problem

Existing methods for creating water-soluble sheets with structured surface patterns often damage the film and are not suitable for mass production due to mechanical and thermal stresses, leading to issues like micro holes, fissures, and equipment wear.

Innovation Solution

A method involving a solution cast process or cast extrusion where a water-soluble polymer solution is deposited onto a substrate with a complementary structured surface pattern, and then dried to form a water-soluble sheet with a structured surface pattern integrated during its formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If embossing is applied to an existing film, then a structured surface pattern is achieved, but the film properties are damaged resulting in micro holes and fissures

Engineering Contradiction:

Improvesurface patternVSAvoidfilm integrity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The structured surface pattern is formed during the film formation process itself, before the film is fully manufactured. The substrate with complementary structured surface pattern is provided in step (a), and the solution is deposited onto it in step (b), so the pattern is built in during formation rather than applied afterward to an existing film.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of applying embossing to an existing film (traditional approach), the invention inverts the sequence by forming the structured surface pattern during the film formation process itself. The substrate provides the complementary pattern that is transferred to the film as it forms, rather than modifying the film after formation.

Inventive Principle:

Principle #13The other way round (Inversion)

2Shape

If embossing is applied to an existing film, then a structured surface pattern is achieved, but significant mechanical and thermal stresses alter the film properties

Engineering Contradiction:

Improvesurface patternVSAvoidsealing strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The structured surface pattern is formed during the film formation process itself, before the film is fully manufactured. The substrate with complementary structured surface pattern is provided in step (a), and the solution is deposited onto it in step (b), so the pattern is built in during formation rather than applying embossing afterward which would require mechanical and thermal stresses.

Inventive Principle:

Principle #10Preliminary action

3Shape

If embossing is applied to an existing film, then a structured surface pattern is achieved, but equipment wear increases significantly

Engineering Contradiction:

Improvesurface patternVSAvoidequipment durability

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The structured surface pattern is formed during the film formation process itself using a substrate with complementary pattern. This eliminates the need for separate embossing equipment and operations, thereby reducing equipment wear and simplifying the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

4Shape

If embossing is applied across the forming area of the film, then surface pattern is achieved, but leaking pouches occur due to damaged film

Engineering Contradiction:

Improvesurface patternVSAvoidpouch sealing

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The structured surface pattern is formed during the film formation process itself, before the film is fully manufactured. The substrate with complementary structured surface pattern is provided in step (a), and the solution is deposited onto it in step (b), so the pattern is built in during formation rather than applying embossing afterward which would damage the film and cause leaking pouches.

Inventive Principle:

Principle #10Preliminary action

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

This method allows for the production of water-soluble sheets with improved appearance, haptic properties, and technical features such as enhanced sealing strength and reduced coefficient of friction, without compromising the film's properties or requiring significant alterations to existing manufacturing processes.

Implementation Method 1

depositing a solution comprising a water-soluble polymer onto the substrate

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 2

drying the solution to form a water-soluble sheet

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20250196418A1Process for manufacturing a water-soluble sheet

Publication Date: 2025.06.19 RECKITT BENCKISER FINISH BV

AI summary

The invention relates to a method of manufacturing a water-soluble sheet having an area of structured surface pattern, the structured surface pattern having one or more structural features having a measurement of less than 1000 μm wherein the method comprises the steps of:a) providing a substrate having an area of complementary structured surface pattern;b) depositing a solution comprising a water-soluble polymer onto the substrate; andc) drying the solution to form a water-soluble sheet comprising an area of structured surface pattern.