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Detergent products, methods and manufacture Number:7,386,971 from the United States Patent and Trademark Office (PTO) owispatent

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Title: Detergent products, methods and manufacture

Abstract: A water-soluble pouch suitable for use in machine dishwashing and which comprises a plurality of compartments in generally superposed or superposable relationship, each containing one or more detergent active or auxiliary components, and wherein the pouch has a volume of from about 5 to about 70 ml and a longitudinal/transverse aspect ratio in the range from about 2:1 to about 1:8, preferably from about 1:1 to about 1:4. The water-soluble pouch allows for optimum delivery of dishwashing detergent. A process for the manufacture of multi-compartment pouches and a pack to contain the pouches are also disclosed.

Patent Number: 7,386,971 Issued on 06/17/2008 to Catlin,   et al.


Inventors: Catlin; Tanguy Marie Louis Alexandre (Brussels, BE), Moussa; Rachid Ben (Montesilvan Colle, IT), Kroese; Timothy Bernard William (Brussels, BE), Gillham; Charles Rupert (Newcastle upon Tyne, GB), Kinloch; James Iain (Cramlington, GB), Smith; David John (Durham, GB), Main; Alison Lesley (Cincinnati, OH), Varley; Helen (Newcastle upon Tyne, GB)
Assignee: The Procter & Gamble Company (Cincinnati, OH)
Appl. No.: 10/978,941
Filed: November 1, 2004


Related U.S. Patent Documents

Application NumberFiling DatePatent NumberIssue Date
09994533Nov., 20017125828
60265462Jan., 2001

Foreign Application Priority Data

Nov 27, 2000 [GB] 0028821.7
Nov 27, 2000 [GB] 0028823.3
May 05, 2001 [GB] 0111131.9
Nov 14, 2001 [GB] 0127279.8

Current U.S. Class: 53/537 ; 53/150; 53/453; 53/474; 53/538; 53/574
Current International Class: B65B 29/10 (20060101)
Field of Search: 53/453,559,474,456,452,147,150,158,537,538,574


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Primary Examiner: Harmon; Christopher
Attorney, Agent or Firm: Bamber; Jeffrey V. Grunzinger; Laura R.

Parent Case Text



CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. Utility application Ser. No. 09/994,533, filed Nov. 27, 2001 now U.S. Pat. No. 7,125,828.
Claims



The invention claimed is:

1. A process for making a water-soluble pouch which comprises a plurality of compartments in generally superposed or superposable relationship, each comprising a detergent active or auxiliary component, the process comprising the steps of: a) forming and partially filling, with a first detergent active or auxiliary component comprising a powder or densified powder, a moving web of open pouches releasably mounted on a moving endless surface having a continuous horizontal rectilinear motion with a constant speed; wherein the moving web of open pouches at least partially comprises a water-soluble film; b) closing and sealing said moving web with a first web closure means moving in synchronism therewith whereby the first web closure means is introduced into the partially filled pouches so as to form a plurality of closed and superposed open compartments; c) filling, with a second detergent active or auxiliary component comprising a liquid, gel, paste or wax, closing and sealing the superposed open compartments by means of a second web closure means moving in synchronism with said moving web; and d) separating said web into a plurality of water-soluble multi-compartment pouches.

2. A process according to claim 1 wherein said sealing steps are undertaken by means of solvent sealing.

3. A process according to claim 1 wherein said web of open pouches in step (a) is filled with a first composition comprising a detergent active or auxiliary component and the composition is densified before closing said moving web in step (b).

4. A process according to claim 3 wherein the densified composition has a bulk density after being densified which is between about 5% and about 30% greater than the bulk density of the composition before being densified.

5. A process according to claim 1 wherein the steps of filling are accomplished using a product filling station moving in synchronism with the endless surface.

6. A process according to claim 5 wherein said product filling station comprises a means for supplying a plurality of product feed streams into each of said compartments.

7. A process according to claim 1 wherein said moving web of open pouches is at least partially formed by feeding said water-soluble film to a die having a series of moulds.

8. A process according to claim 7 wherein said moving endless surface is part of a rotating platen conveyor belt comprising said series of moulds.

9. A process according to claim 7 wherein at least portions of said water-soluble film are drawn into said moulds by vacuum.

10. A process according to claim 9 wherein portions of said water-soluble film are at least partially elastically deformed.

11. A process according to claim 9 wherein the die having a series of moulds further comprises holes which are connected to a device which can provide a vacuum, the series of moulds further comprising a series of mould edges, at least some of the holes being close to the series of mould edges.

12. A process according to claim 1 wherein step (a) is performed before step (b), and the pouches are enlarged before closing said moving web in step (b).

13. A process for making a water-soluble pouch which comprises a plurality of compartments in generally superposed or superposable relationship, each comprising a detergent active or auxiliary component, the process comprising the steps of: a) forming and partially filling with a first detergent active or auxiliary component comprising a powder or densified powder, a moving web of open pouches releasably mounted on a moving endless surface having a continuous horizontal rectilinear motion with a constant speed; wherein the moving web of open pouches at least partially comprises a water-soluble film; b) closing said moving web with a first,web closure means moving in synchronism therewith whereby the first web closure means is introduced into the partially filled pouches so as to form a plurality of closed and superposed open compartments; c) filling with a second detergent active or auxiliary component comprising a liquid, gel, paste or wax, and closing the superposed open compartments by means of a second web closure means moving in synchronism with said moving web; d) sealing said web and said first and second web closure means; and e) separating said web into a plurality of water-soluble multi-compartment pouches.

14. A process according to claim 13 wherein said sealing step is undertaken by means of ultrasonic sealing.

15. A process according to claim 13 wherein the moving endless surface comprises a surface with a plurality of moulds having edges into which the moving web is drawn to form said open pouches, wherein the surface with the plurality of moulds further comprises holes which are connected to a device which can provide a vacuum, at least same of the holes being close to the plurality of would edges.

16. A process for making a water-soluble pouch which comprises a plurality of compartments in generally superposed or superposable relationship, each comprising a detergent active or auxiliary component, the process comprising the steps of: a) forming and filling with a first detergent active or auxiliary component comprising a powder or densified powder, a moving web of open pouches releasably mounted on a moving endless surface having a continuous horizontal rectilinear motion with a constant speed; wherein the moving web of open pouches at least partially comprises a water-soluble film, b) closing and sealing said moving web with a first web closure means moving In synchronism therewith so as to form a plurality of closed compartments; c) forming a recess within some or all of the closed compartments formed in step (b) so as to generate a plurality of open compartments superposed above the closed compartments; d) filling with a second detergent active or auxiliary component comprising a liquid, gel, paste or wax, closing and sealing the superposed open compartments by means of a second web closure means moving in synchronism with said moving web; and e) separating said web into a plurality of water-soluble multi-compartment pouches.

17. A process according to claim 16 wherein the moving endless surface comprises a surface with a plurality of moulds having edges into which the moving web is drawn to form said open pouches, wherein the surface with the plurality of moulds further comprises holes which are connected to a device which can provide a vacuum, at least some of the holes being close to the plurality of mould edges.

18. A process for making a water-soluble pouch which comprises a plurality of compartments in generally superposed or superposable relationship, each comprising a detergent active or auxiliary component, the process comprising the steps of: a) forming and filling with a first detergent active or auxiliary component comprising a powder or densified powder, a moving web of open pouches releasably mounted on a moving endless surface having a continuous horizontal rectilinear motion with a constant speed; wherein the moving web of open pouches at least partially comprises a water-soluble film; b) closing said moving web with a first web closure means moving in synchronism therewith so as to form a plurality of closed compartments and superposed open compartments; c) forming a recess within some or all of the closed compartments formed in step (b) so as to generate a plurality of open compartments superposed above the closed compartments; d) filling the superposed open compartments with a second detergent active or auxiliary component comprising a liquid, gel, paste or wax and closing the superposed open compartments by means of a second web closure means moving in synchronism with said moving web; e) sealing said web and said first and second web closure means; and f) separating said web into a plurality of water-soluble multi-compartment pouches.

19. A process according to claim 18 wherein the moving endless surface comprises a surface with a plurality of moulds having edges into which the moving web is drawn to form said open pouches, wherein the surface with the plurality of moulds further comprises holes which are connected to a device which can provide a vacuum, at least some of the holes being close to the plurality of mould edges.

20. A process for making a water-soluble pouch which comprises a plurality of compartments in generally superposed or superposable relationship, each comprising a detergent active or auxiliary component, the process comprising the steps of: a) forming and partially filling, with a first detergent active or auxiliary component consisting of a powder or densified powder, a moving web of open pouches releasably mounted on a horizontal or substantially horizontal portion of an endless surface moving at a constant speed; wherein the moving web of open pouches at least partially comprises a water-soluble film; b) closing and sealing said moving web with a first web closure means moving in synchronism therewith whereby the first web closure means is introduced into the partially filled pouches so as to form a plurality of closed and superposed open compartments; c) filling, with a second detergent active or auxiliary component comprising a liquid, gel, paste or wax, closing and sealing the superposed open compartments by means of a second web closure means moving in synchronism with said moving web; and d) separating said web into a plurality of water-soluble multi-compartment pouches.
Description



TECHNICAL FIELD

The present invention is in the field of dishwashing, in particular it relates to a water soluble multi-compartment pouch adapted to fit the dishwasher dispenser and to deliver product into the pre-wash, main wash and/or post-rinse cycles of the dishwashing machine. The pouch contains a cleaning composition for release on dissolution of the pouch. The invention also relates to a process for the manufacture of the pouches and to a pack for the storage, distribution and display of the pouches.

BACKGROUND OF THE INVENTION

Unitised doses of dishwashing detergents are found to be more attractive and convenient to some consumers because they avoid the need of the consumer to measure the product thereby giving rise to a more precise dosing and avoiding wasteful overdosing or underdosing. For this reason automatic dishwashing detergent products in tablet form have become very popular. Detergent products in pouch form are also known in the art, they have the advantage over tablets of avoiding the contact of the consumer fingers with the dishwashing composition which may contain bleach and/or other irritant substances.

The automatic dishwashing process usually involves a initial pre-wash cycle, main-wash cycle and several hot rinse cycles. Better performance is obtained when the detergent is delivered at the beginning of the main-wash cycle than when the detergent is delivered in the pre-wash cycle since it can be lost with the initial water. In laundry washing machines the detergent can be placed in the drum or in the dispenser, however, in dishwashers the detergent is generally delivered into the main wash via the dispenser to avoid premature dissolution in the pre-wash. The amount of detergent is therefore limited by the volume of the dispenser. Dispensers vary in volume and shape from manufacturer to manufacturer. In the case of detergent in loose form (i.e., powders, paste and liquids), the volume of the dispenser is a decisive factor. In the case of unit dose forms, such as tablet, the geometry and shape of the dispenser plays also a very important role.

Tablets can be designed to have a size and shape which fit all machines. One of the drawbacks of detergent tablets is the fact that their manufacturing process requires the additional step of powder compaction. This decreases enzyme activity and slows down the dissolution rate of the ingredients forming the tablet, or requires the use of complex and expensive disintegrant systems, or makes it difficult to achieve differential dissolution of the detergent active ingredients.

Some detergent ingredients used in dishwashing detergent compositions are liquids. These liquid ingredients can be difficult or costly to include in a solid detergent composition. Also, certain ingredients are preferably transported and supplied to detergent manufacturers in a liquid form and require additional, and sometimes costly, process steps to enable them to be included in a solid detergent composition. An example of these detergent ingredients is surfactant, especially nonionic surfactant which are typically liquid at room temperature or are typically transported and supplied to detergent manufacturers in liquid form. Another example is organic solvents.

Current methods of incorporating liquid ingredients into solid detergent compositions include absorbing the liquid ingredient onto a solid carrier, for example by mixing, agglomeration or spray-on techniques. Typically, solid detergent compositions comprise only low amounts of these liquid detergent ingredients due to the difficulty and expense of incorporating these liquid ingredients into a solid detergent. Furthermore, the incorporation of liquid ingredients into solid detergent compositions can impact on the dissolution characteristics of the composition (for example as the result of forming surfactant gel phases), can increase the moisture pick-up by water sensitive ingredients and can also lead to problems of flowability. It would be advantageous to have a detergent composition which allows the different ingredients to be in their natural state i.e., liquid or solid. This would facilitate the manufacturing process, increase the component stability and furthermore allow the delivery of liquid ingredients prior or post to the delivery of solid ingredients. For example differential dissolution of active ingredients would be beneficial in the case of enzyme/bleach compositions to avoid oxidation of enzymes by the bleach in the dishwashing liquor. It would also be advantageous to separate bleach from perfume.

Another factor that can contribute to the inefficient delivery of actives to the wash, in the case of tablets, is the need for adding carrier materials, as for example porous materials able to bind active liquid materials, binders and disintegrants. In particular, the incorporation of liquid surfactants to powder form detergent compositions can raise considerable processing difficulties and also the problem of poor dissolution through the formation of surfactant gel phases.

There is still the need for a multi-compartment unitised dose form capable of fitting the dispensers of different dishwashing machine types and which allows for the simultaneous delivery of incompatible ingredients and ingredients in different physical forms. There is also need for a simplified manufacturing process for multi-compartment pouch production and for multi-compartment pouches with improved strength, handling and dissolution characteristics as well as excellent aesthetics.

The most common process for making water-soluble pouches with products such as cleaning products is the so-called vertical form-fill-sealing process. Hereby, a vertical tube is formed by folding a film. The bottom end of the tube is sealed to give rise to an open pouch. This pouch is partially filled allowing a head space whereby the top part of the open pouch is then subsequently sealed together to close the pouch, and to give rise to the next open pouch. The first pouch is subsequently cut and the process is repeated. The pouches formed in such a way usually have pillow shape.

A second known process for making pouches is by use of a die having a series of moulds and forming from a film, open pouches in these moulds, which can then be filled and sealed. This method uses the pouch film material more efficiently and the process has more flexibility in terms of pouch shapes and ingredients used. However, the process has limited suitability for industrial application, because it cannot produce large quantities of pouches (per time unit), in an easy and efficient manner.

A third process proposed is the formation of pouches in moulds present on the surface of a circular drum. Hereby, a film is circulated over the drum and pockets are formed, which pass under a filling machine to fill the open pockets. The filling and sealing needs to take place at the highest point (top) of the circle described by the drum, e.g. typically, filling is done just before the rotating drum starts the downwards circular motion, and sealing just after the drum starts its downwards motion.

One problem associated with the vertical filling machine is that the process is not very efficient: the process is intermittent and very slow, for example due to process speed changes from one step to the next step, and each pouch formation step result typically only in one string of pouches in one dimension; thus, only a limited amount of pouches per minute can be formed. Moreover, large quantities of film are used per product dose, because the method does not allow complete filling of the pouches, there is a substantial seal along the vertical dimension of each pouch, and the method does not allow stretching of the film. Also, there is not much flexibility in shapes of pouches formed.

Problems associated with the second process using a die with moulds include also the fact that the process is intermittent (or an indexing process), and that the process is slow and involves acceleration and deceleration, which reduces the overall speed and moreover, causes product spillage out of the open pouches. Also, the output of this process is not very high (per time unit).

The circular drum process overcomes some of the disadvantages of these processes because it does not entail speed changes (no acceleration/deceleration), it can readily provide pouches arranged in two dimensions and the shape of the pouches can be varied to some extent. However, spillage from the pouches can be quite substantial, due to the circular movement, which causes product to spill onto the sealing area, and this can cause problems with sealing (leaking seals). Also, the process does not allow the pouches to be filled completely, because the spillage is then even more of a problem. Also, this process has even more significant problems when used for liquid products, which are more likely to cause large spillage, due to the circular motion. Moreover, the filling and sealing has to be done around the highest point of the circular path of the drum, thereby hugely reducing the overall speed and the output of the pouch formation process.

All the known processes, moreover are designed primarily for making single compartment pouches. There is still need for a process to make multi-compartment water-soluble pouches which overcome the above issues, namely a continuous process, with a fast production rate and which minimize the amount of film used for each pouch. There is also a need for a process of making multi-compartment water-soluble pouches having improved strength and adapted for use in machine dishwashing.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided a machine dishwashing product in the form of water-soluble pouch. The pouch comprises a plurality of compartments in generally superposed or superposable relationship, for example, the plurality of compartments can be symmetrically arranged one above another, side by side (such that they can be folded into a superposed relationship) or any other convenient disposition provided that the compartments are superposable in use. Each compartment contains one or more detergent active components or detergent auxiliaries. Water-soluble pouches comprising a plurality of compartments are herein referred to as multi-compartment pouches. Multi-compartment pouches in which the compartments are in a superposed relationship are especially advantageous when one or more of the compartments comprise a moisture sensitive ingredient, because the compartment comprising a moisture sensitive ingredient can be placed in intermediate or bottom layers and thus they have less surface area exposed to the surrounding environment, therefore reducing the possibility of picking up moisture from the surroundings.

The pouch preferably has a volume of from about 5 to about 70 ml, preferably from about 15 to about 60 ml, more preferably from about 18 to 57 ml, and a longitudinal/transverse aspect ratio in the range from about 2:1 to about 1:8, preferably from about 1:1 to about 1:4. The longitudinal dimension is defined as the maximum height of the pouch when the pouch is lying on one of the bases which has the maximum footprint with the pouch compartments superposed in a longitudinal direction, i.e. one over another, and under a static load of about 2 Kg. The transverse dimension is defined as the maximum width of the pouch in a plane perpendicular to the longitudinal direction under the same con


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