Dosage element and a method of manufacturing a dosage element

Abstract

A dosage element of a type to be consumed in ware washing comprises first (10) and second joined parts (20). The first part (10) comprises a substrate carrying a substance, but preferably carrying a plurality of mutually separated substances A, C. Opposed, second, part (20) comprises a substrate carrying one or more substances B. The first part (10) is joined to the second part (20) so as to form a closed receptacle enclosing the substances in a meshing or interdigitating manner. This arrangement has benefits in manufacturing and in mechanical properties.

Claims

1. A laundry or machine dishwashing dosage element, the laundry or machine dishwashing dosage element comprising first and second joined parts, wherein the first part comprises a water-soluble polymeric film substrate carrying one or more solid laundry or machine dishwashing substances, wherein the second part comprises a water-soluble polymeric film substrate carrying one or more further solid laundry or machine dishwashing substances, wherein the first part is joined to the second part in peripheral areas thereof so as to form a closed receptacle enclosing said solid laundry or machine dishwashing substances within it and so as to form at least one collapsed space between the solid laundry or machine dishwashing substances, and wherein the water-soluble polymeric film substrate of the first part comprises a plurality of mutually separated solid laundry or machine dishwashing substances arranged in side by side relation such that the plurality of substances carried by the first water-soluble polymeric film substrate and the further solid laundry or machine dishwashing substance or substances carried by the second water-soluble polymeric film substrate mesh or interdigitate within the receptacle.

2. The dosage element of claim 1, wherein each of the first and second parts comprises respective first and second elements, wherein each second element comprises a pocket having one or more compartments for receiving at least one of the solid laundry or machine dishwashing substance therein and wherein each first element closes the pocket formed by the respective second element such that each solid laundry or machine dishwashing substance is enclosed within a respective compartment.

3. The dosage element of claim 1, wherein the first part and the second part are flexible in isolation, but when joined to one another the dosage element formed is shape-stable.

4. The dosage element of claim 1, wherein the water-soluble polymeric film substrate of the first part has a thickness of 60 to 75 m and the water-soluble polymeric film substrate of the second part has a thickness of 90 to 120 m.

5. A method of manufacturing a laundry or machine dishwashing dosage element, the method comprising: (a) forming a first part into a substrate comprising a water-soluble polymeric film carrying one or more solid laundry or machine dishwashing substances; (b) forming a second part into a substrate comprising a water-soluble polymeric film carrying one or more further solid laundry or machine dishwashing substances; wherein at least one of the substrate of the first part and the substrate of the second part carries more than one of the solid laundry or machine dishwashing substances and has at least one space between the solid laundry or machine dishwashing substances; and (c) joining the first part to the second part in peripheral areas thereof so as to form a closed receptacle enclosing the solid laundry or machine dishwashing substances within it and so as to collapse the at least one space between said substances.

6. The method of claim 5, wherein in step (c) the first and second parts are arranged such that the first substrate carries a plurality of solid laundry or machine dishwashing substances and the solid laundry or machine dishwashing substances carried by the first and second substrates mesh or interdigitate.

7. The method of claim 5, wherein steps (a) and (b) each comprises the sub-steps of: (a1, b1) forming a pocket with one or more chambers; (a2, b2) introducing the solid laundry or machine dishwashing substances to the one or more chambers of the pocket; and (a3, b3) sealing the chambers with a lid.

8. The method of claim 7, wherein steps (a1, b1) each comprise thermoforming a film of the water-soluble polymeric substance within a cavity of one or more moulds, and steps (a3, b3) comprise sealing the respective lids to the substrates in the moulds in which they were formed.

9. A dosage element manufactured by the method of claim 5.

10. A method of dishwashing or laundry machine washing, comprising the steps of: providing a dosage element according to claim 1 to a dishwashing or laundry washing machine; providing wares to be washed within the dishwashing or laundry washing machine; operating the dishwashing or laundry washing machine to wash the wares.

Description

(1) For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

(2) FIG. 1 is a schematic diagram showing a side view of first and second parts for a multi-compartment dosage element. This diagram shows the parts separated and opposed;

(3) FIG. 2 is a schematic diagram showing the parts of a dosage element as those parts are brought together;

(4) FIG. 3 is a schematic side view showing the first and second parts of the dosage element being sealed together;

(5) FIG. 4 is a schematic top view of a dosage element in a consolidated state;

(6) FIG. 5 is a perspective view of a dosage element formed in accordance with an embodiment of the inventive method; and

(7) FIG. 6 illustrates a preferred formation for the first/second parts.

(8) Referring to FIGS. 1 to 6 there will now be described a dosage element in accordance with an embodiment of the invention and a method of manufacture thereof.

(9) In FIG. 1 there is shown a two-part dosage element comprising a first part 10 which is a substrate carrying a pair of substances A and C, and a second part 20 comprising a similar substrate carrying a single substance B. Substance A is shown as being carried within a closed compartment 30, whilst substance B is shown within a closed compartment 40 and substance C is shown within a closed compartment 50. All wall materials are water-soluble polyvinyl alcohol (PVOH).

(10) Whilst only the parts required for a single dosage element to be formed are shown in FIG. 1, it will be appreciated that, in fact, the first and second parts 10, 20 form parts of larger sheets which during manufacture are disposed in parallel relation to one another and may be in motion as indicated by the arrows shown in the figure. Each larger sheet may include tens or even hundreds of such partially formed dosage elements on a continuous sheet.

(11) The first and second parts are arranged during the manufacturing process such that substances carried by the first part 10 interdigitate or mesh with substances carried by the second part as the two parts are brought together as shown in FIG. 2.

(12) Referring now to FIG. 6 briefly, a specific formation of the first part 10 will now be described.

(13) The first part 10 as shown comprises first and second elements 10a and 10b respectively that are combined to give the formation shown in FIGS. 1 and 2. The first element 10a as shown in FIG. 6, comprises a sheet like substrate forming a lid, whilst the second element 10b comprises thermoformed elements that form, in the case of first part, two compartments 30, 50. The second element 10b may be made by sucking a sheet of thermoformable material into an appropriate mould so as to form the open compartments as illustrated in FIG. 6. Following the formation of the compartments 30, 50, the substances A, C may then be injected into the open compartments.

(14) The reader will realise that whilst the figure is discussed in relation to the construction of the first part 10, the construction of the second part 20 is identical in all respects other than in the number/location of substance compartments.

(15) The finished intermediate products formed by the first part 10 and the second part 20 are each formed by capping and sealing the respective first elements to serve as lids over the top of the respective second elements, to close the compartments 30, 40, 50.

(16) In each case, the intermediate products formed by the first and second parts 10, 20 may then be lifted from the mould, or the mould dropped away from it, whichever is desired.

(17) Referring back now to FIG. 2, the first and second parts 10, 20 are brought together and, in a consolidating step shown in FIG. 3 are sealed one to another face-to-face around their entire periphery by any convenient process, such as heat sealing/crimping, to provide a single completed article having the formation as shown in FIGS. 4 and 5.

(18) The dosage element formed from the first and second parts is in the shape of a pillow. It is pleasant and feels squashy or compliant, rather than rigid or box-like. It is shape stable, in the sense that although it can be pressed and manipulated it does not lose its pillow shape. Although in isolation the parts 10, 20 are flexible (in the manner defined earlier) they come together to support each other, and the resulting dosage product is surprisingly robust.

(19) As a consequence of the relatively high stability given by the combination of first and second parts 10, 20 joints between these parts, and weak spots such as curves and corners, are not likely to be damaged by stress.

(20) During the consolidating operationin which the first and second parts 10, 20 are brought togetherand the compartments mesh to give interdigitation of the compartmentsthe spaces between the side by side compartments 40, 50, 60 collapse to provide a very compact finished product. The thereby closely fitting water soluble skin provided by first part 10 not only blocks bending of the second part 20, but also provides support to potential weak spots such as that illustrated as w in FIG. 3.

(21) Whilst the method of forming a dosage element has been described in relation to a single tablet, it will be appreciated that a large plurality of such tablets are manufactured in one forming operation.

(22) The preferred process, in detail, for forming dosage elements is as described below.

(23) The present example provides a process for preparing a water-soluble article comprising a water-soluble thermoformed component, which comprises:

(24) (A) Forming a first primary component (bottom film) comprising second element 10b of the first part 10 into a pocket, by thermoforming in the cavity of a thermoforming primary mould. A suitable forming temperature for PVOH is, for example, 120 C. The thickness of the film used to produce the pocket is preferably 90 to 120 m. A suitable forming vacuum is 0 to 2 kPa. The primary mould geometry is designed such that it allows for the possibility of combining the compartments of the first part 10 with the compartments of the second part 20.
(B) Introducing the respective substances A, C into the chambers 30, 50 formed by the second element 10b into the pocket of the primary mould; and
(C) Adding the first element 10a as a lid (top film) over the second element when the latter is still in the primary mould to cover the open and filled compartments 30, 50. Here, the thickness of the covering film is generally 60 to 75 m.
(D) Sealing the first element 10a to the second element 10b components of the primary mould together. The films of the first and second elements 10a, 10b may be sealed together by means of an aqueous solution of PVOH, acting as an adhesive. Alternatively they may be sealed together by any other suitable means, for example by means of a further adhesive or by heat sealing. Other methods of sealing include infra-red, radio frequency, ultrasonic, laser, solvent (such as water), vibration and spin welding. If heat sealing is used, a suitable sealing temperature is for example 125 C. A suitable sealing pressure is readily selected by the person skilled in the art.
(E) Forming the second element 20, as just described for the first element 10. The secondary mould geometry is designed to allow the compartments 10, 20 to be combined, in the interdigitated manner already described.
(F) Indexing and fixing the first and second parts 10, 20 together by interdigitation, in order to form a single pocket. The matrix of the first or second parts, preferably having been ejected from their mould, may be applied to the matrix of the other parts, which may still be in their mould. Separation of dosage elements (e.g. by cutting) may occur with the latter parts still in-mould, or following removal of both matrices of parts from their moulds.

(25) The parts may be sealed together by any suitable means, for example by any of the means described about for joining parts 10a and 10b.

(26) Separation of the dosage elements, wherever undertaken, may be into individual dosage elements or may be into groups of dosage elements, for example 4-16 in number, which are packaged in such groups and are intended to be separated into individual dosage elements by the user.

(27) It will further be understood by the skilled man that the first and second part 10, 20, whilst described as being formed from separate sheets 10a, 10b, or 20a, 20b respectively could instead be formed from a single substrate onto which individual elements comprising materials A, B, C are directly or indirectly adhered.

(28) Whether a single substrate is used, or a combination of sheets as described earlier are used, the preferred thickness of carrier (substrate or first element 10a, 20a) may be within the range of 20-30 m where the substances A, B, C comprise a combination of powders, or may be up to around 60 m where A, B or C comprise a gel. This compares favourably with other products which typically require thicker materials of between 300 and 800 m to ensure a relatively robust end product.

(29) Suitable chemical compositions are as follows. In these examples A and C denote compositions in compartments in the first part and B denotes a composition in a compartment in the second part (see FIG. 1).

EXAMPLE 1

(30) Phosphate-containing composition having percarbonate in a separate compartment (Table 1 below) for use in an automatic dishwasher.

(31) TABLE-US-00001 TABLE 1 A - C - B - Walls - Powder Gel Percarb. PVOH Raw Material (8.4 g) (6.4 g) (1.3 g) (0.5 g) Sodium tripolyphosphate 42.50 Sodium carbonate 16.00 Tri-sodium citrate 22.00 Phosphate speckles 4.00 Benzotriazol 0.40 HEDP 4 Na (88.5%) 0.30 Protease.sup.1 1.50 Amylase.sup.1 1.00 TAED 6.20 1,2-Propylenediglycol 0.98 Dye 0.02 Perfume 0.10 Sulfonated polymer.sup.2 5.00 Sulfonated polymer.sup.2 5.00 Surfactant.sup.3 24.00 Polyglycol.sup.4 9.00 1,2-Propylendiglycol 1.00 Dye 0.03 Antifoam.sup.5 0.25 TAED 3.00 Sodium tripolyphoshate 57.42 Polyglycol 6000 0.30 Sodium percarbonate 100 PVOH (substrate, pockets).sup.7 60 PVOH (lids).sup.8 100 40 100 100 100 100

EXAMPLE 2

(32) Phosphate-containing composition having PAP (phthalimidohexanoic acid) (Table 2 below) in a separate compartment for use in an automatic dishwasher.

(33) TABLE-US-00002 TABLE 2 A - C - B - Walls - Powder Gel PAP PVOH Raw Material (8.4 g) (6.4 g) (1.3 g) (0.5 g) Sodium tripolyphosphate 48.70 Sodium carbonate 16.00 Tri-sodium citrate 22.00 Phosphate speckles 4.00 Benzotriazol 0.40 HEDP 4 Na (88.5%) 0.30 Protease.sup.1 1.50 Amylase.sup.1 1.00 1,2-Propylenediglycol 0.98 Dye 0.02 Perfume 0.10 Sulfonated polymer.sup.2 5.00 Sulfonated polymer.sup.2 5.00 Surfactant.sup.3 24.00 Polyglycol.sup.4 9.00 1,2-Propylendiglycol 1.00 Dye 0.03 Antifoam.sup.5 0.25 Sodium tripolyphoshate 60.42 Polyglycol 6000 0.30 PAP.sup.6 100 PVOH (substrate, pockets).sup.7 60 PVOH (lids).sup.8 40 100 100 100 100

EXAMPLE 3

(34) Sodium citrate-containing composition having percarbonate in a separate compartment (Table 3 below) for use in an automatic dishwasher.

(35) TABLE-US-00003 TABLE 3 A - C - B - Walls - Powder Gel Percarb. PVOH Raw Material (7.0 g) (6.4 g) (2.3 g) (0.4 g) Sodium carbonate 16.00 Tri-sodium citrate 68.50 Benzotriazol 0.40 HEDP 4 Na (88.5%) 0.30 Protease.sup.1 1.50 Amylase.sup.1 1.00 TAED 6.20 1,2-Propylenediglycol 0.98 Dye 0.02 Perfume 0.10 Sulfonated polymer.sup.2 5.00 Sulfonated polymer.sup.2 5.00 Surfactant.sup.3 24.00 Polyglycol.sup.4 9.00 1,2-Propylendiglycol 1.00 Dye 0.03 Antifoam.sup.5 0.25 TAED 3.00 Tri-sodium citrate 56.72 Polyglycol 35000 1.00 Sodium percarbonate 100 PVOH (substrate, pockets).sup.7 60 PVOH (lids).sup.8 40 100 100 100 100

EXAMPLE 4

(36) Sodium citrate-containing composition having PAP in a separate compartment (Table 4 below) for use in an automatic dishwasher.

(37) TABLE-US-00004 TABLE 4 A - C - B - Walls - Powder Gel PAP PVOH Raw Material (7.0 g) (6.4 g) (1.3 g) (0.5 g) Sodium carbonate 16.00 Tri-sodium citrate 74.70 Benzotriazol 0.40 HEDP 4 Na (88.5%) 0.30 Protease.sup.1 1.50 Amylase.sup.1 1.00 1,2-Propylenediglycol 0.98 Dye 0.02 Perfume 0.10 Sulfonated polymer.sup.2 5.00 Sulfonated polymer.sup.2 5.00 Surfactant.sup.3 24.00 Polyglycol.sup.4 9.00 1,2-Propylendiglycol 1.00 Dye 0.03 Antifoam.sup.5 0.25 Tri-sodium citrate 59.72 Polyglycol 35000 1.00 PAP.sup.6 100 PVOH (substrate, pockets).sup.7 60 PVOH (lids).sup.8 40 100 100 100 100

EXAMPLE 5

(38) MGDA-containing composition having PAP in a separate compartment (Table 5 below) for use in an automatic dishwasher.

(39) TABLE-US-00005 TABLE 5 A - C - B - Walls - Powder Gel PAP PVOH Raw Material (6.0 g) (6.4 g) (1.3 g) (0.5 g) Sodium carbonate 16.00 MGDA granules.sup.9 74.70 Benzotriazol 0.40 HEDP 4 Na (88.5%) 0.30 Protease.sup.1 1.50 Amylase.sup.1 1.00 1,2-Propylenediglycol 0.98 Dye 0.02 Perfume 0.10 Sulfonated polymer.sup.2 5.00 Sulfonated polymer.sup.2 5.00 Surfactant.sup.3 24.00 Polyglycol.sup.4 9.00 1,2-Propylendiglycol 1.00 Dye 0.03 Antifoam.sup.5 0.25 MGDA granules.sup.9 60.22 Polyglycol 6000 0.50 PAP.sup.6 100 PVOH (substrate, pockets).sup.7 60 PVOH (lids).sup.8 40 100 100 100 100

EXAMPLE 6

(40) Sodium citrate-containing composition having PAP in a separate compartment (Table 6 below) for use in an automatic dishwasher.

(41) TABLE-US-00006 TABLE 6 A - C - B - Walls - Powder Powder PAP PVOH Raw Material (7.0 g) (7.0 g) (1.3 g) (0.5 g) Sodium carbonate 17.00 17.50 Tri-sodium citrate 68.50 68.50 Benzotriazol 0.40 0.40 HEDP 4 Na (88.5%) 0.30 0.30 Protease.sup.1 1.50 Amylase.sup.1 1.00 TAED 6.20 6.20 1,2-Propylenediglycol 0.98 0.98 Dye 0.02 0.02 Perfume 0.10 0.10 Sulfonated polymer.sup.2 5.00 5.00 Sodium percarbonate 100 PVOH (substrate, pockets).sup.7 60 PVOH (lids).sup.8 40 100 100 100 100

(42) The container used in this example has 3 compartments separated from each other. In one compartment the PAP composition or the percarbonate composition is filled, respectively.

(43) The powder is introduced into the powder compartment. The gel mixture is heated to 65 C. and stirred for 20 min. Then the gel is introduced into the gel compartment and is allowed to cool. Finally the compartments are sealed with PVOH film.

(44) In the example the particle size of the PAP has preferably a size of 0.01-100 m (Q50%<15 m).

(45) In all examples above illustrating the present invention the dosage element is consumed in a washing cycle, in the sense that at the end of cycle no part of it has to be removed from the machine; indeed no part of it can be discerned, within the machine.

(46) Whilst three substances are discussed, the skilled man will realise that, according to a particular function to be performed, more or fewer substances may be utilised and combined in any logical combination without departing from the principles of the present invention.

(47) The dosage element as described above provides a very convenient and compact arrangement that is easy to manufacture, and subsequently which is resistant to bending and other stress.