U.S. patent application number 10/601440 was filed with the patent office on 2004-01-22 for method for producing a packaging filled with tablets and one such packaging.
Invention is credited to Doehler, Rainer, Gawrisch, Wolfgang, Lange, Ilona, Prenger, Gabriele, Vollmerhaus, Dirk.
Application Number | 20040011693 10/601440 |
Document ID | / |
Family ID | 27214213 |
Filed Date | 2004-01-22 |
United States Patent
Application |
20040011693 |
Kind Code |
A1 |
Prenger, Gabriele ; et
al. |
January 22, 2004 |
Method for producing a packaging filled with tablets and one such
packaging
Abstract
A process for making a pack filled with a tablet of active
substance, by inserting a preformed pack-forming film integrally
forming a holding cup a retaining mold, introducing a quantity of
uncompressed active substance into the holding cup, compressing the
active substance in the holding cup to form a compact tablet in the
holding cup itself by means of a compression mold using the holder
of the retaining mold as a support. A pack filled with an active
substance in the form of a compact tablet, the pack having a film
forming a holding cup, the tablet being accommodated in the holding
cup, wherein an edge of the tablet at the bottom of the holding cup
corresponds in its profile to the edge profile of the holding
cup.
Inventors: |
Prenger, Gabriele; (Krefeld,
DE) ; Lange, Ilona; (Langenfeld, DE) ;
Doehler, Rainer; (Dormagen, DE) ; Gawrisch,
Wolfgang; (Duesseldorf, DE) ; Vollmerhaus, Dirk;
(Duesseldorf, DE) |
Correspondence
Address: |
HENKEL CORPORATION
THE TRIAD, SUITE 200
2200 RENAISSANCE BLVD.
GULPH MILLS
PA
19406
US
|
Family ID: |
27214213 |
Appl. No.: |
10/601440 |
Filed: |
June 23, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10601440 |
Jun 23, 2003 |
|
|
|
PCT/EP01/14644 |
Dec 13, 2001 |
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Current U.S.
Class: |
206/531 ;
206/538; 53/438; 53/467 |
Current CPC
Class: |
B30B 11/027 20130101;
C11D 17/044 20130101; B65D 2575/3245 20130101; B65D 75/326
20130101; B65B 1/24 20130101; B65B 9/042 20130101; B65D 75/327
20130101; B65B 63/02 20130101; B65D 73/0092 20130101 |
Class at
Publication: |
206/531 ; 53/438;
53/467; 206/538 |
International
Class: |
B65B 001/24 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 22, 2000 |
DE |
100 64 150.4 |
Dec 22, 2000 |
DE |
100 64 152.0 |
Jun 23, 2001 |
DE |
101 30 391.2 |
Claims
1. A process for the production of a pack filled with an active
substance composition, comprising the steps of: a) inserting a
preformed pack-forming film comprising at least one integrally
formed holding cup having an open side with the holding cup into a
matching holder of a retaining mold; b) introducing a quantity of
uncompressed active substance composition into the holding cup
before, during, or after process step a); c) compressing the
quantity of active substance composition in the holding cup to form
a compact tablet in the holding cup itself by means of a
compression mold using the holder of the retaining mold as a
support; d) on completion of process step c), removing the film
with the active substance composition tablet in the holding cup
from the retaining mold and delivering the film to further handling
stages; and e) before, during, or after process step d), closing
the holding cup on its open side by applying a closure film or a
cover.
2. The process of claim 1, wherein the film is continuously
delivered and the holding cups are formed in the film by a roller
assembly.
3. The process of claim 1, wherein the film is delivered at
intervals and the holding cups are formed in the film by a flat
thermoforming tool.
4. A process for the production of a pack filled with an active
substance composition in tablet form, comprising the steps of: a)
placing a pack-forming film on a retaining mold comprising at least
one holder forming a holding cup; b) introducing in a compression
mold associated with the retaining mold and comprising a premix
holder associated with the holder of the retaining mold, a quantity
of uncompressed active substance composition and then performing
the active substance composition in the premix holder before or
during process step a); c) closing the mold and pressing the
preformed active substance composition from the premix holder onto
the pack-forming film and, together with the film, into the holder
of the retaining mold, shaping the film into a holding cup having
an open side in the process, and compressing the preformed active
substance composition to a compact tablet in the holder of the
retaining mold using that holder as a support; d) on completion of
step c), removing the film with the active substance composition
tablet in the holding cup from the retaining mold and delivering
the film with the active substance composition tablet in the
holding cup to further handling stages; and e) before, during, or
after process step d), closing the holding cup on its open side by
applying a closure film or a cover.
5. The process of claim 4, wherein, in step c), the preformed
active substance composition is forced out of the premix holder by
a punch mounted for displacement in the compression mold.
6. The process of claim 4, wherein, in step c), the preformed
active substance composition is forced out of the premix holder by
compressed air.
7. The process of claim 5, wherein, in step c), the preformed
active substance composition is forced out of the premix holder by
compressed air.
8. The process of claim 4, wherein the drawing of the pack-forming
film into the holder in step c) is supported by air leaving the
holder of the retaining mold or by the suction of air from the
holder of the retaining mold.
9. The process of claim 1, wherein the process steps are carried
out on a continuous film by roller assemblies, co-circulating belt
arrangements or intermittently co-circulating tools.
10. The process of claim 4, wherein the process steps are carried
out on a continuous film by roller assemblies, co-circulating belt
arrangements or intermittently co-circulating tools.
11. The process of claim 1, wherein the process steps are each
carried out quasi-statically on a film section.
12. The process of claim 4, wherein the process steps are each
carried out quasi-statically on a film section.
13. The process of claim 1, wherein several holding cups are formed
beside and/or behind one another in the film and are simultaneously
filled with active substance composition.
14. The process of claim 4, wherein several holding cups are formed
beside and/or behind one another in the film and are simultaneously
filled with active substance composition.
15. The process of claim 1, wherein a plastic film is used as the
pack-forming film.
16. The process of claim 15, wherein the plastic film comprises
polyethylene or polyvinyl chloride.
17. The process of claim 4, wherein a plastic film is used as the
pack-forming film.
18. The process of claim 16, wherein the plastic film comprises
polyethylene or polyvinyl chloride.
19. The process of claim 1, wherein a metal foil is used as the
pack-forming film.
20. The process of claim 19, wherein the metal foil comprises
aluminium.
21. The process of claim 4, wherein a metal foil is used as the
pack-forming film.
22. The process of claim 21, wherein the metal foil comprises
aluminium.
23. The process of claim 1, wherein a metal foil is used as the
closure film.
24. The process of claim 23, wherein the metal foil comprises
aluminium.
25. The process of claim 4, wherein a metal foil is used as the
closure film.
26. The process of claim 25, wherein the metal foil comprises
aluminium.
27. The process of claim 1, wherein a plastic film is used as the
closure film.
28. The process of claim 27, wherein the plastic film comprises
polyethylene or polyvinyl chloride.
29. The process of claim 4, wherein a plastic film is used as the
closure film.
30. The process of claim 29, wherein the plastic film comprises
polyethylene or polyvinyl chloride.
31. The process of claim 1, wherein the closure film or the cover
are joined to the pack-forming film in childproof manner.
32. The process of claim 4, wherein the closure film or the cover
are joined to the pack-forming film in childproof manner.
33. The process of claim 1, wherein the film filled with tablets in
the holding cups and provided with closure film or covers is cut
into marketing units.
34. The process of claim 4, wherein the film filled with tablets in
the holding cups and provided with closure film or covers is cut
into marketing units.
35. The process of claim 33, wherein, to form a marketing unit,
several packs are placed in a paperboard carrier with corresponding
openings.
36. The process of claim 34, wherein, to form a marketing unit,
several packs are placed in a paperboard carrier with corresponding
openings.
37. The process of claim 1, wherein tablets of different active
substance compositions are formed in holding cups in a marketing
unit.
38. The process of claim 4, wherein tablets of different active
substance compositions are formed in holding cups in a marketing
unit.
39. The process of claim 1, wherein a two-layer film is used as the
closure film and an additional body of an active substance
composition is arranged between the layers of the closure film.
40. The process of claim 4, wherein a two-layer film is used as the
closure film and an additional body of an active substance
composition is arranged between the layers of the closure film.
41. A pack filled with an active substance composition in the form
of a compact tablet, the pack comprising a pack-forming film
provided with at least one integrally formed holding cup having an
open side and a bottom and a closure film that closes or covers the
holding cup, the tablet being accommodated in the holding cup,
wherein an edge of the tablet at the bottom of the holding cup
corresponds in its profile to the edge profile of the holding
cup.
42. The pack of claim 41, wherein the tablet bears against an
encircling inner wall of the holding cup over virtually its entire
circumference.
43. The pack of claim 41, wherein the edge of the tablet at the
bottom of the holding cup has a different contour from an edge of
the tablet facing the open side of the holding cup.
44. The pack of claim 41, wherein the pack-forming film is a
plastic film.
45. The pack of claim 44, wherein the plastic film comprises
polyethylene or polyvinyl chloride.
46. The pack of claim 41, wherein the pack-forming film is a metal
foil.
47. The pack of claim 46, wherein metal foil comprises
aluminium.
48 The pack of claim 41, wherein the closure film is a metal
foil.
49. The pack of claim 48, wherein metal foil comprises
aluminium.
50. The pack of claim 41, wherein the closure film is a plastic
film.
51. The pack of claim 50, wherein the plastic film comprises
polyethylene or polyvinyl chloride.
52. The pack of claim 41, wherein the closure film is a two-layer
film between the layers of which an additional body of an active
substance composition can be accommodated under protection.
53. A plurality of packs according to claim 41, placed in a
paperboard carrier with corresponding openings and, with the
carrier, forming a marketing unit.
54. The pack of claim 41, wherein tablets of different active
substance compositions are placed in holding cups in a marketing
unit.
55. The process of claim 1, wherein the active substance
composition comprises a laundry detergent, a dishwasher detergent,
a water-soluble washing or cleaning aid, or an adhesive.
56. The process of claim 4, wherein the active substance
composition comprises a laundry detergent, a dishwasher detergent,
a water-soluble washing or cleaning aid, or an adhesive.
57. The pack of claim 41, wherein the active substance composition
comprises a laundry detergent, a dishwasher detergent, a
water-soluble washing or cleaning aid, or an adhesive.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of
International Application PCT/EP01/14644, claiming priority under
35 U.S.C. .sctn. 365(c) of International Application
PCT/EP01/14644, filed Dec. 13, 2001 in the European Patent Office,
and claiming foreign priority under 35 U.S.C. .sctn. 119 of DE 100
64 150.4, filed Dec. 22, 2000, in the German Patent Office, DE 100
64 152.0, filed Dec. 22, 2000, in the German Patent Office, and DE
101 30 391.2, filed Jun. 23, 2001, in the German Patent Office.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a process for the production of a
pack filled with an active substance composition, more particularly
a detergent, in tablet form, and to a pack filled with an active
substance composition, more particularly a detergent, in the form
of a compact tablet.
[0003] The teaching of the invention may be applied to the
production of active substance compositions in tablet form that are
marketed in a suitable pack. The active substance compositions in
question are, in particular, detergents, such as laundry detergents
and dishwasher detergents, and other water-soluble washing and
cleaning aids, such as bleaching agents, color protectors, perfume
formulations, enzyme compositions, etc. However, the process
according to the invention may also, be used for other active
substance compositions that are to be marketed in tablet form in a
protective pack.
[0004] However, a particular field of application of the process
according to the invention are in fact any forms of laundry
detergents, washing aids, and dishwashing detergents in tablet
form. Another field of application is water-soluble adhesives, more
particularly pastes, in tablet form, which are used for pasting
over large areas, for example for pasting wallpaper.
[0005] The production of active substance compositions,
particularly detergents, in tablet form from generally finely
crystalline, powder-form, or granular starting materials is
generally carried out by tabletting in the presence of added
fillers, binders, disintegrators, lubricants, or the like. The
starting material is tabletted, for example, in eccentric presses
or rotary presses under a pressure suited to the particular
product.
[0006] It is known that active substance compositions, particularly
detergents, can be packaged in tablet form. On the one hand, the
tablet is thus protected against mechanical stressing; on the other
hand, dermatologically aggressive components are occasionally
processed in the production of detergents so that skin contact with
the tablet is avoided by the pack. Finally, the pack prevents
tabletted active substance compositions, particularly detergents,
from prematurely absorbing moisture from the ambient air.
[0007] So-called flowpacks are known for packaging active-substance
compositions, particularly detergents. Active substance
compositions in tablet form are often packaged in pairs in
flowpacks. In the case of a typical laundry detergent/washing aid
combination for example, two such tablets are required for one wash
cycle and are accommodated in an internally divided flowpack (DE
198 40 390 A1). Flowpacks are also known in practice for
water-soluble adhesive tablets in tablet form.
[0008] A common type of pack for active substance compositions in
tablet form is the blister pack. Blister packs are also used for
detergent tablets (EP 0 903 405 A2). The prior art proposes a
tabletted dishwashing detergent with a certain formulation. The
tablets are produced in the usual way in a normal tablet press, for
example a rotary press. The tablets produced by the rotary press
are collected and automatically placed in the holding "cups" of a
preformed pack-forming film. When the cups have been filled with
corresponding tablets, they are hermetically sealed on the open
side by application of a closure film, more particularly by welding
or bonding. Where production is continuous, corresponding strips of
the closed pack--each comprising eight cups in the illustrated
embodiment--are cut off and marketed as such.
[0009] The use of a blister pack for tabletted active substance
compositions enables different--even mutually incompatible--active
substances to be packed in separate cups and to be individually
dosed. Skin contact with the active substance composition is
readily avoidable. It is also possible to make up a marketing unit
from several rows of cups filled with different active substance
compositions, for example laundry detergents on the one hand and
washing aids on the other hand.
[0010] The known blister pack has a pack-forming film of a plastic,
more particularly a thermoplastic, transparent or translucent
plastic, for example polyethylene.
[0011] Packaging of the tablets of the active substance composition
in a blister pack enables the formulation of the active substance
composition to be somewhat more freely selected because the demands
that the dimensional stability of the tablet have to meet are
smaller. Even if the tablet should break, the quantity of active
substance remains accommodated in the cup pending use and,
accordingly, is still available to the user. The above-mentioned
transparent pack in particular can be very attractive to a
potential customer.
[0012] Blister packs for tabletted active substance compositions
have also been known for some time for a water-soluble adhesive,
more particularly a paste (DE 42 00 188 A1). This prior art also
discloses typical formulations for water-soluble adhesives based on
natural starting products or water-soluble derivatives of cellulose
and starch.
[0013] It has been found that the process for the production of a
pack filled with an active substance composition, more particularly
a detergent in tablet form, is in need of improvement in regard to
the sequence of process steps.
DESCRIPTION OF THE INVENTION
[0014] The process according to the invention comprises the
following steps:
[0015] a) a preformed pack-forming film comprising at least one
integrally formed holding cup is inserted with the holding cup into
a matching holder of a retaining mold;
[0016] b) a certain quantity of the as yet uncompressed active
substance composition (premix) is introduced into the holding cup
before, during or after process step a);
[0017] c) the quantity of active substance composition in the
holding cup is compressed to a compact tablet in the holding cup
itself by means of a compression mold using the holder of the
retaining mold as a support;
[0018] d) on completion of process step c), the film with the
active substance composition tablet in the holding cup is removed
from the retaining mold and delivered to further handling
stages;
[0019] e) before, during or after process step d), the holding cup
is closed on its open side by application of a closure film or a
cover.
[0020] The process according to the invention as described above is
of particular advantage when the film is continuously delivered and
the holding cups are formed in the film by means of a roller
arrangement. In an alternative embodiment, the film is delivered in
sections and the holding cups are formed in the film by means of a
flat thermoforming tool.
[0021] According to the invention, the tablet shape of the active
substance composition is produced directly in the integrally formed
holding cup of the pack-forming film. The holding cup of the
pack-forming film held in a retaining mold as a support is also the
compression mold for the tablet. According to the invention, the
"tabletting" and "tablet packaging" steps are combined into a
single process. The formation of the tablet in the pack itself
eliminates the problem or edge breakage and erosion during handling
of the tablets in the automatic loading machine.
[0022] Because the "tabletting" and "tablet packaging" steps are
combined into a single process step, contact of the active
substance composition, more particularly the detergent, with the
ambient air during the production process can be kept very short.
The hitherto usual conditioning of the production rooms can be
reduced and confined to the delivery of the uncompressed raw
material of the active substance composition.
[0023] As for the rest, a pack filled with a tablet-form active
substance composition that has been produced by the process
according to the invention naturally has the same advantages as the
blister pack known from the prior art (EP 0 903 405 A2). Blister
packs are only one variant of corresponding packs according to the
invention. Related packs are push-through packs, press-through
packs, skin packs, etc.
[0024] A particularly preferred embodiment of a process according
to the invention for producing a pack filled with an active
substance composition, more particularly a detergent, in tablet
form does not require a preformed pack-forming film. This
embodiment comprises the following process steps:
[0025] a) a pack-forming film is placed on a retaining mold
comprising at least one holder forming a holding cup;
[0026] b) in a compression mold associated with the retaining mold
and comprising a premix holder associated with the holder of the
retaining mold, a certain quantity of the as yet uncompressed
active substance composition (premix) is introduced into and then
preformed in the premix holder before or during process step
a);
[0027] c) the mold is closed and the preformed active substance
composition is pressed from the premix holder onto the pack-forming
film and, together with the film, into the holder of the retaining
mold, shaping the film into a holding cup in the process, and is
compressed to a compact tablet in the holder of the retaining mold
using that holder as a support;
[0028] d) on completion of step c), the film with the active
substance composition tablet in the holding cup is removed from the
retaining mold and delivered to further handling stages;
[0029] e) before, during or after process step d), the holding cup
is closed on its open side by application of a closure film or a
cover.
[0030] In the above-described variant of the process according to
the invention, another production step is integrated into the
process, namely formation of the holding cup(s) in the pack-forming
film. On the one hand, the tablet is pressed from the premix of the
active substance composition; on the other hand and at the same
time, the pack-forming film is thermoformed in the holder of the
retaining mold. In this embodiment of the process, the tablet of
the active substance composition is on the one hand the object of
the pressing step and, on the other hand, the power transmission
medium for the thermoforming of the pack-forming film.
[0031] In another variant of this particular embodiment of the
process according to the invention, the preformed active substance
composition, more particularly detergent, is pressed out of the
premix holder in step c) by means of a punch arranged for
displacement in the compression mold. An alternative variant is
wherein the preformed active substance composition is pressed out
of the premix holder in step c) by compressed air. The two pressure
generating mechanisms may also be used in combination.
[0032] In another embodiment, the drawing of the pack-forming film
into the holder in step c) is facilitated by air leaving the holder
of the retaining mold or is actively supported by the suction of
air from the holder of the retaining mold.
[0033] Other preferred embodiments and further developments of the
process according to the invention are the subject of the other
subsidiary process claims.
[0034] The present invention also relates to a pack filled with an
active-substance composition, more particularly a detergent, in the
form of a compact tablet and consisting of a pack-forming film
provided with at least one integrally formed holding cup and a
closure film or a cover closing the holding cup, the tablet being
accommodated in the holding cup. More particularly, the invention
relates to a pack produced by the process according to the
invention.
[0035] According to the invention, the pack is wherein the edge of
the tablet at the bottom of the holding cup corresponds in its edge
profile to the edge profile of the holding cup. It is particularly
useful if the tablet bears substantially over its entire
circumference against the encircling inner wall of the holding cup.
Even if the tablet should break, it thus remains dimensionally
stable in the pack and stays usable for the user. The reject rate
is also considerably reduced in this way.
[0036] In addition, a pack produced by the process according to the
invention with the active substance composition accommodated
therein in the form of a tablet is recognizable at least from the
fact that the edge of the tablet at the bottom of the holding cup
has a different contour from the edge of the tablet facing the open
side of the holding cup and, in particular, is more rounded.
[0037] Preferred embodiments of the pack according to the invention
are the subject of the other subsidiary claims relating to the
pack.
DESCRIPTION OF THE DRAWINGS
[0038] Examples of embodiment are described in detail in the
following with reference to the accompanying drawings, wherein:
[0039] FIG. 1 is a plan view of a strip-form pack of several
individual blisters arranged one behind the other.
[0040] FIG. 2 is a schematic illustration explaining a first
process for producing the pack shown in FIG. 1.
[0041] FIG. 3 is a schematic illustration explaining a second
process for producing the pack shown in FIG. 1.
[0042] FIG. 4 is a plan view of a finished pack accommodating a
total of 16 tablets of active substance composition.
[0043] FIG. 5 is a side elevation of the pack shown in FIG. 4.
[0044] FIG. 6 shows another embodiment of a pack comprising a
plurality of tablets accommodated in individual holding cups.
[0045] FIG. 7 is a plan view of a marketing unit comprising several
packs each having two holding cups and tablets of active substance
composition accommodated therein.
[0046] FIG. 8 schematically illustrates a preferred embodiment of a
pack according to the invention with a tablet of active substance
composition accommodated therein.
[0047] As already discussed in the general part of the description,
the process according to the invention is intended for the
production of a pack filled with an active substance composition in
tablet form. The pack may be an individual pack which, for example,
has been cut off from the strip shown in FIG. 1. However, the pack
may also assume the form of relatively large groups of packs, as
the other examples of embodiment clearly show.
[0048] Active substance compositions of any kind can be
accommodated in a pack by the process according to the invention.
However, the teaching according to the invention relates more
particularly to cleaning compositions, more particularly laundry
detergents and washing aids for the cleaning of laundry and
dishwasher detergents. Another particularly interesting application
are water-soluble adhesives, more particularly pastes, as active
substance compositions, as explained in the general part of the
description. Particular reference may be made to the prior art
already cited there with its disclosure on the subject of
water-soluble adhesives in tablet form.
[0049] The blister strip shown in FIG. 1 of a thermoformable
thermoplastic film, for example of polyethylene, shows integrally
formed holding cups with an internal diameter of ca. 44 mm. This is
the size for a tablet of an active substance composition which is
suitable for typical laundry or dishwashing detergents. This size
is of course just one example, the teaching according to the
invention not being confined either to certain tablet sizes or to
certain tablet shapes.
[0050] FIG. 2 illustrates the basic principle of a process for the
production of a pack filled with an active substance composition,
more particularly a detergent, in tablet form. The process steps
are described in the following:
[0051] A preformed pack-forming film 1 with at least one integrally
formed holding cup 2 (in the example illustrated, four holding cups
2 situated beside one another) is placed with the holding cup 2 in
a matching holder 3 of a retaining mold 4. In the example
illustrated, the retaining mold 4 has four holders 3 adjacent one
another. Before, during or after the process step explained above,
a certain quantity of the as yet uncompressed active substance
composition (premix) is introduced into the holding cup 2.
Associated with the retaining mold 4 is a compression mold 6
provided with corresponding compressing projections 5. The mold 6
is lowered onto the retaining mold 4 from above, as indicated by
arrows. The quantity of active substance composition in the
particular holding cup 2 is compressed to a compact tablet 7 in the
holding cup 2 itself by means of the compression mold in
conjunction with the holder 3 of the retaining mold 4 as a support.
FIG. 2 does not yet show the final state of the tablet 7, the
compression step having not yet taken place. The tablets 7 are
clearly visible in FIG. 1 in the holding cups 2 of the strip-like
film 1.
[0052] On completion of the process step described above, the film
1 with the tablets 7 in the holding cup 2 is removed from the
retaining mold 4 and delivered to further handling stages. Before,
during or after this process step, the holding cup 2 is closed on
its open side by application of a closure film 8 as shown, for
example, on the extreme left of FIG. 1 in the interests of greater
clarity. Instead of a closure film 8, which may be used with
particular advantage to close a plurality of holding cups 2 of a
relatively long film strip, covers or cover strips may also be
used.
[0053] The film 1 can be provided with the holding cups 2 either
continuously by means of a roller arrangement or in sections by
means of a flat thermoforming tool. It is assumed for the purposes
of the present process that the film is already provided with
holding cups. Corresponding processes are widely known from the
prior art for blister packs.
[0054] FIG. 3 schematically illustrates an arrangement with which
another process for the production of a pack filled with an active
substance composition in tablet form can be carried out. This
process comprises the following steps:
[0055] A pack-forming film 1 is placed on a retaining mold 4 which
comprises at least one holder 3 that forms a holding cup (in the
example illustrated, four holders 3 situated adjacent one another).
In a compression mold 6 associated with the retaining mold 4 and
comprising a premix holder 9 associated with the holder 3 of the
retaining mold 4, a certain quantity of the as yet uncompressed
active substance composition (premix) is introduced into and
preformed in the premix holder 9 before or during the process step
explained above. FIG. 3 (top) shows the preformed premix supplies
in the premix holders 9 of the compression mold 6.
[0056] Arrows indicate that the mold as a whole is closed. The
preformed active substance composition is forced out of the premix
holder 9 onto the pack-forming film 1 and, together with the film 1
which it shapes into a holding cup in the process, is pressed into
the holder 3 of the retaining mold 4 and compressed therein to form
a compact tablet using the holder 3 of the retaining mold 4 as a
support. Accordingly, this process step ends with the retaining
mold 4 appearing as illustrated in FIG. 2.
[0057] In this process, the shaping of the film 1 by thermoforming
is carried out at the same time as the compression step which again
further simplifies the production process.
[0058] As for the rest, the other steps of the process described
above are the same as those of the process illustrated in FIG.
2.
[0059] For the process in question here, FIG. 3 shows that the
preformed active substance composition can be forced out of the
premix holder 9 by means of a punch mounted for displacement in the
compression mold 6. The mechanical drive source for the punch 10 is
not shown in FIG. 3. Instead, FIG. 3 indicates a pneumatic drive
source to the extent that the punch 10 and the preformed "cake" of
active substance composition are displaced from the premix holder 9
by compressed air supplied via a compressed air system 11.
[0060] The illustrated and hence preferred embodiment also shows
that the deformation of the film 1 into the holders 3 of the
retaining mold 4 is supported by the suction of air from the
holders 3 of the retaining mold 4 by means of the illustrated
suction system 12. At least the retaining mold 4 should be provided
at the holders 3 with air outlets to ensure that the holders 3 are
vented rearwards during the thermoforming and compression step.
[0061] The illustrated embodiment shows that the process steps of
both the processes described above are each carried out
quasi-statically on a section of film. Alternatively, however,
these process steps may also be carried out on a continuous film 1
by means of roller assemblies, co-circulating belt arrangements or
intermittently co-circulating tools. Corresponding processes are
known from the prior art on tablet production, more particularly in
conjunction with eccentric presses and rotary presses. However, the
quasi-static procedure is particularly simple from the tooling
perspective.
[0062] Typical pressures for producing tablets with an area of 10
to 15 cm.sup.2 are between 10 and 60 kN.
[0063] FIG. 4 shows that several holding cups 2 can be formed
beside and/or behind one another and can be simultaneously filled
with detergent.
[0064] Plastic films, more particularly PE films or PVC films, are
preferably used for the pack-forming film 1. By contrast, the
closure films 9 are paper-thin metal foils which typically can be
pushed through or peeled off. The closure film 8 is fixed to the
pack-forming film 1 by standard techniques, such as bonding,
welding, high-frequency joining techniques, etc.
[0065] The pack-forming films 1 and the closure films 8, as plastic
films, may generally be divided into water-insoluble and
water-soluble films. Both types of film are equally suitable.
Water-insoluble films are produced, for example, from PVC, PE, PP
and mixtures of PE and polystyrene. Water-soluble films are made,
for example, from polyvinyl alcohol, starch, cellulose, gelatine
(with corresponding reactive additives). A particularly suitable
water-insoluble film for the closure film 9 is of course the
above-mentioned metal foil, i.e. in particular an aluminium
foil.
[0066] The use of water-soluble films for a pack filled with an
active substance composition has also been known for some time from
the prior art (WO 89/04282 A1). The packaging of different
water-soluble active substance compositions in a water-soluble pack
for portioning and handling purposes is apparent from this prior
art.
[0067] FIG. 6 shows another pack modified to the extent that it is
made childproof by an additional overcap 13 from which the
marketing unit with several tablets 7 cannot be removed without
additional manipulation in the arrowed direction. The cap 13 also
provides a useful surface for advertizing, directions for use or
company logos.
[0068] The closure film 8 or the cover can also be joined to the
pack-forming film 1 in particularly childproof manner, for example
by making the tear-open forces required so strong that they could
not be applied by a small child.
[0069] A particular measure can be taken, for example, by making
the closure film 8 a two-ply film between the layers of which an
additional body of an active substance composition can be
accommodated with protection. This additional body may be, for
example, a perfume "sachet" which must not come into contact with
the tablet 7 of active substance composition so as not to affect
its storage life, but which can readily be removed from the pack
together with the tablet 7. Corresponding additional bodies could
also be formed by bleaching agents or enzyme components.
[0070] The illustrated embodiments make it clear that the
pack-forming films 1 filled with tablets 7 of active substance
composition in the holding cups 2 and provided with closure film 8
or covers are cut into typical commercial units (marketing units),
optionally into single units (FIG. 5).
[0071] FIG. 7, for example, shows a multiple pack with paired
holding cups 2. The embodiment of FIG. 5 shows single holding cups
2.
[0072] FIG. 5 also shows that, to form a marketing unit 14, several
packs have been inserted into a paperboard carrier 15 with
corresponding openings. The carrier 15 forms the "sales-active"
surface of the marketing unit 14 of FIG. 4 which can be hung on
display walls using a so-called Euro hanger.
[0073] FIGS. 4 and 6 show embodiments of marketing units which
contain tablets 7 of different active substance compositions. For
laundry care purposes, a marketing unit as shown in FIG. 4 may
contain, for example, two rows of detergent, one row of bleaching
agent and one row of color protector or one row of enzyme-based
washing aid. This flexibility in the filling of marketing units 14
comes from the individual accommodation of the tablets 7 in the
individual holding cups 2.
[0074] The direct compression of the active substance premix in the
holding cup 2 or the holder 3 of the retaining mold 4 in both
variants of the described process enables a formulation with few,
if any, dimensionally stabilizing components to be used for the
active substance composition. The tablet 7 is situated from the
outset in the holding cup 2 of the film 1 and is not itself handled
in the production process for the pack.
[0075] As for the rest, reference is again made to the general part
of the description so far as the advantages of the process
according to the invention are concerned.
[0076] FIGS. 4 and 5 illustrate the final form of a filled,
marketable pack in a particularly preferred embodiment. The pack
consists of a pack-forming film 1 provided with at least one
integrally formed holding cup 2 and a closure film 8 (or a
corresponding cover) which closes the holding cup 2. The tablet 7
of active substance composition is hermetically sealed in the
holding cup 2.
[0077] The effect of directly forming the tablet 7 in the holding
cup 2 is that the edge of the tablet 7 at the bottom of the holding
cup 2 corresponds in its profile to the edge profile of the holding
cup 2. In practice, this edge is not as sharp as indicated in FIG.
5, but is rounded off with a radius that suits practical
requirements. The compression step in the holding cup 2 with the
holder 3 of the retaining mold 4 as support ensures that the edge
of the tablet 7 formed is correspondingly adapted.
[0078] Another effect of the compression step in the holding cup 2
is that the tablet bears against the encircling inner wall of the
holding cup 2 over virtually its entire circumference. This has
also not been shown in FIG. 5 to enable the pack-forming film 1 to
be distinguished from the edge of the tablet 7.
[0079] Finally, a pack of the type in question is generally made in
such a way that the edge of the tablet 7 at the bottom of the
holding cup 2 has a different contour from the edge of the tablet 7
facing the open side of the holding cup 2 and, more particularly,
is more rounded than that contour. The compression tool, i.e.
preferably the punch 10 on the compression mold 6, enters the
holder 3 and leads to a sharp edge contour of the tablet 7 possibly
showing a slight encircling bead. This is not the case with the
edge of the tablet 7 at the bottom of the holding cup 2.
[0080] In practice, the formation of separate holding cups 2 for
holding a tablet 7 of the active substance composition creates a
number of possibilities for the design of the tablets 7, more
particularly laundry detergent tablets or washing aid tablets.
[0081] There are also numerous possibilities for the design of the
pack.
[0082] In the prior art, as described at the beginning, the film 1
and the closure film 8 are normally disposed of as waste after the
tablets 7 accommodated in the pack have been used.
[0083] According to a first proposal, this has now been changed to
the extent that the pack-forming film 1 and the closure film 8 or
the cover consist of water-soluble materials, more particularly
water-soluble plastics or water-solubilized plastics, and, in order
to use the active substance composition, more particularly the
detergent, in a water bath, the pack as a whole is added to the
water bath. The problem of waste from the pack is thus readily
solved for the user and it is only where other materials are used
in a multiple pack (marketing unit), for example where the
above-mentioned carrier 15 of paperboard is used, that those
materials have to be disposed of as wastepaper.
[0084] In this connection, reference may be made to the above
references to water-insoluble and water-soluble films.
[0085] A water-soluble pack-forming film 1 or closure film 8 may be
attended by the problem that, in the event of prolonged storage, it
absorbs so much water from the surrounding atmosphere that it loses
its protective effect. Accordingly, it may be advisable
additionally to wrap the pack in a thin film substantially
impermeable to water vapor for the purposes of transportation and
storage. This film may be designed solely for the task of keeping
out water vapor and need not have to withstand severe mechanical
stressing because this purpose is of course served by the
pack-forming film 1 in conjunction with the closure film 8.
[0086] For the release, particularly the delayed release, of active
substance, it is occasionally advisable to provide the active
substance composition with a coating. The described solution
enables the pack-forming film 1 and the closure film 8 to have
material properties of a coating corresponding to the intended
application of the active substance composition.
[0087] In an alternative advantageous design of a pack of the type
in question, the tablet 7 has a multilayer structure of at least
two layers 20, 21 of identical or different active substance
compositions and at least one layer 22 of a neutral release
agent.
[0088] FIG. 8 shows an example of a correspondingly modified tablet
7 which may be used one or more times in the same pack. Through the
introduction of a neutral layer 22 of a release agent, the active
substance components in the two other layers 20,21 are separated
from one another. Mutually incompatible components of the active
substance composition can thus be processed in one and the same
tablet 7. The stability of the pack enables this to be readily
achieved because the boundary layers between the individual layers
of a multilayer tablet 7 are not exposed to major forces in this
pack. In addition, the pack closely surrounds the tablet 7 and
keeps it dimensionally stable, particularly where it is produced by
the process described at the beginning.
[0089] In addition, suitable marking materials may be embedded or
present in the layers 20, 21, 22, more particularly in the layer 22
of release agent, for product identification purposes.
[0090] Another alternative for the design of the tablet 7 is
wherein a solid additional body, a paste-like additional body or a
liquid additional body surrounded by a protective envelope, more
particularly a gel-form envelope, is provided in the tablet 7
either inside or towards the upper or lower outer surface.
Different active substances can be accommodated in the same tablet
7 in this way also.
[0091] Finally, the pack offers another advantageous design
possibility which is wherein the closure film 8 is a two-layer film
and in that an additional body of an active substance composition
is arranged between the layers of the closure film 8. It is
possible in this way, too, to accommodate an additional, possibly
incompatible, active substance composition separately from the
tablet 7 in the pack and nevertheless to ensure that it is dosed at
the same time as the tablet 7 at the point of use. For example, a
perfume sachet, enzymes or a bleaching component may thus be added
to the washing process.
[0092] The two-layer construction of the closure film 8 can be of
particular importance for delayed cleaning processes when a
water-soluble closure film 8 and a pack-forming film 1 are
provided. This is because the outer layer of the closure film 8 can
first be dissolved so that active substance composition present
between the layers is released. After a given time interval, the
inner layer of the closure film 8 and the pack-forming film 1
itself are dissolved and release the tablet 7 with the other active
substance composition, again after a given time interval. This
delayed release of active substance composition is applied not only
in laundry care, it may also be applied, for example, to a cleaner
for lavatory bowls.
[0093] As already mentioned, the relatively large pack described
has several holding cups 2 and tablets 7 of mutually incompatible,
storable active substance compositions are accommodated in the
holding cups 2 and/or several packs are placed in a paperboard
carrier 15 with corresponding openings.
* * * * *