U.S. patent application number 10/491951 was filed with the patent office on 2004-12-16 for method of manufacturing embedded water soluble film carrier.
Invention is credited to Patel, Shilpan Pravinchandra, Saiyad, Atikullah Hussainmiya.
Application Number | 20040253434 10/491951 |
Document ID | / |
Family ID | 11097245 |
Filed Date | 2004-12-16 |
United States Patent
Application |
20040253434 |
Kind Code |
A1 |
Patel, Shilpan Pravinchandra ;
et al. |
December 16, 2004 |
Method of manufacturing embedded water soluble film carrier
Abstract
This invention relates to a water-soluble film (WSF) system with
embedded/entrapped water-soluble films (WSF). More particularly,
the invention relates to a WSF system with actives
embedded/entrapped therein such as to provide precise and desired
release of actives there from and its method of manufacturing for
diverse applications, in which a variety of substances such as
detergents, enzymes, softeners, perfumes, pesticides, fungicides,
active ingredients, dyes, pigments, hazardous chemicals, active
agents for cleaning laundry, dishes, floorings, walls, furniture,
fluffs, pulp, etc., and the like can be so embedded/entrapped for
such purpose. The invention further discloses novel online and
offline process for the manufacture of such multi-layered WSF with
or without liners and of desired shapes to selectively entrap
interacting/non-interacting materials and their combinations. The
process also provides options for the use of a wide range of raw
materials, liners such as paper, film, foil, fabric, etc.
Inventors: |
Patel, Shilpan Pravinchandra;
(Maharashtra, IN) ; Saiyad, Atikullah Hussainmiya;
(Gujurat, IN) |
Correspondence
Address: |
Monique A Morneault
Wallenstein Wagner & Rockey
311 S Wacker Dr
53rd Floor
Chicago
IL
60606
US
|
Family ID: |
11097245 |
Appl. No.: |
10/491951 |
Filed: |
April 7, 2004 |
PCT Filed: |
October 7, 2002 |
PCT NO: |
PCT/IN02/00202 |
Current U.S.
Class: |
428/324 |
Current CPC
Class: |
B29K 2003/00 20130101;
Y10T 156/10 20150115; B29K 2001/00 20130101; C11D 3/37 20130101;
B29K 2029/04 20130101; C08J 5/18 20130101; B29K 2033/08 20130101;
B29K 2089/00 20130101; B29K 2995/0062 20130101; B29C 41/36
20130101; B29C 39/203 20130101; B29K 2093/00 20130101; B29C 41/24
20130101; C11D 17/042 20130101; B29C 41/44 20130101; Y10T 428/251
20150115; C11D 1/722 20130101; B29K 2005/00 20130101; B29K 2071/02
20130101; B29K 2033/20 20130101; C11D 3/38681 20130101; B29C 39/14
20130101 |
Class at
Publication: |
428/324 |
International
Class: |
B32B 005/16 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 9, 2001 |
IN |
443/MUM/2001 |
Claims
1-52. (Cancelled).
53. A water soluble film (WSF) system comprising at least one water
soluble film having at least one active material of selective
concentration and depth embedded therein such that said active
material can be delivered in desired quantity.
54. A water soluble film system as claimed in claim 53 wherein said
active materials are selected from the group comprising detergents,
enzymes, softeners, perfumes, pesticides, fungicides, active
ingredients, dyes, pigments, hazardous chemicals, active agents for
cleaning laundry, dishes, floorings, walls, furniture.
55. A water soluble film system as claimed in claim 53 comprising a
removable liner for the water soluble film, for example the liner
may be selected from material such as paper, film foil or fabric,
such as polyester film and the film line material is preferably
selected from the group comprising plain, embossed, metalized,
gloss, matte, extrusion coated laminated or release coated.
56. A water soluble film system according to claim 53 comprising a
plurality of water soluble films having active material embedded
therein, and the films are preferably soluble in a selected one of
hot and cold water, for example, the system may comprise films that
are soluble in cold water only, hot water only or a combination of
hot and cold water.
57. A water soluble film system as claimed in claim 53 wherein the
films range from around 2 microns to around 500 microns, preferably
in the range of around 10 microns to around 300 microns, more
preferably in the range of around 12 microns to around 250
microns.
58. A process for the manufacture of a water soluble film system
comprising the following steps: providing a formulation of said
water soluble film; casting said formulation to form a water
soluble film; embedding at least one desired active material in
said formulation of the said water soluble film prior to and/or
after casting the said water soluble film; and drying the film with
the embedded active material.
59. A process as claimed in claim 58 further comprising the step of
metering said water soluble film onto a casting conveyor or a liner
at a casting head, smoothing the film with the embedded active
material at a primary station, and stripping the water soluble film
from the conveyor or liner.
60. A process as claimed in claim 59 further comprising the step of
stripping the water soluble film from the liner immediately after
drying or after a self-curing ageing period ranging from 1 hrs. to
720 hrs.
61. A process as claimed in claim 58 wherein the water soluble film
with embedded active material has a percentage of solid content in
the range of 3% to 85%, preferably in the range of 4% to 70%, more
preferably in the range of 5% to 65%;
62. A process as claimed in claim 58 wherein casting is carried out
at a temperature in the range from 10.degree. C. to 95.degree. C.,
preferably 13.degree. C. to 90.degree. C., more preferably
15.degree. C. to 85.degree. C.
63. A process as claimed in claim 58 wherein drying is carried out
at a temperature in the range from 50.degree. C. to 250.degree. C.,
preferably from 60.degree. C. to 200.degree. C., more preferably
from 55.degree. C. to 170.degree. C.
64. A process as claimed in claim 58 wherein active material is
added to the formulation of the water soluble film system prior to
casting the water soluble film.
65. A process as claimed in claim 58 wherein active material is
applied to the water soluble film after casting in a controlled
dosing by spraying of premeasured material to be embedded onto the
cast film prior to drying.
66. A process as claimed in claim 58 further comprising the step of
casting one or more additional water soluble films with or without
embedded active material onto the dried water soluble film at a
secondary casting head and smoothing and drying each additional
film to form a multilayered water soluble film.
67. A process as claimed in claim 66 wherein the additional water
soluble film is dried at a temperature in the range from 50.degree.
C. to 200.degree. C., preferably 60.degree. C. to 160.degree. C.,
more preferably 55.degree. C. to 140.degree. C.
68. A process as claimed in claim 66 further comprising the step of
passing the multilayered water soluble film through a hot/chill
device and optionally splitting the multilayered water soluble film
prior to collection, for example in sheet or roll form.
69. A process as claimed in claim 66 wherein multilayered water
soluble film comprises layers selected from one or more of cured
film, uncured film, hot water soluble film, cold water soluble
film, embedded active material film and liner.
70. A process as claimed in claim 58 further comprising the step of
entrapping moistened active material between two water soluble
films.
71. A process as claimed in claim 70 wherein the entrapped active
material is provided in selective areas of the water soluble film
in desired shapes, for example with the use of dimpled or other
embossed or patterned designs.
72. A water soluble film system for delivering active ingredients
in a controlled manner by embedding at least one active material in
a single or multilayer water soluble film for releasing the active
material at precisely regulated dosages.
Description
FIELD OF INVENTION
[0001] This invention relates to a water soluble film (WSF) system
with embedded/entrapped water-soluble films (WSF) and a process of
manufacturing the same. More particularly, the invention relates to
a WSF system with actives embedded/entrapped therein such as to
provide precise and desired release of actives therefrom and its
method of manufacturing for diverse applications, in which a
variety of substances such as detergents, enzymes, softeners,
perfumes, pesticides, fungicides, active ingredients, dyes,
pigments, hazardous chemicals, active agents for cleaning laundry,
dishes, floorings, walls, furniture, etc., and the like can be so
embedded/entrapped for such purpose.
BACKGROUND ART
[0002] In various processes/operations and in day-to-day life, a
number of substances including hazardous or non-hazardous chemicals
are required to be delivered in the precisely measured doses.
[0003] Attempts by the packaging industry has been to develop
approaches to evolve accurate delivery systems for active materials
especially those that are expensive or are environmentally
sensitive or have possibilities of reacting with other ingredients
in formulations. There have been several attempts in the past to
either encase or laminate or package different materials in
water-soluble films (WSF).
[0004] The objective of delivering precise quantities of products
like detergents have been being addressed by the industry for
example by packaging detergents in "soluble" and "non-soluble"
sachets in dosages ranging from 20 gms/sachet to 50 gms/sachet. In
case of non-soluble sachets the detergents tend to adhere to
statically charged packaging material surface thereby inhibiting
their total transfer to the point of application. Similar problems
of particles adhering to statically charged surface are faced when
small and precise quantities of pesticides actives are to be packed
in non soluble sachets. In the case of soluble sachets problem
arising out of chemical reaction of the ingredients to the film
cause serious problems in its smooth applications. Similarly in the
case of pesticide packaging the active ingredients in the package
varies from about 2% to about 30% based on the formulation.
[0005] U.S. Pat. No. 4,416,791 discloses a packaging film
comprising a base film of at least partially water-soluble plastics
material carrying on one surface only a protective layer, in
particulate form, of an inert plastics material having a contact
angle to water of at least 80.degree, the said layer being
effective to protect the base film surface from attack by aqueous
media. Such a packaging film has the advantages that, on its
unprotected side, it can be dissolved away, or partly dissolved and
partly dispersed, by water, whereas on the side carrying the
protective layer it is protected from attack by aqueous systems and
other aggressive media. It is essential that the inert protective
layer be in the form of substantially un-coalesced discrete
particles attached firmly to the base film but only loosely or not
at all to each other, so that if the base film is dissolved away
the protective layer has little or no integrity and is rapidly
dispersed. Further it provides a package comprised of the packaging
film defined above, having the protective layer on its internal
surface(s), so that the layer protects the package from attack by
any water present inside the package. It is claimed that such a
product can be used to package liquid or solid detergent useful for
dosing into domestic or commercial washing machines.
[0006] In one of the methods described in the patent a
cold-water-soluble polyvinyl alcohol/polyvinyl acetate film having
a thickness of 0.0038 cm was heated to a temperature just above its
glass transition temperature to render it slightly tacky.
Polytetrafluoroethylene powder is sprinkled onto the upper surface
of the heated film. The film is then passed between rollers heated
and then allowed to cool.
[0007] The limitation of U.S. Pat. No. 4,416,791 is that it
requires a pre formed WSF substrate and the extent of coating of
the Polytetrafluoroethylene powder would be restricted to the
surface of the WSF. By this process it would not be possible to
control the depth to which the Polytetrafluoroethylene powder can
be embedded.
[0008] The end use of this invention would be limited to the water
repelancy and the release properties of Polytetrafluoroethylene
powder on the surface of the pre formed WSF.
[0009] U.S. Pat. No. 4,176,079 discloses an invention for
dispersing an enzyme into water soluble resin and forming the resin
by casting or extruding into a sheet. The sheet is then dried, if
necessary, and, if required, cut into "ribbons" for incorporation
into the detergent product. The ribbons of enzyme-dispersed resin
may be admixed with a detergent composition in granular, viscous
liquid, paste or gel form. The resulting mixture may be used
directly in the washing process, particularly in an automatic
dishwasher, or it may be incorporated within a water-soluble
packet, for easy and convenient dispensing. In this case the water
soluble resin is being used as a means to bind the enzyme to its
matrix. This method of preparing the ribbons also suffers from the
shortcoming that two or more reacting substances cannot be
dispersed in the same film as they would interact with each other
and degrade.
[0010] U.S. Pat. No. 6,378,274 discloses a process for producing a
thermoformed package of the type comprising the steps of placing a
first sheet of formable film over a forming die having a cavity,
moulding the film into the cavity thereby forming a recess in the
film, placing a composition in the thus formed recess, and sealing
a second sheet of film across the recess to close the package. In
particular, the prior art relates to such a process for producing a
water-soluble package containing a detergent composition. The
disclosure is restricted thermo formed packages formed out of a
combination of soluble and insoluble films. It also needs pre
formed films to be operated on offline equipment for packaging
applications thereby making the process of incorporating the
materials within the films very complex and requiring expensive
equipment.
[0011] Patent No. EP 0493553 relates to a containerization system
and to containers which are particularly suitable for storing,
packaging and transporting toxic or hazardous products, such as
agricultural chemicals. The containerization system comprises the
chemical in the form of a gel, which is contained within a water
soluble or water-dispersible bag. This EP '553 has limitations as
it is restricted to toxic products that can be converted into gels
and then packaging of gel into a WSF bag.
[0012] Patent No. EP 0347220B1 relates to a package comprising e.g.
a liquid chemical or a chemical dissolved or dispersed in an
organic liquid contained in an envelope of water-soluble or water
dispersible material and having a water-soluble or water
dispersible seal. The patent also provides a process for the
preparation of a package according to the invention which comprises
heat sealing the envelope material to obtain a water dispersible
or, preferably, a water soluble heat seal. This prior art
specifically discusses packaging of pesticides by means of an
efficient heat seal system into a container.
[0013] Patent GB 2244258B relates to a package comprising hazardous
chemical dissolved or dispersed in a liquid or gel which is
contained in an envelope of water-soluble or water-dispersable
material. The patent seeks to provide a new container system for
agrochemicals which is safe to handle. This patent also provides a
package which comprises a hazardous chemical dissolved or dispersed
in a liquid or gel contained in a water-soluble or
water-dispersible laminated film. There is also discussed the
delivery of toxic and hazardous materials by means of plain and
laminated soluble sachets.
[0014] It would be evident from the above state of the art that
none of the prior art teach or provide for delivery of the encased,
laminated or packaged material in precise quantities. It is
therefore the long-standing need of industry to develop efficient
and cost effective stable embedded WSFs for controlled dosing in
diverse applications and especially to embed a wide variety of
substances avoiding interaction with each other within films.
Further the need for carriers that can selectively carry
combination of materials with dissimilar properties such as
miscible/in-miscible, hydrophobic/hydrophilic ingredients continues
to elude the industry.
OBJECT OF THE INVENTION
[0015] The main object of the present invention is to provide
stable water soluble film system having embedded/entrapped actives
and to a process for the manufacture of such stable water soluble
films for diverse applications, in which a variety of substances
such as detergents, enzymes, softeners, perfumes, pesticides,
fungicides, pigments, hazardous chemicals, active agents for
cleaning laundry, dishes, floorings, walls, furniture etc., and the
like are embedded/entrapped singly or in combination for delivering
them in precise and desired dosages.
[0016] Another object of the present invention is to provide an
offline process for the manufacture of stable water soluble films
for diverse applications, in which a variety of substances such as
detergents, enzymes, softeners, perfumes, pesticides, fungicides,
pigments, hazardous chemicals, active agents for cleaning laundry,
dishes, floorings, walls, furniture etc., and the like are
embedded/entrapped singly or in combination for delivering them in
precise and desired dosages.
[0017] Another object of the invention is to provide a process of
entrapping absorbent materials such as fluff, pulp and the like
within WSFs.
[0018] It is yet another object of the invention to disperse
diverse non-water-soluble materials on the surface and within
WSFs.
[0019] Yet another object of the present invention is to provide a
process for manufacture of multi-layered WSF to selectively entrap
interacting/non-interacting materials.
[0020] Yet another object of the present invention is to provide a
process for manufacture of multi-layered WSF to selectively entrap
combination of materials with similar and/or dissimilar
properties.
[0021] It is yet another object of the invention to provide a
process of manufacturing of WSFs with materials embedded in
selective areas of the WSFs in desired shapes.
[0022] It is yet another object of the invention to provide WSFs
for diverse applications, in which a variety of substances such as
detergents, enzymes, softeners, perfumes, pesticides, fungicides,
pigments, hazardous chemicals, active agents for cleaning laundry,
dishes, floorings, walls, furniture etc., and the like are embedded
for delivering them in precise and desired quantities.
[0023] It is yet another object of the invention to provide a
process for the manufacture of WSFs exploiting the various
embodiments of the invention using a wide range of raw materials
including polyvinyl alchohol copolymer ionomers, polyvinyl alchohol
homopolymer. non-ionomeric poly vinyl alchohol polymer,
polymethacrylate., polyvinyl alchohol, polyacrylamide,
polymethacrylamide, polyacrylic acid, polymethacrylic acid,
polyethyleneglycol, polyvinylpyrrolidone, proteinaceous binders
such as gelatin modified gelatins such as phthaloyl gelatin,
polysaccharides, such as starch, gum arabic and dextrin and
water-soluble cellulose derivatives.
[0024] It is yet another object of the invention to provide a
process for the manufacture of WSFs with the options to use a range
of liners such as paper, film, foil or fabric, preferably of film,
more preferably of polyester film. The film liners may be plain,
metalised, embossed, gloss or matte depending upon the desired end
product parameters. Paper liner can be plain, embossed, gloss,
matte, extrusion coated laminated or release coated. Fabrics made
of cotton or synthetic yarns, solution coated, plain, embossed,
gloss, matte, extrusion coated or laminated may be used as liner
dependant dependent upon the desired end product properties. Foils
made of steel, aluminum, copper or mixture thereof, more preferably
aluminum foil, plain, embossed, gloss, matte, extrusion coated
laminated or release coated. A liner may be made of a combination
of any or all of the above materials. A liner may be used for
single use or may be used for multiple uses.
SUMMARY OF THE INVENTION
[0025] Thus according to one aspect of the present invention there
is provided a WSF system comprising at least one active material
embedded and/or entrapped at selected concentrations and
depths/dispositions therein such that said active material thus
embedded/entrapped could be delivered at precisely regulated
dosages.
[0026] According to another aspect the present invention is
directed to a process for the manufacture of embedded/entrapped
water-soluble film (WSF) system comprising:
[0027] i) providing the formulation of said WSF with or without
liner material
[0028] ii) subjecting the said WSF to casting wherein at least one
desired active material is embedded/entrapped prior to and/or after
the said casting of the WSF.
[0029] According to another aspect the present invention is
directed to a process for the manufacture of embedded/entrapped
water-soluble film (WSF) system using a casting liner or a conveyor
comprising:
[0030] i) Mixing of the formulation of WSF;
[0031] ii) casting of at least one WSF at at least one casting
head;
[0032] iii) metering of the cast film at the respective casting
head, wherein said active material to be embedded is added with the
WSF prior to casting and/or at least during casting;
[0033] iv) smoothening of the at least one film thus formed;
and
[0034] v) drying of the WSF.
[0035] According to another aspect the present invention is
directed to a process comprising the steps of dispersing of
material to be embedded on said cast WSF prior to the step of
smoothing at anyone or more of said casting heads for casting of
the films. The WSF films thus embedded are wound and retained.
[0036] According to another aspect the present invention is
directed to a process comprising:
[0037] i) unwinding a pre-formed WSF from an unwinder and guiding
it through guide rolls to meet the WSF with said embedded materials
for further entrapping of the materials embedded; followed by
[0038] ii) guiding the multilayered WSF of step (i) through
hot/chill device for rewinding or splitting.
[0039] According to another aspect the present invention is
directed to using a casting conveyor without liner comprising:
[0040] i) casting of WSF with embedded material the temperature
range maintained from 10.degree. C. to 95.degree. C., preferably
13.degree. C. to 90.degree. C., more preferably 15.degree. C. to
85.degree. C.;
[0041] ii) metering of the cast film at casting head;
[0042] iii) smoothening of the film with the embedded materials at
the primary station;
[0043] iv) drying of the WSF from step (i), the temperature range
in the dryers ranging from 50.degree. C. to 250.degree. C.,
preferably from 60.degree. C. to 200.degree. C., more preferably
from 55.degree. C. to 170.degree. C.;
[0044] v) rewinding of the WSF.
[0045] According to yet another aspect the present invention is
directed to a process using a Casting WSF on a liner
comprising:
[0046] i) providing a liner for the formation of WSF with or
without treating/coating;
[0047] ii) casting of WSF with embedded material, the temperature
range of the batch solution maintained from 10.degree. C. to
95.degree. C., preferably from 13.degree. C. to 90.degree. C., more
preferably from 15.degree. C. to 85.degree. C.;
[0048] iii) metering of the cast film at casting head;
[0049] iv) smoothening of the film with the embedded material at
primary station, the percentage of solid content maintained in the
range of 3% to 85%, preferably in the range of 4% to 70%, more
preferably in the range of 5% to 65%;
[0050] v) drying of the WSF, the temperature range in the dryers
maintained from 50.degree. C. to 250.degree. C., preferably from
60.degree. C. to 200.degree. C., more preferably 55.degree. C. to
170.degree. C.;
[0051] vi) casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s);
[0052] vii) drying of the WSF, the temperature range in the second
dryers maintained from 50.degree. C. to 200.degree. C., preferably
60.degree. C. to 160.degree. C., more preferably 55.degree. C. to
140.degree. C.;
[0053] viii) guiding the multi-layered WSF through hot/chill device
for rewinding or splitting.
[0054] According to a further aspect the present invention is
directed to a process using a spraying method comprising:
[0055] i) unwinding of the liner for the formation of WSF and/or a
conveyor is provided.
[0056] ii) optional coating of the liner via a primer coating
station;
[0057] iii) casting of WSF with material to be embedded at a
primary casting head, the temperature range of the batch solution
maintained from 10.degree. C. to 95.degree. C., preferably
13.degree. C. to 90.degree. C., more preferably 15.degree. C. to
85.degree. C.;
[0058] iv) metering of the cast film at a casting head;
[0059] v) executing a controlled dosing by spraying of pre-measured
material to be embedded by primary sprayer;
[0060] vi) smoothening of the film with the embedded material at a
primary station;
[0061] vii) drying of the WSF at a dryer, the temperature range in
the dryers maintained in the range of 50.degree. C. to 250.degree.
C., preferably from 60.degree. C. to 200.degree. C., more
preferably 55.degree. C. to 170.degree. C.;
[0062] viii) casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s);
[0063] ix) drying of the WSF, the temperature range in the second
dryer maintained 50.degree. C. to 200.degree. C., preferably
60.degree. C. to 160.degree. C., more preferably 55.degree. C. to
140.degree. C.;
[0064] x) guiding the multilayered WSF through hot/chill cylinder
for rewinding or splitting.
[0065] According to another aspect the present invention is
directed to a process using a Secondary application on partially
formed film comprising:
[0066] i) unwinding of the liner for the formation of WSF and/or
providing a conveyor;
[0067] ii) optional coating of the liner via a primer coating
station;
[0068] iii) casting of WSF with material to be embedded at primary
casting head, the temperature range of the batch maintained in the
range of 10.degree. C. to 95.degree. C., preferably 13.degree. C.
to 90.degree. C., more preferably 15.degree. C. to 85.degree.
C.;
[0069] iv) metering of the cast film at casting head;
[0070] v) smoothening of the film with the embedded material at
primary station, drying of the WSF, the temperature range in the
dryers maintained in the range of 50.degree. C. to 250.degree. C.,
preferably from 60.degree. C. to 200.degree. C., more preferably
55.degree. C. to 170.degree. C.;
[0071] vi) executing a controlled dosing by spraying of
pre-measured material to be embedded by secondary disperser;
[0072] vii) smoothening of the film with the embedded material at
secondary station;
[0073] viii) casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s);
[0074] ix) drying of the WSF, the temperature range in the second
dryers) maintained in the range of 50.degree. C. to 200.degree. C.,
preferably 60.degree. C. to 160.degree. C., more preferably
55.degree. C. to 140.degree. C.;
[0075] x) guiding the multilayered WSF through hot/chill cylinder
for rewinding or splitting. Optionally offline or online splitting
between the WSF film and the liner.
[0076] According to another aspect the present invention is
directed to online entrapment comprising:
[0077] i) unwinding of the liner for the formation of WSF and/or
providing a conveyor;
[0078] ii) optional coating of the liner via a primer coating
station;
[0079] iii) casting of WSF with material to be embedded at primary
casting head the temperature range maintained 10.degree. C. to
95.degree. C., preferably 13.degree. C. to 90.degree. C., more
preferably 15.degree. C. to 85.degree. C.;
[0080] iv) metering of the cast film at casting head;
[0081] v) smoothening of the film with the embedded material at
primary station;
[0082] vi) drying of the WSF, the temperature range in the dryers
maintained in the range of 50.degree. C. to 250.degree. C.,
preferably from 60.degree. C. to 200.degree. C., more preferably
from 55.degree. C. to 170.degree. C.;
[0083] vii) casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s);
[0084] viii) drying of the WSF, the temperature range in the second
dryers maintained from 50.degree. C. to 200.degree. C., preferably
60.degree. C. to 160.degree. C., more preferably 55.degree. C. to
140.degree. C.;
[0085] ix) unwinding of a pre-formed WSF from an unwinder and
guiding it through the guide rolls to meet the WSF, with embedded
material for entrapping of materials embedded.
[0086] Preferably, in the above process of the invention, the
materials of the WSF formulation is taken in a batch reactor and
mixed intimately to ensure complete dissolution in the desired
solvent. As would be evident from the above various possible
embodiments of the process can be followed.
[0087] In one of the embodiments of this of this invention the
materials to be embedded in the WSF are added to the batch solution
and mixed thoroughly before feeding it to the casting head for
further processing. The materials that can be taken into the batch
mixing are selected from those that are water-soluble, sheer
insensitive, temperature resistant, like certain agrochemicals,
pesticides, insecticides, softners, surfactants, perfumes for
detergent and laundry industry, disinfectants, de-odorizing
liquids, etc.
[0088] In another embodiment of this invention the materials to be
embedded in the WSF may optionally be introduced in the process at
the primary, secondary, tertiary and subsequent sprayers and or at
the second or subsequent casting heads fed from second and/or
subsequent batch mixers.
[0089] In another embodiment of the present invention the materials
to be embedded is dispensed in between incoming cured or uncured
WSFs
[0090] In another embodiment of the present invention the process
maybe carried out with the aid of a self-rolling conveyor.
[0091] In yet another embodiment of the present invention the
process maybe carried out with the aid of a casting liner.
DETAILED DESCRIPTION IN RELATION TO ACCOMPANYING FIGURES
[0092] The details of the invention its objects and advantages are
explained hereunder in greater details in relation to non-limiting
exemplary illustrations given in FIGS. 1-4
[0093] The explanation to the part numbers in FIG. 1 is given
below:
[0094] 1 Conveyor; 2 Guide Roll; 3 Batch Mix; 4 Primary Casting
Head; 5 Primary Sprayer; 6 Smoothening Rolls; 7 Dryer; 8 Secondary
Sprayer; 9 Secondary Casting Head; 10 Dryer; 11 Tertiary Sprayer;
12 Disperser for Entrapment; 13 Guide Roll; 14 Chilling Cylinder;
15 Rewinder; 16 Guide Rolls; 17 Unwinder; 18 Smoothening Rolls; 19
Batch Mix; 20 Nip Roll;
[0095] Accordingly as illustrated in FIG. 1 the process comprises
of the following steps:
[0096] 1. Batch Mixing of the formulation of WSF and optionally the
material to be embedded;
[0097] 2. Casting of WSF with or without the material to be
embedded at primary casting head;
[0098] 3. Metering of the cast film at casting head;
[0099] 4. Optionally dispersing of material to be embedded by
primary sprayer;
[0100] 5. Smoothening of the film with or without the embedded
materials at the primary station;
[0101] 6. Drying of the WSF from step 2;
[0102] 7. Optional spraying of material to be embedded using a
secondary sprayer;
[0103] 8. Smoothening of the film with or without the embedded
materials at the secondary station;
[0104] 9. Drying of the WSF from step 7;
[0105] 10. Casting of WSF with or without the material to be
embedded at secondary casting head;
[0106] 11. Optional spraying of material to be embedded by a
tertiary disperser;
[0107] 12. Rewinding of the WSF;
[0108] 13. Optionally as a post-step 11 step unwind a pre-formed
WSF from an unwinder and guiding it through the guide rolls to meet
the WSF from step 11 for entrapping of materials to be
embedded;
[0109] 14. Guide the multilayered WSF of step 13 through hot/chill
cylinder for rewinding or splitting;
[0110] Optionally the steps 1 to 14 may also be carried out on a
casting liner (FIG. 1) or a conveyor (FIG. 2).
[0111] The invention and the various embodiments are further
explained hereunder in relation to the accompanying figures:
[0112] Casting Conveyor without Liner [FIG. 1]
[0113] This process comprises of the following:
[0114] 1. Casting of WSF on (1) at (4) with embedded material in
the batch mix. The temperature range of the batch solution is in
between may vary from around 10.degree. C. to around 95.degree. C.,
preferably around 13.degree. C. to around 90.degree. C., preferably
around 15.degree. C. to around 85.degree. C.
[0115] 2. Metering of the cast film at casting head.
[0116] 3. Smoothening of the film with the embedded materials at
the primary station (6).
[0117] 4. Drying of the WSF from step 1 at (7). The temperature
range in the dryers may vary from around 50.degree. C. to around
250.degree. C., preferably between around 60.degree. C. to around
200.degree. C., more preferably between around 55.degree. C. to
around 170.degree. C. Rewinding of the WSF at (15).
[0118] Casting WSF on a Liner (FIG. 2)
[0119] The explanation to the part numbers in FIG. 2 is given
below:
[0120] 25 Unwinder of "Carrier Web"; 26 Primer Coating; 27 Batch
Mix; 28 Primary Casting Head; 29 Primary Sprayer; 30 Smoothening
Roll; 31 Dryer; 32 Secondary Sprayer; 33 Secondary Casting Head; 34
Dryer; 35 Tertiary Sprayer; 36 Disperser for Entrapment; 37 Guide
Roll; 38 Chilling Cylinder; 39 Rewinder; 40 Guide Rolls; 41
Unwinder; 42 Smoothening Rollers; 43 Batch Mix; 44 Nip Roll;
[0121] This process comprises of the following:
[0122] 1. Unwinding of the liner at (25) for the formation of WSF
which can be optionally treated or untreated and coated or
uncoated. Liners can be of paper, film, foil or fabric, preferably
of film, more preferably of polyester film. The films can be in the
range of 2 microns to 500 microns, preferably in the range of 10
microns-300 microns, more preferably in the range of 12 microns-250
microns. The film liner may be plain, metallised, embossed, gloss,
matte, extrusion coated laminated or release coated depending on
the desired characteristics of the end product. Paper Liner are
also used for production of WSF film. Paper liners that accept
temperatures needed for production of WSF, GSM (Grams per sq
meter--the standard for measuring weight of paper) may be in the
range of around 7 gms to around 500 gms, preferably a range of
around 20 gm to around 300 gms, more preferably in the range of
around 60 gm to around 180 gms. The paper liner may be plain,
embossed, gloss, matte, extrusion coated laminated or release
coated depending on the desired characteristics of the end product.
Fabrics made of cotton or synthetic yarns, solution coated, plain,
embossed, gloss, matte, extrusion coated or laminated may be used
as liner based on the desired end product properties.
[0123] 2. Optional coating of the liner via a primer coating
station (26).
[0124] 3. Casting of WSF on (25) at (28) with embedded material in
the batch mix. The temperature range of the batch solution may be
around 10.degree. C. to around 95.degree. C., preferably around
13.degree. C. to around 90.degree. C., more preferably around
15.degree. C. to around 85.degree. C.
[0125] 4. Metering of the cast film at casting head.
[0126] 5. Smoothening of the film by (30) with the embedded
material at primary station.
[0127] The percentage of solid content may be in the range of
around 3% to around 85%, preferably in the range of around 4% to
around 70%, more preferably in the range of around 5% to around
65%
[0128] 6. Drying of the WSF from step 3 at (31). The temperature
range in the dryers may be set from around 50.degree. C. to around
250.degree. C., preferably from around 60.degree. C. to around
200.degree. C., more preferably around 55.degree. C. to around
170.degree. C. The temperature range of the batch solution may vary
from around 10.degree. C. to around 95.degree. C., preferably
around 13.degree. C. to around 90.degree. C., more preferably
around 15.degree. C. to around 85.degree. C.
[0129] 7. Casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s) (33).
[0130] 8. Drying of the WSF from step 7 at (34). The temperature
range in the second dryers (34) may be from around 50.degree. C. to
around 200.degree. C., preferably around 60.degree. C. to around
160.degree. C., more preferably around 55.degree. C. to around
140.degree. C.
[0131] 9. The multi-layered WSF of step 8 is guided through
hot/chill cylinder (38) for rewinding or splitting at (39).
[0132] Spraying Method (FIG. 2)
[0133] This process comprises of the following
[0134] 1. Unwinding of the liner at 25 for the formation of WSF.
Optionally a conveyor can be used.
[0135] 2. Optional coating of the liner via a primer coating
station (26).
[0136] 3. Casting of WSF with material to be embedded at primary
casting head (28). The temperature range of the batch solution may
vary from around 10.degree. C. to around 95.degree. C., preferably
around 13.degree. C. to around 90.degree. C., more preferably
around 15.degree. C. to around 85.degree. C.
[0137] 4. Metering of the cast film at casting head.
[0138] 5. Spraying of pre-measured material to be embedded by
primary sprayer (29).
[0139] 6. Smoothening of the film with the embedded material at
primary station (30).
[0140] 7. Drying of the WSF from step 5 at dryer (31). The
temperature range in the dryers may be set from 50.degree. C. to
around 250.degree. C., preferably from around 60.degree. C. to
around 200.degree. C., more preferably around 55.degree. C. to
around 170.degree. C.
[0141] 8. Casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s) (33).
[0142] 9. Drying of the WSF from step 8 at dryer (34). The
temperature range in the second dryer (34) may be from around
50.degree. C. to around 200.degree. C., preferably around
60.degree. C. to around 160.degree. C., more preferably around
55.degree. C. to around 140.degree. C.
[0143] 10. The multilayered WSF of step 8 is guided through
hot/chill cylinder (38) for rewinding or splitting at (39).
[0144] Secondary Application on Partially Formed Film [FIG. 2]
[0145] This process comprises of
[0146] 1. Unwinding of the liner at (25) for the formation of WSF.
Optionally a conveyor can be used.
[0147] 2. Optional coating of the liner via a primer coating
station (26).
[0148] 3. Casting of WSF with material to be embedded at primary
casting head (28). The temperature range of the batch solution may
vary from around 10.degree. C. to around 95.degree. C., preferably
around 13.degree. C. to around 90.degree. C., more preferably
around 15.degree. C. to around 85.degree. C.
[0149] 4. Metering of the cast film at casting head.
[0150] 5. Smoothening of the film with the embedded material at
primary station (30).
[0151] 6. Drying of the WSF from step 5 at dryer (31). The
temperature range in the dryers may be set from 50.degree. C. to
around 250.degree. C., preferably from around 60.degree. C. to
around 200.degree. C., more preferably around 55.degree. C. to
around 170.degree. C.
[0152] 7. Spraying of pre-measured material to be embedded by
secondary disperser (32).
[0153] 8. Smoothening of the film with the embedded material at
secondary station (42).
[0154] 9. Casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s) (33).
[0155] 10. Drying of the WSF from step 9 at dryer (34). The
temperature range in the second dryers (34) may be from around
50.degree. C. to around 200.degree. C., preferably around
60.degree. C. to around 160.degree. C., more preferably around
55.degree. C. to around 140.degree. C.
[0156] 11. The multilayered WSF of step 9 is guided through
hot/chill cylinder (38) for rewinding or splitting at (39).
Optionally offline or online splitting between the WSF film and the
liner can be done.
[0157] Online Entrapment Method [FIG. 21]
[0158] The process comprises of the following:
[0159] 1. Unwinding of the liner at (25) for the formation of WSF,
optionally a conveyor can be used.
[0160] 2. Optional coating of the liner via a primer coating
station (26).
[0161] 3. Casting of WSF with material to be embedded at primary
casting head (28). The temperature range of the batch solution may
vary from around 10.degree. C. to around 95.degree. C., preferably
around 13.degree. C. to around 90.degree. C., more preferably
around 15.degree. C. to around 85.degree. C.
[0162] 4. Metering of the cast film at casting head.
[0163] 5. Smoothening of the film with the embedded material at
primary station (30).
[0164] 6. Drying of the WSF from step 5 at dryer (31) The
temperature range in the dryers may vary from around 50.degree. C.
to around 250.degree. C., preferably from around 60.degree. C. to
around 200.degree. C., more preferably from around 55.degree. C. to
around 170.degree. C.
[0165] 7. Casting of WSF with or without the material to be
embedded at secondary/tertiary subsequent casting head(s) (33).
[0166] 8. Drying of the WSF from step 7 at dryer (34). The
temperature range in the second dryers (7) may be from around
50.degree. C. to around 200.degree. C., preferably around
60.degree. C. to around 160.degree. C., more preferably around
55.degree. C. to around 140.degree. C.
[0167] 9. Unwinding of a pre-formed WSF from an unwinder (41) and
guiding it through the guide rolls (40) to meet the WSF from step 8
for entrapping of materials to be embedded. Both the liners along
with WSF film, which may be semi-cured WSF and the entrapments, may
remain in the roll form or sheet form in its original construction,
stripping from casting liner can be done immediately or after an
self-curing ageing period ranging from around 1 hrs. to around 720
hrs., prior to splitting the liners so as to deliver the final WSF
product with entrapped materials.
[0168] 10. If desired the multi-layered WSF of step 9 may be guided
through hot/chill cylinder (38) for rewinding or splitting at (39).
Optionally offline or online splitting between the WSF film and the
liner can be done
[0169] The process described above offers various possibilities for
the manufacture of WSFs with entrapped materials either on a liner
or a conveyor. Some of the product options the may be exercised are
as follows:
[0170] H/E/H
[0171] H/E/C
[0172] H/E/H/E/H . . . n times
[0173] C/E/C/E/ . . . n times
[0174] C/E/C/E/C . . . n times
[0175] C/E/C . . . n times
[0176] L/UC/E/UH/E . . . n times
[0177] L/UH/E/UH/E . . . n times
[0178] L/UC/E/UC/E . . . n times
[0179] L/UC/E/H/L/E . . . n times
[0180] L/UH/E/H/L/E . . . n times
[0181] L/UC/E/C/L/E . . . n times
[0182] Where
[0183] U=Uncured; H=Hot Water Soluble Film; C=Cold Water Soluble
Film
[0184] E=Embedded Material; L=Liner
[0185] and the value of "n" is decided based on the application of
the final multilayered embedded WSF.
[0186] The above sequence may be repeated in multiple layers as per
the requirements of the end use of the multiply embedded WSFs.
Further this process also allows the manufacture of multilayered
embedded WSF using combinations of Cold WSFs and Hot WSFs in
various sequences. It also provides the options of using
cured/uncured films of CWSFs and HWSFs in any desired sequences
[0187] Dimples or other embossed or patterned designs can be
created during entrapment by using such designed male/female
rollers (46,51 Sheet No. 3) or rollers (60,61 Sheet No. 4). In case
of casting on liner method both the liners along with WSF film,
semi-cured WSF and the entrapments may remain in roll form or sheet
form in its original construction, stripping from casting liner can
be done immediately or after an self curing aging period ranging
from around 1 hrs to around 720 hrs., prior to splitting the liners
so as to deliver the final WSF film with entrapped materials.
[0188] Certain materials such as highly alkaline or highly acidic
materials may react adversely if added in the batch mix process or
if sprayed before the gelling process or before the film forming
process and may therefore necessitate the use of entrapment method
for incorporating such materials. Certain liquids like oil based
perfumes, aromas, softening agents, cleaning agents etc or solvent
based aromas, softening agents, cleaning agents etc may be
entrapped more efficiently with entrapment method disclosed in this
invention.
[0189] Offline Entrapment Method
[0190] The process to incorporate such sensitive materials
described above comprises of the following:
[0191] Vertical Entrapment Method (FIG. 3).
[0192] The explanation to the part numbers in FIG. 3 is given
below:
[0193] 45 Unwinder; 46 Affixing Roller; 47 Guide Roll; 48 Disperser
for Vertical Entrapment; 49 Guide Roll; 50 Unwinder; 51 Affixing
Roller; 52 Rewinder;
[0194] 1. Unwinding of the WSF films (45) and (50) with or without
liner.
[0195] 2. Dispensing of the embodiment at (48) in between two
affixing guide rollers (47 & 49).
[0196] 3. Affixing of the WSF films from step 2 at the affixing
rollers (46 & 51).
[0197] 4. Rewinding in roll form or sheet form or fan-fold form.
Optionally the film can be with or without casting liners. The
casting liners can be stripped immediately or after aging period of
around 1 to around 720 hrs. or can be supplied all together and the
end user may be informed to strip the casting liner before use. The
entrapped film can also be slit in ribbons, tapes, perforated
sheets, perforated tapes, perforated ribbons or cut sheets of any
size.
[0198] Such a process offers various process and product options
such as:
[0199] 1. Entrapped material in WSF With or without carrier.
[0200] 2. Entrapped material in WSF in Roll form or pouch form
[0201] 3. Entrapped material in WSF in Roll form with
perforates
[0202] 4. Entrapped material in WSF in Sheet form with multiple
pouches
[0203] 5. All above Entrapped material in WSF with casting liner
for the consumer to remove immediately or after aging period of
around 1 hr to around 720 hrs.
[0204] Some of the product options the may be exercised are as
follows:
[0205] H/E/H
[0206] H/E/C
[0207] H/E/H/E/H . . . n times
[0208] C/E/C/E . . . n times
[0209] C/E/C/E/C . . . n times
[0210] C/E/C . . . n times
[0211] L/UC/E/UH/E . . . n times
[0212] L/UH/E/UH/E . . . n times
[0213] L/UC/E/UC/E . . . n times
[0214] L/UC/E/H/L/E . . . n times
[0215] L/UH/E/H/L/E . . . n times
[0216] L/UC/E/C/L/E . . . n times
[0217] Where
[0218] U=Uncured; H=Hot Water Soluble Film; C=Cold Water Soluble
Film
[0219] E=Embedded Material; L=Liner
[0220] and the value of "n" is decided based on the application of
the final multilayered embedded WSF.
[0221] The above sequence may be repeated in multiple layers as per
the requirements of the end use of the multiply embedded WSFs.
Further this process also allows the manufacture of multilayered
embedded WSF using combinations of Cold WSFs and Hot WSFs in
various sequences. It also provides the options of using
cured/uncured films of CWSFs and HWSFs in any desired sequences
[0222] Horizontal Entrapment Method (FIG. 4).
[0223] The explanation to the part numbers in FIG. 4 is given
below:
[0224] 55 Unwinder; 56 Guide Roll; 57 Disperser for Horizontal
Entrapment; 58 Guide Roll; 59 Unwinder; 60 Affixing Roller; 61
Affixing Roller; 62 Rewinder; 63 Spillage Controller Knife;
[0225] 1. Unwinding of the WSF films (59) and (55) with or without
liner.
[0226] 2. Dispensing of the embodiment at (57) in between two
affixing guide rollers (58 & 56).
[0227] 3. Affixing of the WSF films from step 2 at the affixing
rollers (60 & 61).
[0228] 4. Rewinding in roll form or sheet form or fan-fold form.
Optionally the film can be with or without casting liners. The
casting liners can be stripped immediately or after aging period of
around 1 hr to around 720 hrs. or can be supplied all together and
the end user may be informed to strip the casting liner before use.
The entrapped film can also be slit in ribbons, tapes, perforated
sheets, perforated tapes, perforated ribbons or cut sheets of any
size.
[0229] Such a process offers various process and product options
such as:
[0230] 1. Embedded/entrapped material in WSF With or without
carrier.
[0231] 2. Embedded/Entrapped material in WSF in Roll form or pouch
form
[0232] 3. Embedded/Entrapped material in WSF in Roll form with
perforates
[0233] 4. Embedde/Entrapped material in WSF in Sheet form with
multiple pouches
[0234] 5. All above Embedded/Entrapped materials in WSF with
casting liner for the enduser to remove after aging period of
around 1 hr to around 720 hrs.
[0235] In the above options the WSF film may be pre-embedded and
used for the manufacture of the above product options.
[0236] In yet other embodiment of the invention, materials that are
stable in hot water conditions may be introduced into Hot Water
Soluble Films (HWSF) and those that are sensitive to cold
conditions can be incorporated in Hot or Cold Water Soluble Films
(CWSF).
[0237] Applications of the Process Options
[0238] The invention with various embodiments are now further
illustrated with a few non-limiting Examples:
EXAMPLE I
[0239] Embedding of Actives such as Piian Liquid in WSF
[0240] Piian is a water dispersable deodorizer which is
commercially available from Piian Systems, USA. Piian was added to
the pre-mixed WSF formulation batch and stirred for 6 hours. This
was followed by a period of another 6 hours with continuous slow
stirring of the solution. The solution was then casted on a
continuous casting line. It was then dried and spilt. Several
samples of varying compositions were made to incorporate 10% Piian
to 90% in WSFs.
[0241] The Grammage per Square Meter (GSM) for the Piian
incorporated WSF measured as per IS1060 is represented as (A).
[0242] A reference WSF without the incorporation of Piian was
prepared under identical conditions. The GSM of this reference
sample is represented as (B). The Piian loaded in the WSF is
therefore A-B=C.
[0243] Strips of 10.times.10 cms were cut from the material WSF
loaded with Piian.
[0244] Following are the characteristics of the WSF strips loaded
with Piian.:
1 Piian Loaded film = 30.5 GSM (.+-.1/2 Gm) Loading of Piian= 5 GSM
Film thickness of Piian loaded WSF = 28 microns GSM of the
Reference film without Piian = 26 gms.(.+-.1 gm)
[0245] Following are test results of reference WSF and Piian loaded
WSF
2 Tensile Strength of the reference film (kg/cm.sup.2)Dir-I =
380.74 Test Method - ASTM D-883 Dir-II = 382.67 Test Method - ASTM
D-883 Young Modulus (kg/mm.sup.2)Dir-I = 13.19 Test Method - ASTM
D-882 Dir-II = 8.14 Test Method - ASTM D-882 Elongation(%)
(kg/cm.sup.2)Dir-I = 259.27 Test Method - ASTM D-882 Dir-II =
252.90 Test Method - ASTM D-882 Puncture Resistance (Ozs.
Inches/Tear Inch) = 270.00 Test Method - IS-1060
[0246]
3 Tensile Strength of the Piian Load WSF (kg/cm.sup.2)Dir-I = 329.5
Test Method - ASTM D-883 Dir-II = 381.1 Test Method - ASTM D-883
Young Modulus (kg/mm.sup.2)Dir-I = 7.38 Test Method - ASTM D-882
Dir-II = 11.81 Test Method - ASTM D-882 Elongation(%)
(kg/cm.sup.2)Dir-I = 252.36 Test Method - ASTM D-882 Dir-II =
291.50 Test Method - ASTM D-882 Puncture Resistance (Ozs.
Inches/Tear Inch) = 225.00 Test Method - IS-1060 Dissolution in
seconds = 86 secs at 30 C. Breaking of the film = 3.14 secs at 30
C.
[0247] The film properties of the Piian laoded WSF, together with
the uniform dispersion of the Piian in the WSF illustrates that
Piian can be delivered in precise quantities by incorporating it in
the WSF using the process disclosed in the invention.
[0248] In one of the variants of the process described in this
invention, pre-dissolved enzymes may be mixed in a WSF formulation
and a controlled casting on a preformed substrate/liner based WSF
film is possible. Alternatively two pre-formed substrate based WSF
films may be used. A water-based enzyme may be loaded to precisely
fill the center of the two films. The water based enzyme helps to
affix the two films substrates so that the enzymes are sandwiched
in between the films thereby resulting in an enzyme loaded WSF. The
two substrates can then be stripped off after appropriate
ageing.
[0249] Enzymes in precise quantities can be incorporated in singly
or multi-layered WSFs by the process described in this invention so
that the processor or the user does no inhalation of the enzyme.
The enzyme embedded WSF can be incorporated into detergent
formulations or added to washing medium in a machine or a washing
vessel such as a bucket to ensure that the precise dosage of
enzymes are added at the point of application.
EXAMPLE II
[0250] Incorporation of Large Particles in WSFs
[0251] Non-soluble Acrylic resins (72-75 microns) were dispersed
into cold water-based solutions to form a high viscous dispersion.
The liquid dispersion was dropped in between two films through a
motorized valve controlled slot nozzle to have a margin at the end
of the webs, thereby not allowing the dispersion to ooze out from
the sides. Cold water was used as the solvent. Both the WSFs used
were Hot Water Soluble formulations. In this process the Hot Water
Soluble Films. Do not get affected by cold-water dispersion and
therefore remain entrapped till the acrylic entrapped film passes
through the dried and reaches the rewinder. Typically the film is
split from its casting liner after an appropriate aging period.
[0252] The properties of the acrylic incorporated films were:
4 Acrylic Loaded GSM = 60 GSM (.+-.1/2 Gm) Microns of Acrylic
loaded film 140 microns Base films GSM = 58 GSM (.+-.1 gm) Weight
of Acrylic Entrapping = 2 GSM
[0253] Similarly following are test results of reference WSF and
Acrylic resin loaded WSF
5 Tensile Base film (kg/cm.sup.2)Dir-I = 380.74 Test Method - ASTM
D-883 Dir-II = 382.67 Test Method - ASTM D-883 Young Modulus
(kg/mm.sup.2)Dir-I = 13.19 Test Method - ASTM D-882 Dir-II = 8.14
Test Method - ASTM D-882 Elongation(%) (kg/cm.sup.2) Dir-I = 259.27
Test Method - ASTM D-882 Dir-II = 252.90 Test Method - ASTM D-882
Puncture Resistance (Ozs. Inches/Tear Inch) = 270.00 Test Method -
IS-1060
[0254]
6 Tensile Acrylic Entrapped film (kg/cm.sup.2)Dir-I = 80.69 Test
Method - ASTM D-883 Dir-II = 83.46 Test Method - ASTM D-883 Young
Modulus (kg/mm.sup.2)Dir-I = 2.79 Test Method - ASTM D-882 Dir-II =
3.25 Test Method - ASTM D-882 Elongation(%) (kg/cm.sup.2)Dir-I =
229.5 Test Method - ASTM D-882 Dir-II = 206.7 Test Method - ASTM
D-882 Puncture Resistance (Ozs. Inches/Tear Inch) = 180.0 Test
Method - IS-1060 Dissolution of film in seconds = 47 secs at 30 C.
Breaking of the film = 3.75 secs at 30 C.
[0255] The WSF characteristic with the hydrophobic polymer
indicates that the process disclosed in the invention can be
effectively used to embed any hydrophobic materials of diverse
shapes and sizes within a WSF matrix.
[0256] Also this application shows the possibility of using two hot
water soluble films or a combination thereof, taking advantage of
the hydrophilic properties. This application also shows the
advantage of using casting liners.
EXAMPLE III
[0257] Films incorporating water insoluble fine particles
[0258] The performance of the films based on water insoluble fine
particles were prepared by the process described in this invention.
Fine particle sized iron oxide (5-10 Microns) was dispersed in
water based formulations to form a high viscous dispersion. The
liquid dispersion thus obtained was precisely dropped in between
two films through a motorized valve controlled slot nozzle in such
a manner that a margin was available at the end of the webs, so as
not to allow the dispersion to ooze out from the sides. In this
case warm water at around 40.degree. C. was used to deliver the
dispersion to between two Cold WSF webs.
[0259] The properties of the ferric oxide incorporated films
were:
7 GSM of Iron Oxide Loaded WSF = 73 GSM (.+-.1/2 Gm) Thickness of
Iron Oxide Loaded WSF = 55 microns GSM of reference WSF = 58 GSM
(.+-.1 gm) Weight of Iron Oxide Entrapping = 15 GSM
[0260]
8 Tensile Strength of Entrapped film (kg/cm.sup.2)Dir-I = 325.87
Test Method - ASTM D-883 Dir-II = 327.77 Test Method - ASTM D-883
Young Modulus (kg/mm.sup.2)Dir-I = 7.18 Test Method - ASTM D-882
Dir-II = 8.26 Test Method - ASTM D-882 Elongation(%)
(kg/cm.sup.2)Dir-I = 341.9 Test Method - ASTM D-882 Dir-II = 324.27
Test Method - ASTM D-882 Puncture Resistance (Ozs. Inches/Tear
Inch) = 600 Test Method - IS-1060 Dissolution in seconds = 37 secs
at 60 C. Breaking of the film = 19 secs at 60 C.
[0261] As illustrated in the earlier examples the material embedded
films have favorable film properties and cab be used for diverse
application. This application provides possibilities of embedding
environmentally sensitive materials, wastes and toxic materials of
diverse shapes, sizes and reactivities within an appropriate WSF
Matrix in precise quantities for storage, transportation or
disposal. This method may also be used to embed powdered or
granular materials of any shapes or sizes such as pesticides, solid
deodorants, disinfectants, uncoated enzymes, toxic products etc.
which are to be delivered to their point of application/action or
storage.
[0262] These applications also clearly demonstrate the wide number
of product and process options using the methods disclosed in this
invention.
* * * * *