U.S. patent application number 14/410481 was filed with the patent office on 2015-11-26 for apparatus and method for continuous motion rotatable forming of soluble pouches.
This patent application is currently assigned to Rideau Machinery Inc.. The applicant listed for this patent is Rideau Machinery Inc.. Invention is credited to James FOWLER, Boris MAKUTONIN.
Application Number | 20150336691 14/410481 |
Document ID | / |
Family ID | 49029143 |
Filed Date | 2015-11-26 |
United States Patent
Application |
20150336691 |
Kind Code |
A1 |
FOWLER; James ; et
al. |
November 26, 2015 |
APPARATUS AND METHOD FOR CONTINUOUS MOTION ROTATABLE FORMING OF
SOLUBLE POUCHES
Abstract
A machine and method of forming multi-compartment pouches is
disclosed in which two pouches formed on separate adjacent formers
(1, 3) are brought together in register and the lidding webs (9,
15) of the pouches joined to form a combined pouch (33). The
pouches may be held on the formers (1, 3) by vacuum until the
pouches are joined whereupon the vacuum holding one of the pouches
on its former (1) is released while maintaining the vacuum holding
the other pouch on its former (3) so that the combined pouches (33)
are held on that former by the vacuum until the vacuum is
released.
Inventors: |
FOWLER; James; (St. Charles,
IL) ; MAKUTONIN; Boris; (Cincinatti, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rideau Machinery Inc. |
Aurora |
IL |
US |
|
|
Assignee: |
Rideau Machinery Inc.
Aurora
IL
|
Family ID: |
49029143 |
Appl. No.: |
14/410481 |
Filed: |
June 21, 2013 |
PCT Filed: |
June 21, 2013 |
PCT NO: |
PCT/IB2013/055114 |
371 Date: |
December 22, 2014 |
Current U.S.
Class: |
206/524.7 ;
53/158; 53/445; 53/450; 53/553 |
Current CPC
Class: |
B29C 51/10 20130101;
B65B 2009/047 20130101; B65B 51/026 20130101; B65B 61/02 20130101;
B65D 75/42 20130101; B29C 2791/006 20130101; B65D 81/3261 20130101;
B65D 65/46 20130101; B29C 51/225 20130101; B65B 9/045 20130101;
B29C 51/20 20130101; B65B 9/042 20130101; B65B 2230/02 20130101;
B65D 81/3272 20130101 |
International
Class: |
B65B 9/04 20060101
B65B009/04; B65D 75/42 20060101 B65D075/42; B65D 65/46 20060101
B65D065/46; B65B 51/02 20060101 B65B051/02; B65B 61/02 20060101
B65B061/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 23, 2012 |
GB |
1211179.5 |
Nov 29, 2012 |
GB |
1221526.5 |
Claims
1. A continuous motion machine for producing water-soluble pouches
comprising two or more compartments from four water-soluble
polymeric webs wherein two pouches are formed, filled and sealed on
separate, adjacent donating and receiving formers, each pouch being
formed from two water-soluble polymeric webs, and wherein the two
such pouches are held by vacuum on their formers until they are
joined together in register to form a combined pouch whereupon the
vacuum in the donating former is removed releasing its pouch to the
receiving former and the combined pouch still held by vacuum in the
receiving former is separated from the combined web.
2. The machine according to claim 1 wherein the machine is
configured to provide a partial perimetric seal between lidding
webs of the two pouches.
3. The machine according to claim 1 wherein the machine is
configured to provide a complete perimetric seal between lidding
webs of the two pouches.
4. The machine according to claim 2 wherein the machine is
configured to place a solid item between the lidding webs of the
two pouches before the lidding webs are sealed together, thereby
creating a compartment between the lidding webs.
5. The machine according to claim 4 wherein the machine is
configured such that the solid item is visible through at least one
window within both webs of either or both pouches
6. The machine according to claim 1 wherein the machine is
configured to perforate a base web of at least one of the
pouches.
7. The machine according to claim 6 wherein the machine is
configured to perforate the base web prior to a forming
operation.
8. The machine according to claim 6 wherein the machine is
configured to perforate the base web during a forming
operation.
9. The machine according to claim 6 wherein the machine is
configured to perforate the base web after a forming operation
10. A method of producing water-soluble pouches comprising two or
more compartments by forming, filling and sealing two pouches on
separate, adjacent formers each from two water-soluble polymeric
webs, bringing the two webs together with the two such pouches in
register while they are held by vacuum on their formers and joining
the two such pouches together to form a combined web and combined
pouch comprising two or more compartments, and removing the vacuum
in one former releasing its pouch to the other former so that the
combined pouch is still held by vacuum in the other former and
separating the combined pouch from the combined web.
11. (canceled)
12. The method according to claim 10 wherein one or more
compartments contain a combination of at least two components
comprising a granular or powder product, a thickened liquid or gel,
and a three dimensional solid item such that all of the components
retain their identity and none of the components become mutually
antagonistic.
13. The method according to claim 10 wherein a partial perimetric
seal is formed between lidding webs of the two pouches.
14. The method according to claim 10 wherein a complete perimetric
seal is formed between lidding webs of the two pouches.
15. The method according to claim 13 wherein a solid component is
inserted between the lidding webs of the two pouches prior to the
two pouches being sealed or bonded together, thereby creating a
compartment between the lidding webs.
16. The method according to claim 15 wherein the solid component is
visible through at least one window within both webs of either or
both pouches
17. The method according to claim 10 wherein a base web of at least
one of the pouches is perforated before, during or after a forming
operation.
18. The method according to claim 10 including removing the vacuum
holding the separated, combined pouch on the other former.
19. The method according to claim 10 wherein a sealing pressure
between the lidding films of pouches held by vacuum on the donating
and receiving formers is adjustable.
20-22. (canceled)
23. A multi-compartment water-soluble pouch formed by combining two
separate pouches, each pouch having one or more sealed
compartments, wherein lidding webs of the combined pouches are
joined by a perimetric seal to form a further compartment between
the lidding webs of the combined pouches.
24. The multi-compartment water-soluble pouch of claim 23 wherein
the perimetric seal forms a partial seal between the lidding webs
of the combined pouches.
Description
[0001] This invention concerns improvements in or relating to
continuous motion rotatable forming of soluble pouches. More
especially, the invention concerns machines and methods for
producing multi-compartment pouches from four soluble
substrates.
[0002] In WO 2002/085736, a process has been described for
producing a water-soluble container comprising at least two
compartments by sealing together two single compartment pouches.
The compartments may be formed by any method which produces an open
container, for example by vacuum forming, thermoforming, blow
moulding or injection moulding, and are adjacent to each other
having been formed concurrently. The compartments are then filled
with a composition and closed with a lid such that the compartments
are joined by a folding portion. The folding portion is then folded
such that the lids of each of the compartments adhere to each
other. Any method of sealing the two compartments together may be
used, including pressure as in a snap-fit, an adhesive such as an
aqueous solution of PVOH, or heat sealing. Other methods of sealing
include infra-red, radio frequency, ultrasonic, laser, solvent,
vibration and spin welding are described. The adhesive can be
applied to the lids by spraying, transfer coating, roller coating,
or otherwise coating, or the lids can be passed through a mist of
the adhesive. The folding portion may be subsequently removed in
order to provide an even more attractive appearance.
[0003] The above process has disadvantages. The presence of a
folding portion means that the at least two compartments must be
adjacent to each other in order to allow subsequent folding. The
process is difficult to scale up in order to achieve economies of
scale as the folding and trimming process is cumbersome,
particularly where the at least two compartments contain different
products, and it is difficult to envisage how a folding mechanism
can allow a number of compartments greater than two.
[0004] In one aspect the present invention provides a continuous
motion machine for producing water-soluble pouches comprising two
or more compartments from four water-soluble polymeric webs wherein
two pouches are formed, filled and sealed on separate, adjacent
donating and receiving formers, each pouch being formed from two
water-soluble polymeric webs, and wherein the two such pouches are
held by vacuum on their formers until they are joined together in
register to form a combined pouch whereupon the vacuum in the
donating former is removed releasing its pouch to the receiving
former and the combined pouch still held by vacuum in the receiving
former is separated from the combined web.
[0005] The water soluble substrates may comprise any suitable
polymeric material such as those based substantially upon polyvinyl
alcohol. The polymeric material may be extruded or cast in solution
to form a web. The web may be a single or multi-layer water soluble
film. The polymeric material may be approved for ingestion by
humans and/or by animals.
[0006] It may be that the pouches are formed by two webs, a base
web and a lidding web. The formers may have recesses to create open
compartments or pouches in the base web by any suitable forming
operation such as vacuum forming or thermoforming. The open
compartments or pouches may be filled with one or more products
before being closed by the lidding webs and then sealed or bonded
together to form a combined web of sealed and filled closed
pouches. The base webs preferably comprise polymeric material that
is sufficiently elastic and of a sufficient thickness to allow it
to be vacuum formed or thermoformed into the cavities of the
respective former without being punctured.
[0007] It may be that the lidding web of a closed pouch on one
former is only partially sealed or bonded to the lidding web of a
closed pouch on the other former to form a combined pouch. As a
result, an aqueous medium into which the combined pouch is placed
may be able to penetrate between lidding webs of the closed pouches
more quickly and thereby accelerate dissolution.
[0008] It may be that a perimetric seal is formed between the
lidding webs of two pouches. The perimetric seal may be a partial
seal or a complete seal.
[0009] It may be that the contents of each compartment are released
into an aqueous medium at different times. Alternatively, the
contents of each compartment may be released into an aqueous medium
at substantially the same time.
[0010] It may be that a solid item is placed between lidding webs
of the closed pouches before the lidding webs are sealed together,
thereby creating a further compartment.
[0011] It may be that a device is provided for perforating one or
more of the base webs.
[0012] It may be that the one or more base webs are perforated
prior to forming open compartments or pouches.
[0013] It may be that the one or more base webs are perforated
while forming open compartments or pouches.
[0014] It may be that the one or more base webs are perforated
subsequent to forming open compartments or pouches.
[0015] It may be that different levels of vacuum can be applied at
different positions around one or both formers. For example, when
the pouches are combined and held on one former, the level of
vacuum holding the combined pouch may be increased.
[0016] In another aspect the present invention provides a method of
producing water-soluble pouches comprising two or more compartments
by forming, filling and sealing two pouches on separate formers
each from two water soluble substrates and joining the two such
pouches together to form a combined pouch comprising two or more
compartments.
[0017] The water soluble substrates may comprise any suitable
polymeric material such as those based substantially upon polyvinyl
alcohol. The polymeric material may be in the form of a web. The
web may be a single or multi-layer water soluble film. The
polymeric material may be approved for ingestion by humans and/or
by animals.
[0018] It may be that the method uses a machine according to the
preceding aspect of the invention.
[0019] It may be that one or more compartments contain a
combination of at least two components comprising a granular or
powder product, a thickened liquid or gel, and a three dimensional
solid item such that all of the components retain their identity
and none of the components become mutually antagonistic.
[0020] It may be that base webs of the pouches comprise a polymeric
material that is sufficiently elastic and of a sufficient thickness
to allow it to be vacuum formed or thermoformed into the cavities
of the respective former without being punctured.
[0021] It may be that lidding webs of the pouches are only
partially sealed or bonded together. In this way an aqueous medium
into which a pouch is placed may be able to penetrate between
lidding webs of the pouches more quickly and thereby enhance
dissolution.
[0022] It may be that a perimetric seal is formed between the
lidding webs of two pouches. The perimetric seal may be a partial
seal or a complete seal.
[0023] It may be that one of the pouches is transferred from its
rotatable former to a second rotatable former, the lidding webs of
both pouches sealed or bonded together to form a joined pouch, and
the joined pouches separated from the web.
[0024] It may be that the method includes forming a first web of
pouches on a rotatable donating former, forming a second web of
pouches on a rotatable receiving former, bringing the first and
second webs of pouches together with pouches in the first web in
register with pouches in the second web, joining the pouches in the
first web to the pouches in the second web and removing the vacuum
holding the pouches on the donating former to release the combined
web of combined pouches from the donating former while the combined
web of combined pouches is still held by vacuum on the receiving
former, separating the combined pouches from the combined web and
subsequently removing the vacuum holding the separated, combined
pouches on the receiving former.
[0025] Each web of pouches may comprise a base web and a lidding
web. The base web may be formed to provide open compartments or
pouches to receive one or more components prior to closing the open
compartments or pouches with the lidding web to form closed
pouches. The lidding webs of the closed pouches on one former may
be joined to the lidding webs of the closed pouches on the other
former. The lidding webs may be joined by a perimetric seal. The
perimetric seal may be a partial seal or a complete seal.
[0026] It may be that different levels of vacuum can be applied at
different positions around one or both formers. For example, when
the pouches are combined and held on one former, the level of
vacuum holding the combined pouch may be increased.
[0027] In another aspect the present invention provides a
water-soluble pouch comprising two or more compartments made by the
machine or method according to the preceding aspects of the
invention.
[0028] It may be that the pouches are only partially sealed or
bonded together in order to enhance dissolution.
[0029] It may be that a solid component is inserted between the two
pouches prior to the two pouches being sealed or bonded
together.
[0030] In the present invention, the aforementioned disadvantages
of WO 2002/085736 are overcome by a process in which the
compartments are provided by independently forming, filling and
sealing pouches on separate formers and then presenting the pouches
to each other for sealing to form a multi-compartment pouch. In
this way, the filled and sealed pouches providing the compartments
may be accurately positioned one on top of the other and then
sealed together to form the multi-compartment pouch. The rotatable
formers may be of the type disclosed in our earlier patent
application WO 2011/061628. In certain of the simplest embodiments
of the present invention, the appearance of the finished product is
not dissimilar to that produced by means of WO 2002/085736, but the
process by which it has been made is different.
[0031] The machine and method of the preceding aspects of the
invention produce pouches comprising two or more compartments from
four water-soluble substrates. Two such substrates are needed to
produce each independently formed compartment and a further
compartment may be created between the two independently formed
compartments immediately prior to sealing the two independently
formed compartments together. One or more of the four substrates
may be perforated. Each substrate may dissolve at the same
temperature or pH. Alternatively, each substrate may, for example,
dissolve at a different temperature or at a different pH in order
to allow sequential release of the contents of each compartment.
The water soluble substrates may comprise any suitable polymeric
material such as those based substantially upon polyvinyl alcohol.
The polymeric material may be in the form of a web. The web may be
a single or multi-layer water soluble film. The polymeric material
may be approved for ingestion by humans and/or by animals.
[0032] The thickness of each water-soluble substrate may vary
according to: [0033] 1. The depth of forming of each base web and
the volume of each compartment [0034] 2. The type of fill, whether
by way of example, a solid item, powder, granules, liquid,
thickened liquid, gel, hot molten liquid, or other types of
presentation [0035] 3. The desired dissolution time of each pouch
[0036] 4. The quantity and/or pattern of solvent applied to each
lidding web prior to sealing of each compartment
[0037] The application of solvent to a lidding web prior to sealing
reduces the strength of that web due to partial dissolution and
re-plasticization or softening of the web. However, lidding webs
may nevertheless typically be thinner than base webs as lidding
webs are not subjected to a forming operation. In this invention,
the lidding webs of each compartment are subsequently sealed
together to form a combined web which may have a thickness more or
less equal to the sum of the thicknesses of the two lidding webs.
The thickness of the combined lidding webs can increase dissolution
time. Where speed of dissolution is important, it may be desirable
to minimize the thickness of each lidding web in order to minimize
an increase in dissolution time. The double thickness of the seal
or bond between the two pouches may be detrimental to the speed of
dissolution of the joined pouch. In order to reduce any increase in
dissolution time, the lidding webs may not be completely sealed
together but only partially sealed together. This may be achieved
by applying solvent only to part of the lidding web and/or applying
heat and pressure only to part of the flange surrounding the
compartment. By this means, the dissolution time may not
necessarily increase as the aqueous medium into which the pouch is
placed, will be able to penetrate more easily into the space
between the two lidding webs. Subject always to the above speed of
dissolution considerations, as much as possible of the periphery of
the seal or bond between the two pouches may be sealed in order to
enhance the attractiveness of the joined pouches.
[0038] It may be that the lidding webs of each compartment are
superimposed one upon the other prior to sealing together the two
compartments. It may be that the lidding webs of each compartment
are brought together in such a way that one compartment is placed
in a required position upon the second compartment. The first
compartment may be symmetrically placed upon the second compartment
but in some embodiments of the present invention, the first
compartment may be asymmetrically placed upon the second
compartment but nevertheless still in register. The process of
bringing two pouches together in a required position relative to
each other is referred to in the art as bringing the two pouches
together in register. Bringing the two pouches together in register
is desirable in order that the subsequent process of separating the
two or more compartment pouches from each other by slitting in the
machine direction and then in the transverse direction can be
carried out effectively. Accurate registration of the two pouches
prior to sealing together may also beneficial for the commercial
attractiveness of a two or more compartment pouch. Accurate
registration may be achieved by use of a separate servo drive on
each former, one being a master and one being a slave.
[0039] The time taken for each compartment to release its contents
into the aqueous medium into which a two or more compartment pouch
according to this invention has been placed may be varied in order
that the release time of the contents of each compartment is
different. Such a sequential release may be of commercial value in
applications where the contents of one pouch are required for
immediate release and the contents of a second pouch are required
at a later time.
[0040] A tablet or other solid object may be placed between the two
pouches after each has been closed with a lidding web but before
the two pouches are joined together. The contents of each
compartment may be solid, granular or powder, liquid of any
viscosity, or gel. In the case where one of the compartments
contains a solid material, the placement of a tablet between two
sealed pouches may be facilitated by providing the sealed pouch
containing a solid material with a perforated base web allowing
excess air to be drawn by vacuum from the sealed pouch prior to
placement of a tablet in the greater space so created between the
two sealed pouches.
[0041] The sealing or bonding of two pouches to form a combined
pouch comprising two or more compartments is typically effected by
a combination of pressure and partial or complete wetting, leading
to adhesivity, of the external (top) surface of either of the
lidding webs. The selection as to which lidding web is partially or
completely wetted prior to sealing or bonding together of the two
pouches will depend upon the thickness of the respective lidding
webs and their dissolution properties. Either lidding web may be
selected for application of the wetting agent. Typically, the less
readily soluble of the respective lidding webs will be selected for
wetting partially or completely prior to sealing or bonding
together of the two pouches. Where the lidding webs are made from
the same water-soluble polymer formulation, the lidding film which
is selected for wetting is typically thicker than the unwetted
lidding film. For example the wetted lidding film may be up to 50%
thicker than the unwetted lidding film.
[0042] During the process by which the two pouches are combined
together into a multi-compartment pouch, the vacuum holding each
pouch in its respective pocket is regulated and controlled. The
vacuum in the pockets of the donating former is maintained, for
example by means of a precisely designed and positioned vacuum
shoe, until the two pouches have been combined together at which
precise point the vacuum of the donating former is released.
Conversely, the vacuum in the pockets of the receiving former is
maintained whilst the two pouches are combined together and
thereafter whilst the joined multi-compartment pouches, by now
joined together in a combined web, are transported to a cutting
station on the receiving former where they are separated from each
other, for example by knives mounted in both machine direction and
transverse direction, and the vacuum is subsequently released
allowing the joined multi-compartment pouches to fall off or be
blown off the receiving former on to a moving conveyor which
transports the web of multi-compartment pouches to a downstream
packaging operation. Once the multi-compartment pouches have been
separated from each other, the side trim from the web is drawn by
vacuum or otherwise into a collecting system for disposal or
recycling.
[0043] In another aspect, the present invention provides a
multi-compartment water-soluble pouch produced from four
water-soluble webs comprising a first water-soluble pouch and a
second water-soluble pouch wherein a compartment is created between
the two pouches.
[0044] It may be that a solid object such as a tablet or a
water-soluble pouch or capsule made off-line is inserted into the
compartment between the two pouches.
[0045] It may be that the two pouches are sealed or bonded together
by means of a partial perimetric seal.
[0046] It may be that the two pouches are sealed or bonded together
by means of a complete perimetric seal.
[0047] It may be that at least one of the compartments of the first
or second water-soluble pouch is perimetric.
[0048] It may be that the seal pressure exerted between the first
and second water-soluble pouches is adjustable.
[0049] Features of any of the preceding aspects of the invention
may be employed separately or in combination with the same or
different aspects of the invention,
[0050] The invention will now be described in more detail by way of
example with reference to the accompanying drawings wherein:
[0051] FIG. 1 shows a machine according to a first embodiment of
the invention;
[0052] FIG. 2 shows a machine according to a second embodiment of
the invention;
[0053] FIG. 3 shows a machine according to a third embodiment of
the invention;
[0054] FIGS. 4a and 4b are plan and sectional views of a
multi-compartment pouch produced by the machines of FIGS. 1 to
3;
[0055] FIG. 5 shows a machine for producing multi-compartment
pouches according to a fourth embodiment of the invention;
[0056] FIGS. 6a and 6b are plan and sectional views of a
multi-compartment pouch produced by the machine of FIG. 5;
[0057] FIGS. 7a, 7b show plan and sectional views of an alternative
multi-compartment pouch according to the invention;
[0058] FIGS. 8a, 8b show plan and sectional views of an alternative
multi-compartment pouch according to the invention;
[0059] FIGS. 9a, 9b show plan and sectional views of an alternative
multi-compartment pouch according to the invention;
[0060] FIGS. 10a, 10b, 10c, 10d show plan, perspective and
sectional views of an alternative multi-compartment pouch according
to the invention;
[0061] FIGS. 11a, 11b show plan and sectional views of an
alternative multi-compartment pouch according to the invention;
[0062] FIGS. 12a, 12b show plan and sectional views of an
alternative multi-compartment pouch according to the invention;
[0063] FIGS. 13a, 13b show plan and sectional views of an
alternative multi-compartment pouch according to the invention;
[0064] FIGS. 14a, 14b, 14c show plan, perspective and sectional
views of an alternative multi-compartment pouch according to the
invention;
[0065] FIGS. 15a, 15b show plan and sectional views of an
alternative multi-compartment pouch according to the invention;
[0066] FIGS. 16a, 16b, 16c show plan, perspective and sectional
views of an alternative multi-compartment pouch according to the
invention;
[0067] FIGS. 17a, 17b, 17c show an alternative method of wetting
the lidding webs;
[0068] FIGS. 18a, 18b show an alternative method of wetting the
lidding webs;
[0069] FIGS. 19a, 19b show an alternative method of wetting the
lidding webs; and
[0070] FIGS. 20a and 20b shows a method of inserting a solid object
between the lidding webs and a pouch so formed.
[0071] In the following description of exemplary embodiments, terms
such as top, bottom, upper, lower, horizontal are used with
reference to the orientation of the embodiments depicted in the
drawings are not limiting on the scope of the embodiments.
[0072] In the exemplary embodiment of FIG. 1, multi-compartment
pouches are produced by forming two webs of closed pouches and
joining the webs together whereby the pouches in one web are
superposed in register on the pouches in the other web using two
continuously rotatable formers 1, 3. Each former 1, 3 is similar
and has a forming surface 1a, 3a that is circular, for example a
continuously rotating drum containing pockets 1b, 3b. Further
details of the construction and operation of each former 1, 3 can
be obtained by referring to the description in our earlier
application WO2011/061628 to which the reader is directed and only
features necessary for an understanding of the present invention
are described in the following description.
[0073] As shown in FIG. 1, a plurality of open compartments or
pouches is formed in the pockets or recesses 1b in the circular
forming surface 1a of the former 1 by a first water soluble
polymeric web 5. The open pouches are filled via a product feed 7
and then closed by a second water soluble polymeric web 9 to form a
first web of closed pouches. A plurality of open compartments or
pouches is formed in the pockets or recesses 3b in the circular
forming surface 3a of the former 3 by a third water soluble
polymeric web 11. The open pouches are filled via a product feed 13
and then closed by a fourth water soluble polymeric web 15 to form
a second web of closed pouches. The first and third polymeric webs
5, 11 are base webs and the second and fourth polymeric webs 9, 15
are lidding webs for the open pouches formed by the first and third
base webs 5, 11. The lidding webs 9, 15 are wetted via wetting
rollers 17, 19 to provide adhesion to the first and third base webs
5, 11 to produce the first and second webs of closed pouches on the
formers 1, 3. Sealing rollers 21, 23 are provided to seal the
lidding webs 9, 15 to the first and third base webs 5, 11. The
pouches may be vacuum or thermoformed. The pouches may be held on
the formers 1, 3 by a vacuum applied through the pockets in the
formers 1, 3 as described in WO 2011/061628.
[0074] An additional wetting roller 25 is provided for wetting the
external (top) surface of the lidding web 9 of the first web of
closed pouches on the former 1 to be wetted prior to being brought
into contact with the external (top) surface of the lidding web 15
of the second web of closed pouches on the former 3 at 27. The
lidding web 9 may be partially or completely wetted in order to
produce adhesivity when the lidding webs 9, 15 of the two webs of
closed pouches are brought together at 27. At 27, the lidding webs
9, 15 are sealed or bonded together by a combination of pressure
exerted between the two rotating formers 1, 3 and the adhesivity of
the external (top) surface of the lidding web 9 produced by the
action of the wetting roller 25. As a result, the first and second
webs of closed pouches are combined together with closed pouches in
the first web of pouches aligned with and in register with closed
pouches in the second web of pouches to produce multi-compartment
combined pouches from the pouches in both webs. In an alternative
arrangement (not shown), the external (top) surface of the lidding
web 15 of the second web of closed pouches may be partially or
completely wetted prior to being brought into contact with the
external (top) surface of the lidding web 9 of the first web of
closed pouches at 27 to provide adhesion to the second web of
closed pouches. Alternatively, the external (top) surface of both
lidding polymeric webs 9, 15 may be wetted prior to being brought
together to provide adhesion between the combined webs of closed
pouches.
[0075] During the process by which the multi-compartment pouches
are formed, the vacuum holding each pouch in its respective pocket
is regulated and controlled. The vacuum is maintained, until the
two pouches have been joined together at which point the vacuum in
the pockets of one of the formers (the donating former) is released
while the vacuum in the pockets of the other former (the receiving
former) is maintained. In this way the combined web of
multi-compartment pouches formed by combining the webs of pouches
on both formers is retained by the receiving former. In this
embodiment, former 1 is the donating former and former 3 is the
receiving former but this could be reversed with former 3 being the
donating former and former 1 the receiving former.
[0076] The multi-compartment pouches so formed can be separated
from the combined webs at a cutting station on the receiving former
3 where they are separated from each other by any suitable device
29 for example cutting the combined webs in both the longitudinal
direction and the transverse direction with a blade or knife or
laser as will be familiar to those skilled in the art and the
vacuum holding the pouches in the pockets 3b subsequently released
allowing the joined multi-compartment pouches to fall off the
receiving former 3 on to a moving conveyor 31 which transports the
multi-compartment pouches 33 to a packaging operation. Once the
multi-compartment pouches 33 have been separated from each other,
the side trim from the web may be drawn by vacuum or otherwise into
a collecting system for disposal or recycling. Transfer of the
pouches may be assisted by applying fluid pressure through holes in
the base of the pockets to eject the pouches from the pockets. The
fluid may be air or any other fluid inert to the water-soluble
substrates of the pouches.
[0077] The pressure exerted between the two rotating formers 1, 3
and/or the adhesivity of the external (top) surface of the lidding
polymeric web(s) may be adjusted according to the required quality
of the seal or bond between the two webs of pouches. If a partial
seal or bond is required in order to enhance speed of dissolution
of the combined pouch, this can be obtained by means of an engraved
wetting roller such that the external (top) surface of the lidding
web(s) is not completely covered but only partially covered,
resulting in a partial seal or bond between the lidding web(s) at
27.
[0078] The thicknesses and dissolution or other characteristics of
the four polymeric webs 5, 9, 11, 15 may be identical or different
according to any one or more of the following list of features
given by way of non-limiting example only: [0079] the size of the
compartments [0080] the material contained within each compartment
[0081] the release time of each compartment by which we mean the
time for each compartment (for the avoidance of doubt, the release
time of each compartment need not necessarily be the same) to have
released its contents into an aqueous medium into which the
multi-compartment pouch is placed. [0082] the time to complete
dissolution of each compartment.
[0083] In FIG. 1, the former 1 is shown above and offset to one
side of the former 3 allowing the webs of open pouches on both
formers to be filled and closed at the top of the formers 1, 3
thereby increasing the available volume that can be filled without
spillage, especially when introducing a flowable product into the
open pouches. It will be understood however, that other
arrangements of the formers may be employed, whereby, for example
the formers may be arranged one above and offset to the other side
as well as the offset arrangement shown in FIG. 1. By the term
offset in this context, we mean any arrangement in which the
sealing or bonding of the combined pouch takes place (with
reference to FIG. 1) between 9 o'clock and 11 o'clock provided that
sufficient space remains between 11 o'clock and 1 o'clock for a
filling station to be positioned.
[0084] In FIG. 1, the diameter of the drums of each former 1, 3 is
shown to be identical. However, it will be understood that it is
not essential for the drum diameters of each former to be
identical. Indeed, there may be advantages to make the drum
diameters different. For example by making the diameter of the
lower former greater than that of the higher former a greater
distance may be available around the circumference of the lower
former in which to fit one or more filling stations and one or more
cutting stations.
[0085] In the exemplary embodiment of FIG. 2, the same principle as
described above for FIG. 1 is applied to a different configuration
of continuously rotatable formers. For convenience, like reference
numerals in the series 100 are used to indicate the same or similar
parts.
[0086] In FIG. 2, the first former 101 has a forming surface 101a
that is circular, for example a continuously rotating drum
containing pockets 101b, and the second former 103 has a forming
surface 103a that is flat, typically horizontal, for example a
continuously rotatable endless chain or belt containing pockets
103b. Further details of the construction and operation of each
former 101, 103 can be obtained by referring to the description in
our earlier application WO2011/061628 to which the reader is
directed and only features necessary for an understanding of the
present invention are described in the following description.
[0087] As shown in FIG. 2, a plurality of open compartments or
pouches is formed in the pockets 101b in the circular forming
surface 101a of the former 101 by the water soluble base web 105.
The open pouches are filled via product feed 107 and then closed by
the second water soluble web 109 to form a first web of closed
pouches. A plurality of open compartments or pouches is formed in
the pockets 103b in the horizontal forming surface 103a by a third
water soluble web 111. The open pouches are filled via a product
feed 113 and then closed by a fourth water soluble web 115 to form
a second web of closed pouches. The first and third webs 105, 111
are base webs and the second and fourth webs 109, 115 are lidding
webs for the open pouches formed by the first and third base webs
105, 111. The lidding webs 109, 115 are wetted via wetting rollers
117, 119 to provide adhesion to the first and third base webs 105,
111 to produce the first and second webs of closed pouches on the
formers 101, 103. Sealing rollers 121, 123 are provided to seal the
lidding webs 109, 115 to the first and third base webs 105, 111.
The first and second webs of closed pouches so formed are held in
place on the formers 101, 103 by applying vacuum through the
pockets in the forming surfaces of the formers as described in WO
2011/061628.
[0088] An additional wetting roller 125 is provided for wetting the
external (top) surface of the lidding web 109 of the first web of
closed pouches on the former 101 to be wetted prior to being
brought into contact with the external (top) surface of the lidding
web 115 of the second web of closed pouches on the former 103 at
127. The lidding polymeric web 109 may be partially or completely
wetted in order to produce adhesivity when the lidding polymeric
webs 109, 115 of the two webs of closed pouches are brought
together at 127. At 127, the lidding webs 109, 115 are sealed or
bonded together by a combination of pressure exerted between the
two rotating formers 101, 103 and the adhesivity of the external
(top) surface of the lidding web 109 produced by the action of the
wetting roller 125. As a result, the first and second webs of
closed pouches are combined together with closed pouches in the
first web of pouches aligned with and in register with closed
pouches in the second web of pouches to produce multi-compartment
combined pouches 133 from the pouches in both webs. In an
alternative arrangement (not shown), the external (top) surface of
the lidding web 115 of the second web of closed pouches may be
partially or completely wetted prior to being brought into contact
with the external (top) surface of the lidding web 109 of the first
web of closed pouches at 127 to provide adhesion to the second web
of closed pouches. Alternatively, the external (top) surface of
both lidding webs 109, 115 may be wetted prior to being brought
together to provide adhesion between the combined webs of closed
pouches.
[0089] As described previously, the vacuum holding the first web of
pouches on the donating former 101 is released during the sealing
or bonding process while maintaining the vacuum holding the second
web of pouches on the receiving former 103 so that the
multi-compartment pouches formed by the combined webs are retained
on the receiving former 103 and can be separated from the combined
webs by any suitable device 129 for example cutting with a blade or
knife or laser as will be familiar to those skilled in the art and
released from the receiving former 103 on to a conveyor (not shown)
or similar arrangement for delivering the individual
multi-compartment combined pouches 133 to a collection point (not
shown) for a packaging operation or other processing as required.
In a modification, the former 101 may be the receiving former and
the former 103 may be the donating former. In this arrangement the
vacuum holding the second web of pouches on the donating former 103
may be released while maintaining the vacuum holding the first web
of pouches on the receiving former 101 so that the combined webs
are retained on the receiving former 101 and can be separated and
delivered to a collection point as described previously.
[0090] The pressure exerted between the two rotatable formers 101,
103 and/or the adhesivity of the external (top) surface of the
lidding web(s) may be adjusted according to the required quality of
the seal or bond between the two webs of pouches. If a partial seal
or bond is required in order to enhance speed of dissolution of the
combined pouch, this can be obtained by means of an engraved
wetting roller such that the external (top) surface of the lidding
web(s) is not completely covered but only partially covered,
resulting in a partial seal or bond between the lidding webs at
127. In FIG. 2 the circular forming surface 101a of the donating
former 101 is positioned above the horizontal forming surface 103a
of the receiving former 103 and the first and second webs of closed
pouches are brought together so that the closed pouches in the web
on the donating former 101 are positioned above and in register
with the closed pouches in the web on the receiving former 103. As
a result, the first and second webs of closed pouches are combined
together to produce multi-compartment combined pouches from the
pouches in both webs.
[0091] The thicknesses and dissolution or other characteristics of
the four polymeric webs 105, 109, 111, 115 may be identical or
different according to any one or more of the following list of
features given by way of non-limiting example only: [0092] the size
of the compartments [0093] the material contained within each
compartment [0094] the release time of each compartment by which we
mean the time for each compartment (for the avoidance of doubt, the
release time of each compartment need not necessarily be the same)
to have released its contents into an aqueous medium into which the
multi-compartment pouch is placed. [0095] the time to complete
dissolution of each compartment.
[0096] In the exemplary embodiment of FIG. 3, the same principle as
described above for FIGS. 1 and 2 are applied to another different
configuration of continuously rotatable formers. For convenience,
like reference numerals in the series 200 are used to indicate the
same or similar parts.
[0097] In FIG. 3, both the first former 201 and the second former
203 have forming surfaces 201a, 203a that are flat, typically
horizontal, for example a continuously rotatable endless chain or
belt containing pockets 201b, 203b. Further details of the
construction and operation of each former 201, 203 can be obtained
by referring to the description in our earlier application
WO2011/061628 to which the reader is directed and only features
necessary for an understanding of the present invention are
described in the following description.
[0098] As shown in FIG. 3, a plurality of open compartments or
pouches is formed in the pockets 201b in the horizontal forming
surface 201a of the former 201 by the water soluble base web 205.
The open pouches are filled via product feed 207 and then closed by
the second water soluble web 209 to form a first web of closed
pouches. A plurality of open compartments or pouches is formed in
the pockets 203b in the horizontal forming surface 203a by a third
water soluble web 211. The open pouches are filled via a product
feed 213 and then closed by a fourth water soluble web 215 to form
a second web of closed pouches. The first and third webs 205, 211
are base webs and the second and fourth webs 209, 215 are lidding
webs for the open pouches formed by the first and third base webs
205, 211. The lidding webs 209, 215 are wetted via wetting rollers
217, 219 to provide adhesion to the first and third base webs 205,
211 to produce the first and second webs of closed pouches on the
formers 201, 203. Sealing rollers 221, 223 are provided to seal the
lidding webs 209, 215 to the first and third base webs 205, 211.
The first and second webs of closed pouches so formed are held in
place on the formers 201, 203 by applying vacuum through the
pockets in the forming surfaces of the formers as described in WO
2011/061628.
[0099] An additional wetting roller 225 is provided for wetting the
external (top) surface of the lidding web 209 of the first web of
closed pouches on the former 201 to be wetted prior to being
brought into contact with the external (top) surface of the lidding
web 215 of the second web of closed pouches on the former 203 at
227. The lidding polymeric web 209 may be partially or completely
wetted in order to produce adhesivity when the lidding polymeric
webs 209, 215 of the two webs of closed pouches are brought
together at 227. At 227, the lidding webs 209, 215 are sealed or
bonded together by a combination of pressure exerted between the
two rotating formers 201, 203 and the adhesivity of the external
(top) surface of the lidding web 209 produced by the action of the
wetting roller 225. As a result, the first and second webs of
closed pouches are combined together with closed pouches in the
first web of pouches aligned with and in register with closed
pouches in the second web of pouches to produce multi-compartment
combined pouches from the pouches in both webs. In an alternative
arrangement (not shown), the external (top) surface of the lidding
web 215 of the second web of closed pouches may be partially or
completely wetted prior to being brought into contact with the
external (top) surface of the lidding web 209 of the first web of
closed pouches at 227 to provide adhesion to the second web of
closed pouches. Alternatively, the external (top) surface of both
lidding webs 209, 215 may be wetted prior to being brought together
to provide adhesion between the combined webs of closed
pouches.
[0100] As described previously, the vacuum holding the first web of
pouches on the donating former 201 is released during the sealing
or bonding process while maintaining the vacuum holding the second
web of pouches on the receiving former 203 so that the
multi-compartment combined pouches 233 so formed by the combined
webs are retained on the receiving former 203 and can be separated
from the combined webs by any suitable device 229 for example
cutting with a blade or knife or laser as will be familiar to those
skilled in the art and released from the receiving former 203 on to
a conveyor (not shown) or similar arrangement for delivering the
individual multi-compartment pouches to a collection point (not
shown) for a packaging operation or other processing as required.
In a modification, the former 201 may be the receiving former and
the former 203 may be the donating former. In this arrangement the
vacuum holding the second web of pouches on the donating former 203
may be released while maintaining the vacuum holding the first web
of pouches on the receiving former 201 so that the combined webs
are retained on the receiving former 201 and can be separated and
delivered to a collection point as described previously.
[0101] The pressure exerted between the two rotatable formers 201,
203 and/or the adhesivity of the external (top) surface of the
lidding web(s) may be adjusted according to the required quality of
the seal or bond between the two webs of pouches. If a partial seal
or bond is required in order to enhance speed of dissolution of the
combined pouch, this can be obtained by means of an engraved
wetting roller such that the external (top) surface of the lidding
web(s) is not completely covered but only partially covered,
resulting in a partial seal or bond between the lidding web(s) at
227. In FIG. 3 the horizontal forming surface 201a of the donating
former 201 is positioned above the horizontal forming surface 203a
of the receiving former 203 and the first and second webs of closed
pouches are brought together so that the closed pouches in the web
on the donating former 201 are positioned above and in register
with the closed pouches in the web on the receiving former 203. As
a result, the first and second webs of closed pouches are combined
together to produce multi-compartment combined pouches from the
pouches in both webs.
[0102] The thicknesses and dissolution or other characteristics of
the four polymeric webs 205, 209, 211, 215 may be identical or
different according to any one or more of the following list of
features given by way of non-limiting example only: [0103] the size
of the compartments [0104] the material contained within each
compartment [0105] the release time of each compartment by which we
mean the time for each compartment (for the avoidance of doubt, the
release time of each compartment need not necessarily be the same)
to have released its contents into an aqueous medium into which the
multi-compartment pouch is placed. [0106] the time to complete
dissolution of each compartment.
[0107] In an exemplary embodiment, the sealing pressure exerted by
the formers 1, 3 (FIG. 1) or 101, 103 (FIG. 2) or 201, 203 (FIG. 3)
can be adjusted to obtain a desired strength of the seal between
the two pouches. Different films or different pouch designs may
require different sealing pressures
[0108] The machine preferably has a main frame to which the both
formers 1, 3 (FIG. 1) or 101, 103 (FIG. 2) or 201, 203 (FIG. 3) can
be mounted in order to achieve the initial adjustment of the
sealing pressure between the two pouches. To achieve variable seal
pressures, the top former is preferably mounted on a separate sub
frame which is movable in a vertical direction in order to provide
seal pressure adjustment. The weight of the sub-frame is preferably
supported by springs, pneumatic or hydraulic cylinders, air springs
or servo-controlled actuators or other similar means. Seal pressure
adjustment may be achieved by tightening one or more adjusters such
as micro screws against the spring force allowing a precise and
repeatable adjustment. Seal pressure may be remotely controlled by
an operator, for example by means of a read out on a main display
panel. The adjusters, for example micro screws, may be powered, for
example by small servo or stepping motors. The seal pressure
exerted during the process of sealing the two pouches may be
monitored, for example by one or more load sensors at the sealing
surface, and a digital signal representative of the sealing
pressure may be provided, for example at the main display panel,
allowing the operator to adjust the seal pressure by the above
mentioned adjusters, for example micro screws.
[0109] When the top former sub frame is installed, the pressure at
the sealing surface may be measured and used to calibrate the
pressure load sensors for repeatability. Then, by means of a series
of test runs with different setting combinations, sets of sample
pouches may be produced and evaluated for seal quality and
integrity, establishing a baseline against which future production
can be monitored. Data sets from the series of test runs can then
be used to determine the best combination of parameters for the
pouch production. In addition, the drum may be mounted so that a
skew angle of the drum to the chain can be micro-adjusted--to
compensate for (or, in some cases, create) misalignment for
appearance effect.
[0110] Sealing of the two pouches can be achieved by several
different methods, depending on the pouch design/appearance
requirement. For example, an incomplete or partial circumferential
seal (stitch sealing) between the two pouches can be produced by
different methods. One such method may include placing a series of
liquid droplets on the mating surface of one or other of the
pouches. The volume of each droplet can be precisely measured by
the use of precision nozzles. The number of liquid droplets and the
location and timing of placing the liquid droplets on the mating
surface of one or other pouch, can be calculated depending on the
machine speed, and the pressure and temperature selected to make an
optimum strength seal. A dedicated screen can be provided for this
task to take account of the temperature, humidity and other
parameters of the environment of the production room where
manufacturing is taking place. In this way, the quality of the
stitched seal between the two pouches can be repeated even when
environmental factors change, for example, due to a change in the
environment of the production room or due to machine relocation to
a different facility.
[0111] The same nozzles can be utilized if a complete
circumferential seal between the pouches if desired. A complete
circumferential seal can be provided by changing the pattern and
volume of the droplets. In the case where an integral seal is
desired, by which we mean that the entire mating surface of one of
the pouches is wetted prior to the two pouches being brought
together to be sealed, a wetting roller can be provided for this
purpose. However, the use of nozzles is preferable as it can be
used to provide either "stitched" or complete circumferential seals
whereas the use of a wetting roller requires a change in the set up
of the machine and consequential loss of productivity and
flexibility.
[0112] A silicone or natural rubber gasket placed around the open
pockets of one or both of the rotatable formers may facilitate
greater control of the sealing pressure.
[0113] An example of a multi-compartment pouch 151 formed by the
machines shown in FIGS. 1, 2 and 3 is shown in FIGS. 4a and 4b. The
materials contained within the compartments are not shown for
convenience and clarity. In this embodiment, there are two
compartments A and B comprised within the combined pouch when the
two webs of closed pouches are brought together and joined.
[0114] In FIG. 5, a modification of the machine of FIG. 2 is shown
whereby the machine is converted to form multi-compartment pouches
by a different mode of operation. For convenience and clarity, like
reference numerals are used to indicate the same or similar parts
and some parts of the machine shown in FIG. 2 are omitted or
depicted diagrammatically.
[0115] As shown in FIG. 5, a plurality of open compartments or
pouches are formed in the pockets 103b in horizontal forming
surface 103a of the former 103 by the water soluble polymeric web
111 as described previously for FIG. 2. The open pouches are filled
via product feed 113 but, unlike the mode of operation described
previously for FIG. 2, the open pouches are closed by a web of
already closed pouches formed in the pockets (not shown) in the
circular forming surface 101a of the former 101. The webs of open
and closed pouches are brought together at 127 and combined by
wetting (not shown) the external (top) surface of the lidding web
109 of the web of closed pouches so as to provide adhesivity to the
base web 111 of open filled pouches around the perimeter of the
open pouches so as to close the open pouches. Depending on the
contents of the open pouches, the lidding polymeric web 109 may be
wetted to provide selective adhesivity to the polymeric web 111 by
which term we mean to close completely or partially (for example,
by means of a "stitched" seal) the open pouches. As a result, the
web of open pouches and the web of closed pouches are combined
together in register at 127 to produce multi-compartment pouches
comprising three water-soluble substrates from the pouches in both
webs. A further water-soluble polymeric web 115 is then sealed or
bonded to the combined webs at 135 to provide a further compartment
aligned with and in register with the compartments formed at 127 by
the pouches in the combined webs, prior to separating the resulting
multi-compartment pouches from the combined webs as described
previously for FIG. 2. A similar modification may be employed in
the machine shown in FIG. 3.
[0116] An example of a multi-compartment pouch formed by the
machine shown in FIG. 5 is illustrated in FIGS. 6a and b. In this
embodiment, there are three compartments A, B and C. Compartments A
and B are produced by the superimposed pouches when the two webs
are brought together and joined at 127. Compartment C is produced
when the polymeric web 115 is joined to the combined webs at 135.
Compartment C formed by the polymeric web 115 may be empty in order
to enhance the appearance of the multi-compartment pouch.
[0117] As will be appreciated, four water soluble substrates are
used to produce the multi-compartment pouches formed by the mode of
operation of the machines shown in FIGS. 1, 2 and 3 and by the mode
of operation of the machine shown in FIG. 5. The reconfiguration of
the machine shown in FIG. 2 to provide the mode of operation shown
in FIG. 5 is simply performed by moving the unwind for the
water-soluble polymeric web 115 from its position upstream of the
circular forming surface 101a in FIG. 2 to a position downstream of
the circular forming surface 101a in FIG. 5.
[0118] Further examples of novel multi-compartment pouches that can
be made using the machine and the method described herein are shown
in FIGS. 7a, 7b through FIGS. 16a, 16b. Each pouch has been made by
combining two pouches each made from two water-soluble polymeric
webs and therefore comprises four separate water-soluble
substrates. The first and second pouches can contain a single
compartment containing, for example, a powder formulation, a
granular formulation, a liquid formulation, a gel formulation, or a
molten formulation. Alternatively, one or other or both of the
first and second pouches can comprise more than one compartment
each containing either a single formulation as described above or a
plurality of different formulations, for example, a first molten
formulation able to become solidified quickly enough for a second
formulation to be inserted thereupon without mutual antagonism
developing between the first and second formulations. These
examples are not to be taken as limiting as many combinations of
the principles illustrated in these examples can be made.
[0119] In FIGS. 7a, 7b, a first pouch comprising a single
compartment A is sealed to a second pouch comprising a single
compartment B but immediately prior to sealing, a third compartment
H is created between the first and second pouches by the insertion
of component E which, for example, may be a solid object such as a
tablet or a water-soluble pouch or capsule which has been made
off-line and inserted between the first and second pouches by the
machine of the present invention. Note that compartment H is empty
except for the presence of component E and that the two pouches are
similar in profile providing a symmetrical appearance to the
combined pouch comprising three compartments.
[0120] In FIGS. 8a, 8b, the construction of the first and second
pouches are similar to those illustrated in FIGS. 7a, 7b, but here,
component E is inserted into compartment A of the first pouch and
component F is inserted into compartment B of the second pouch
respectively prior to each pouch being sealed with a second web of
water-soluble film. Unlike the example illustrated in FIGS. 7a, 7b,
a third compartment is no longer created between the two pouches
when the first and second pouches are sealed together to form a
combined pouch. Note that the two pouches are similar in profile
providing a symmetrical appearance to the combined pouch comprising
two compartments with each compartment (A and B) containing two
components.
[0121] In FIGS. 9a, 9b, the construction of the combined pouch is
similar to that illustrated in FIGS. 7a, 7b but here the first and
second pouches comprise two compartments each, instead of the
single compartments shown in FIGS. 7a, 7b. The first pouch
comprises compartments A and B and the second pouch comprises
compartments C and D. Component E is inserted between the first and
second pouches creating a further compartment H according to the
same method described above for FIG. 7a, 7b. It should be noted
that in FIGS. 9a, 9b, compartments B and D are perimetric
compartments that surround the central compartments A and C. Note
that the two pouches are again similar in profile providing a
symmetrical appearance to the combined pouch which, in this
example, comprises five compartments A, B, C, D and H.
[0122] In FIGS. 10a, 10b, 10c, 10d a modification of the pouch
illustrated in FIGS. 9a, 9b is shown in which the central
compartment of each pouch has been removed in order to allow the
presence of component E to be clearly visible within compartment H
through the water-soluble film windows W1 and W2 which replace the
central compartments A and C. In this example, the compartments B
and D are perimetric compartments that surround the central windows
W1, W2 through which component E becomes visible. Note that the two
pouches are similar in profile providing a symmetrical appearance
to the combined pouch which, in this example, comprises three
compartments, B, D, and H.
[0123] By the term perimetric compartment in FIGS. 9a, 9b and FIGS.
10a, 10b, 10c, 10d we mean a compartment situated around the
perimeter of, and therefore surrounding, preferably without
interruption, a central compartment, shown in FIG. 9b as
compartments A and C or a central window, shown in FIG. 10b as
windows W1 and W2. Perimetric compartments could be described as
annular were they to be circular in plan view. Note that the two
pouches are again similar in profile providing a symmetrical
appearance to the combined pouch comprising five compartments in
the case of the combined pouch shown in FIGS. 9a, 9b and three
compartments in the case of the combined pouch shown in FIGS. 10a,
10b, 10c, 10d.
[0124] In FIGS. 11a, 11b, the construction of the combined pouch is
similar to that illustrated in FIGS. 9a, 9b but here component E is
not inserted between the pouches allowing the first and second
pouches to touch each other throughout the mating surfaces by which
term is meant the area of each pouch in contact with the other
during the sealing process. Note that the two pouches are similar
in profile providing a symmetrical appearance to the combined pouch
which, in this example, comprises four compartments, A, B, C and D
with compartments B and D being perimetric compartments that
surround central compartments A and C.
[0125] In FIGS. 12a, 12b, the construction of the first pouch (the
upper pouch as viewed in the drawing) is similar to that shown in
FIG. 11b with a perimetric compartment D that surrounds central
compartment C but, in this example, the second pouch (the lower
pouch as viewed in the drawing) is no longer a mirror image of the
first pouch. The second pouch comprises a single compartment A
extending to the perimeter seal. Note that the two pouches are
dissimilar in profile providing an asymmetrical appearance to the
combined pouch which comprises three compartments, A, C and D.
[0126] In FIGS. 13a, 13b, the construction of the first pouch (the
upper pouch as viewed in the drawing) is again similar to that
shown in FIG. 11b with a perimetric compartment D that surrounds
central compartment C but, in this example, the second pouch (the
lower pouch as viewed in the drawing) is again no longer a mirror
image of the first pouch. The second pouch comprises a single
perimetric compartment B that surrounds a central window W allowing
visible access to compartment C of the first pouch. Note that the
two pouches are dissimilar in profile providing an asymmetrical
appearance to the combined pouch which comprises three compartments
B, C and D.
[0127] In FIGS. 7a, 7b through FIGS. 13a, 13b the first and second
pouches are generally circular or elliptical in plan view. This is
not essential.
[0128] In FIGS. 14a, 14b, 14c the first and second pouches are
similar to that shown in FIGS. 12a, 12b, but in this example the
pouches are rectangular in plan view allowing each of the three
compartments A, C and D to assume a rectangular shape. This has the
benefit that each compartment fills a greater percentage of the
available web surface area, thereby reducing the flange area
surrounding compartments A and C and avoiding the need for removal
of waste from the flange area. Note that the two pouches are
dissimilar in profile providing an asymmetrical appearance to the
combined pouch which comprises three compartments, A, C and D.
[0129] In FIGS. 15a, 15b the first and second pouches are similar
to that shown in FIGS. 9a, 9b but, in this example the pouches are
triangular in plan view. Note that the two pouches are similar in
profile providing a symmetrical appearance to the combined pouch
which comprises four compartments, A, B, C and D.
[0130] Other shapes of pouches may be employed. For example,
perimetric compartments comprising two half circles joined by
straight lines thereby forming a "racetrack" in plan view.
[0131] In FIGS. 9a, 9b through FIGS. 15a, 15b, the perimetric
compartments comprise a single compartment that completely
surrounds either a central compartment or a window. This is not
essential.
[0132] In FIGS. 16a, 16b, 16c, the construction of the second pouch
is similar to that shown in FIGS. 8a, 8b but, in this example, the
perimetric compartment of the first pouch is divided into two
semi-perimetric compartments, B and D. In FIGS. 16a, 16b, 16c, we
show an example where compartments B and D are equal in size
although this is not necessary as the two compartments B and D may
be unequal in size. Note that the two pouches are dissimilar in
profile providing an asymmetrical appearance to the combined pouch
which comprises four compartments, A, B, C and D.
[0133] Other configurations of perimetric compartments may be
employed. For example the single perimetric compartments shown in
FIGS. 9a, 9b through FIGS. 15a, 15b may be divided into two or more
partly perimetric compartments of the same or different shape.
[0134] The following table provides a summary of features of the
pouches described herein.
TABLE-US-00001 Component Number of Number of between Perimetric
Inserted WSP Webs Compartments Pouches Symmetrical compartment
Component FIGS. 4a, 4b 4 2 No Yes No FIGS. 6a, 6b 4 3 No No No
FIGS. 7a, 7b 4 3 Yes Yes No A solid object such as a tablet or a
water-soluble pouch or capsule made off line FIGS. 8a, 8b 4 2, each
containing No Yes No two components FIGS. 9a, 9b 4 5 Yes Yes Yes
around both pouches A solid object such as a tablet or a
water-soluble pouch or capsule made off line FIGS. 10a, 10b, 4 3
Yes Yes Yes around both pouches A solid object such as a 10c. 10d
tablet or a water-soluble pouch or capsule made off line FIGS. 11a,
11b 4 4 No Yes Yes around both pouches FIGS. 12a, 12b 4 3 No No Yes
around first pouch FIGS. 13a, 13b 4 3 No No Yes around first pouch
FIGS. 14a, 14b, 4 3 No No Yes around first pouch 14c FIGS. 15a, 15b
4 4 No Yes Yes, around both pouches FIGS. 16a, 16b, 4 4 No No Yes,
around first pouch but 16c divided into two compartments
[0135] Referring now to FIGS. 17a, 17b, 17c, FIGS. 18a, 18b and
FIGS. 19a, 19b, different methods are illustrated of wetting the
external (top) surface of the lidding web of sealed pouches on one
former prior to sealing or bonding to the lidding web of sealed
pouches on the other former to produce combined water-soluble
pouches containing two or more compartments. These illustrations
are by no means limiting of methods of wetting the external (top)
surface of either lidding web to obtain the desired adhesivity at
the point where the webs are brought together with the pouches in
register.
[0136] In FIGS. 17a, 17b, 17c, the wetting is effected by means of
nozzles 53. The nozzles 53 may be configured to apply water
droplets 53a to the external (top) surface of the lidding web 54 of
sealed pouches on one former. The nozzles 53 may be calibrated to
apply a controlled amount of water or other aqueous medium in a
controlled pattern. The nozzles 53 may apply water droplets to that
part of the external surface surrounding the sealed pouches. By
this means, the risk of softening that part of the lidding web 54
that comprises part of the sealed pouches is reduced. If that part
of the lidding web 54 that comprises part of the sealed pouches is
over wetted, there could be a risk of partial dissolution leading
to rupture of the pouch and partial or complete release of the
contents. The wetted lidding web 54 is sealed to lidding web 55 of
sealed pouches on the other former at sealing point 56 to form
combined water soluble pouches 57. The nozzles 53 may be adjustable
to alter the spacing of the water droplets. In this way the seal
between the lidding webs 54, 55 can be complete or partial. In use,
a partial seal permits entry of an aqueous medium between the two
lidding webs 54, 55 of the combined pouch 57 to accelerate the
speed of dissolution of the combined pouch in the aqueous
medium.
[0137] In FIGS. 18a, 18b, the wetting is effected by means of a
servo-controlled roller 58. The roller 58 may be configured to
apply a controlled amount of water or other aqueous medium to the
external (top) surface of the lidding web 55 in a controlled
pattern. The roller 58 may apply water to only that part of the
external surface surrounding the sealed pouches. By this means, the
risk of softening that part of the lidding web 55 that comprises
part of the sealed pouches is reduced. If that part of the lidding
web 55 that comprises part of the sealed pouches is over wetted,
there could be a risk of partial dissolution leading to rupture of
the pouch and partial or complete release of the contents. The
degree of adhesivity may be controlled by moving the roller 58
nearer to, or further away from, the external (top) surface of the
lidding web 55 of the sealed pouches held on the former by a vacuum
contained therewithin.
[0138] In FIGS. 19a, 19b, the wetting is effected by means of a
plate 59. The plate 59 is provided with apertures 60 for applying a
controlled amount of water or other aqueous medium from a supply 61
to the external (top) surface of the lidding web 54 in a controlled
pattern. The plate 59 may apply water to only that part of the
external surface surrounding the sealed pouches. By this means, the
risk of softening that part of the lidding web 54 that comprises
part of the sealed pouches is reduced. If that part of the lidding
web 54 that comprises part of the sealed pouches is over wetted,
there could be a risk of partial dissolution leading to rupture of
the pouch and partial or complete release of the contents. The
degree of adhesivity may be controlled by moving the plate 59 up
and down as the lidding web 54 moves continuously towards the
sealing point 56 thereby ensuring that the desired level of
adhesivity is obtained.
[0139] Referring now to FIGS. 20a, 20b, a method and device is
shown for inserting a solid object 66 such as a tablet between the
lidding webs 54, 55 of the pouches held by vacuum on the formers
prior to sealing or bonding the webs together, thereby forming a
compartment 67 containing the solid object 66 between the lidding
webs 54, 55. In FIG. 20a, a tablet 66 is placed upon the lidding
web 54 by a tablet feeder 68 allowing the tablet 66 to be
subsequently sealed in the compartment 67 formed between the two
lidding webs 54, 55 in the combined pouch 57. The combined pouch 57
is shown in FIG. 20b.
[0140] An exemplary embodiment provides a machine and method of
forming multi-compartment pouches in which two pouches can be
formed simultaneously on separate adjacent formers and brought
together in register so that the pouches can be joined to form a
combined pouch. The pouches may be held on the formers by vacuum
until the pouches are joined whereupon the vacuum holding one of
the pouches on its former is released while maintaining the vacuum
holding the other pouch on its former so that the combined pouches
are held on that former by the vacuum until the vacuum is
released.
[0141] While exemplary embodiments have been described, it will be
understood that the invention is not limited thereto and that
modifications can be made within the scope of the invention as
defined in the claims.
* * * * *