U.S. patent application number 17/368655 was filed with the patent office on 2021-10-28 for systems and methods for forming dual layer water soluble packets.
This patent application is currently assigned to RADIENZ LIVING CHICAGO, LLC. The applicant listed for this patent is RADIENZ LIVING CHICAGO, LLC. Invention is credited to Andreas KEPINSKI, Thomas MCLENITHAN.
Application Number | 20210331822 17/368655 |
Document ID | / |
Family ID | 1000005698787 |
Filed Date | 2021-10-28 |
United States Patent
Application |
20210331822 |
Kind Code |
A1 |
KEPINSKI; Andreas ; et
al. |
October 28, 2021 |
SYSTEMS AND METHODS FOR FORMING DUAL LAYER WATER SOLUBLE
PACKETS
Abstract
A method of forming dual layer water soluble packets includes
drawing a base film into a cavity of a mold, drawing air through
openings in the base film, metering an amount of a first product of
a first color onto the base film in the cavity, metering an amount
of a second product of a second color onto the amount of the first
product, and, sealing a lid film to the base film.
Inventors: |
KEPINSKI; Andreas; (Mt.
Prospect, IL) ; MCLENITHAN; Thomas; (Mt. Prospect,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
RADIENZ LIVING CHICAGO, LLC |
Mt. Prospect |
IL |
US |
|
|
Assignee: |
RADIENZ LIVING CHICAGO, LLC
Mt. Prospect
IL
|
Family ID: |
1000005698787 |
Appl. No.: |
17/368655 |
Filed: |
July 6, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16397300 |
Apr 29, 2019 |
11077974 |
|
|
17368655 |
|
|
|
|
14921766 |
Oct 23, 2015 |
10273027 |
|
|
16397300 |
|
|
|
|
62068348 |
Oct 24, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 57/02 20130101;
B65B 61/02 20130101; B65B 2009/047 20130101; B65B 47/10 20130101;
B29L 2031/712 20130101; B65B 1/02 20130101; B29K 2995/0062
20130101; B29K 2029/04 20130101; B29K 2105/256 20130101; B65B
37/005 20130101; B65B 9/042 20130101; B65B 55/24 20130101 |
International
Class: |
B65B 47/10 20060101
B65B047/10; B65B 37/00 20060101 B65B037/00; B65B 55/24 20060101
B65B055/24; B65B 57/02 20060101 B65B057/02; B65B 61/02 20060101
B65B061/02; B65B 1/02 20060101 B65B001/02; B65B 9/04 20060101
B65B009/04 |
Claims
1. A system to form dual layer water soluble packets, the system
comprising a plurality of cavities operatively engaged to a motor
for moving the cavities, wherein each of the cavities includes a
vacuum opening that is in fluidic communication with a vacuum
passage; a base film supply roll configured to supply a base film
to cover the plurality of cavities; a laser configured to form
openings in the base film; a vacuum source configured to draws a
vacuum through the vacuum passage and draw air through the
openings; at least one product feeder configured to meter an amount
of a product into the plurality of cavities over the base film; and
a lid film supply roll configured to supply a lid film to the
cavities.
2. The system of claim 1 comprising a drum, a belt, a flat-bed, or
platens that move the cavities.
3. The system of claim 1 wherein the laser forms the openings when
the base film is over or drawn into the plurality of cavities.
4. The system of claim 3 wherein the laser forms the openings
before the product is added to the base film.
5. The system of claim 3 wherein the laser is focused toward
individual cavities of the plurality of cavities.
6. The system of claim 5 wherein air is drawn into the vacuum
passage through the vacuum opening in the bottom of each of the
individual cavities and the vacuum draws and stretches the base
film into the individual cavities.
7. The system of claim 6 wherein the openings are formed by the
laser after the base film has been stretched into the cavities by
the vacuum.
8. The system of claim 6 wherein the base film forms a receptacle
shape in the individual cavities to receive the product and the
laser forms the openings in the base film before the product is
added to the base film positioned in the cavities.
9. The system of claim 3 wherein the openings have a size up to
approximately 1000 .mu.m.
10. The system of claim 3 wherein the openings are sized to allow
air to be pulled through the openings, but not allow powder to leak
out.
11. The system of claim 3 wherein the laser is a 30 watt laser.
12. The system of claim 3 further comprising a controller and an
encoder configured to register and send signals to the laser to
strike the base film when it is over or drawn into the plurality of
cavities.
13. The system of claim 12 wherein the laser is positioned
stationary with respect to the moving base film and the controller
times the laser to intermittently pulse the laser as the film moves
under the laser.
14. The system of claim 2 comprising a rotating drum that moves the
cavities.
15. The system of claim 2 comprising a horizontal form, fill and
seal machine that moves the cavities.
16. A method of forming dual layer water soluble packets,
comprising: drawing a base film into a cavity of a mold; forming
openings in the base film with a laser; drawing air through
openings in the base film; metering an amount of a product onto the
base film in the cavity; and sealing a lid film to the base
film.
17. The method of claim 16 further comprising drawing air into a
vacuum passage through a vacuum opening in the bottom of the cavity
and the vacuum draws and stretches the base film into the
cavity.
18. The method of claim 17 wherein the laser forms the openings
when the base film is over or drawn into cavity and before the
product is added to the base film.
19. A method of forming dual layer water soluble packets comprising
drawing a base film into a cavity of a packet forming assembly;
forming one or more openings in the base film with a laser;
vacuuming air through the openings in the base film; metering an
amount of a product onto an upper side of the base film in the
cavity while applying a vacuum to a lower side of the base
film.
20. The method according to claim 19 further comprising increasing
a density of the product by the vacuuming.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/397,300 filed Apr. 29, 2019, which is a
continuation of U.S. patent application Ser. No. 14/921,766 filed
Oct. 23, 2015, now U.S. Pat. No. 10,273,027, which claims the
benefit of U.S. Provisional Patent Application 62/068,348 filed
Oct. 24, 2014, all of which are hereby incorporated by
reference.
FIELD OF INVENTION
[0002] The present invention relates to systems and methods for
forming dual layer water soluble packets.
BACKGROUND OF INVENTION
[0003] Water soluble packets, also commonly referred to as pouches
or sachets, provide a single dose of a product in one convenient
unit. The water soluble packets include a water soluble film sealed
around a pre-measured amount of the product. During exposure or
contact with water, the film dissolves and the product mixes with
the water. The water soluble packets provide many benefits to the
consumer. The water soluble packets are pre-measured, and thus
avoid any measuring by the consumer. The product is contained by
the film, and is not prone to spilling.
[0004] The water soluble packets are commonly used with dishwasher
and laundry detergents. During a wash cycle, the water soluble film
dissolves when exposed to the wash water allowing the detergent to
mix with the wash liquid. The water soluble packets may also be
used in any of a variety of different applications and contain any
of a variety of different products. For example, herbicides,
fertilizers, lawn chemicals, rinse-aids, cleaners, etc. may all be
sealed within the water soluble packets.
[0005] Conventional water soluble packets are formed by using
machines, such as drums, flat-bed platen, or other endless or
non-endless belt systems, having rows of cavities on its exterior
surface. A base or bottom layer of film, such as a polyvinyl
alcohol (PVA) film, is applied over the cavities. The base layer of
film forms receptacles in the cavities to receive the product. A
specified amount of the product is next metered onto the base layer
of film. A lid or an upper layer of film, such as additional PVA
film, is then sealed over the base layer of the film. The product
is now sealed inside of a combination of the base layer and the lid
layer of films. Rows and rows of water soluble packets are formed
as part of a continuous process. Individual water soluble packets
are cut from the rows of water soluble packets. Such processes and
equipment are described in U.S. Pat. No. 3,218,776, which is hereby
incorporated by reference.
SUMMARY OF INVENTION
[0006] Systems and methods for forming dual layer water soluble
packets are herein described. Layers of film contain several layers
of powder to form the packets. The several layers of powder form
the dual layer of powder in the packets. Packet forming assemblies
and methods are described for producing the dual layer water
soluble packets from multiple cavities. The packet forming
assemblies include drums, flat-bed platen, and/or other endless or
non-endless belt systems that include the multiple cavities that
form the packets.
[0007] The systems and methods form openings in a base layer of the
film. A vacuum draws ambient air through the openings, while the
layers of powder are deposited onto the base layer of film. The
vacuum generally holds the powder in position. The layers of powder
of different colors are deposited onto the base layer of the film
and/or on top of previously deposited layers of powder. By
depositing the powder while the vacuum is applying the vacuum
through the openings, denser and more compacted layers of the
powders are formed. The packets formed by the systems and methods
herein have a distinct boundary between the layers of powder and
exhibit a firmer and harder feeling. The water soluble packets
formed herein are not generally pliable and do not exhibit a loose
feel common to conventional water soluble packets. The packets
formed by the systems and methods herein exhibit improved cosmetic
properties, which may be attractive to consumers. The different
layers of powder are less likely to blend or mix together. This
provides the packet with the distinctive boundary between the
different colored powders, which is less prone to blending.
[0008] The openings are formed in the base layer of the film. The
vacuum force is applied simultaneously with the depositing of the
different layers of powder. Typically, a first color of powder is
deposited onto the base layer of film under vacuum. Next, a second
color of the powder is deposited over the first color of powder
under vacuum. The vacuum pulls air through the layers of powder
compressing them.
[0009] The openings may be formed using a variety of different
techniques. For example, a laser may forms the openings in the base
layer of film. The laser burns or cuts the openings into the base
layer of the water soluble film that forms the water soluble
packet. For example, a water mist may be applied to the base layer.
The water mist dissolves portions of the base layer to form the
openings. For example, a mechanical roller with piercing members,
such as pins, or other mechanical piercing apparatus may form the
openings in the base layer.
[0010] The openings may include holes, perforations, voids, vents,
etc. in the film. The openings permit air to be drawn by the vacuum
through the base layer of film and through the layers of product.
The water soluble packets are packed more tightly with the
product.
[0011] The use of the laser provides several advantages. The laser
openings do not discolor the entire film of the water soluble
packet. Second, the laser openings do not make the water soluble
packets sticky, which can be a problem associated with the use of
the water mist.
[0012] During the manufacturing process, the product is filled into
cavities of a packet forming assembly, which are lined with a base
layer of the film. After the filling, a lid layer of film is sealed
to the base layer over the product.
[0013] The laser may be configured to form the openings at any of a
variety of stages during the industrial manufacture of the water
soluble packets. The laser may form the openings at a pre-fill
stage in the manufacturing process of the water soluble packets. In
a first pre-fill process, the laser forms the openings after the
base film is positioned over or drawn into the cavities of the
packet forming assembly and before adding the product to the
cavities. In a second pre-fill process, the laser forms the
openings before the base film is positioned over the cavities. For
example, the laser forms the openings in the base film as the base
film is unrolled.
[0014] The openings are formed as part of a continuous
manufacturing process, i.e., the openings are formed while the film
is moving. Typically, the films or water soluble packets are not
intermittently stopped in order to form the openings with the
laser. As such, the methods and systems do not slow down production
rates of the water soluble packets. The systems and methods
described herein may be integrated into both rotary and horizontal
form fill machines.
[0015] In an aspect, a method of forming dual layer water soluble
packets is described. The method includes drawing a base film into
a cavity of a mold. The method includes drawing air through
openings in the base film. The method includes metering an amount
of a first product onto the base film in the cavity. The method
includes metering an amount of a second product of a second
material which may or may not be of a different color onto the
amount of the first product. The method includes sealing a lid film
to the base film.
[0016] In another aspect, a method of forming dual layer water
soluble packets is described. The method includes drawing a base
film into a cavity of a packet forming assembly. The method
includes forming one or more openings in the base film with a
laser. The method includes vacuuming air through the openings in
the base film. The method includes metering an amount of a first
product onto an upper side of the base film in the cavity while
applying a vacuum to a lower side of the base film. The method
includes metering an amount of a second product onto the amount of
the first product while applying the vacuum to the lower side of
the base film.
[0017] In another aspect, a method of forming dual layer water
soluble packets is described. The method includes forming openings
in the base film. The method includes drawing the base film into a
cavity of a mold. The method includes depositing an amount of a
first product of a first color onto a first side of the base film
in the cavity while applying a suction force to a second side of
the base film. The method includes depositing an amount of a second
product of a second color onto the amount of the first product
while applying the suction force to the second side of the base
film. The method includes sealing a lid film to the base film.
[0018] In another aspect, a system to form dual layer water soluble
packets is described. The system includes a rotating drum
operatively engaged to a motor for rotating the drum. The drum
includes one or more of cavities. A base film supply roll supplies
a base film to the drum to cover the one or more cavities. A laser
forms openings in the base film. A vacuum draws air through the
openings. A first feed hopper supplies a first conveyor with a
first product. The first conveyor meters an amount of the first
product into the one or more cavities over the base film. A second
feed hopper supplies a second conveyor with a second product. The
second conveyor meters an amount of the second product into the one
or more cavities over the amount of the first product. A lid film
supply roll supplies a lid film to the cavities.
[0019] In another aspect, a system to form dual layer water soluble
packets is described. The system includes a rotating drum
operatively engaged to a motor for rotating the drum. The drum
includes one or more cavities. A base film supply roll supplies a
base film to the drum to cover the one or more cavities. A
mechanical piercing member forms openings in the base layer. A
vacuum draws air through the openings. A first feed hopper supplies
a first conveyor with a first product. The first conveyor meters an
amount of the first product into the one or more cavities over the
base film. A second feed hopper supplies a second conveyor with a
second product. The second conveyor meters an amount of the second
product into the one or more cavities over the amount of the first
product. A lid film supply roll supplies a lid film to the
cavities.
[0020] In another aspect, a system to form dual layer water soluble
packets is described. The system includes a rotating drum
operatively engaged to a motor for rotating the drum. The drum
includes one or more cavities. The cavities are in an exterior
surface of the rotating drum. A base film supply roll supplies a
base film to the drum to cover the one or more cavities. A water
sprayer dissolves openings in the base film. A vacuum to draws air
through the openings. A first feed hopper supplies a first conveyor
with a first product. The first conveyor meters an amount of the
first product into the one or more cavities over the base film. A
second feed hopper supplies a second conveyor with a second
product. The second conveyor meters an amount of the second product
into the one or more cavities over the amount of the first product.
A lid film supply roll supplies a lid film to the cavities.
[0021] In another aspect, a system to form dual layer water soluble
packets is described. The system includes a plurality of cavities
operatively engaged to a motor for moving the cavities. A base film
supply roll supplies a base film to cover the plurality of more
cavities. The system includes a water sprayer, a laser or
mechanical piercing member to form openings in the base film. A
vacuum draws air through the openings. A first product feeder
meters an amount of a first product into the plurality of cavities
over the base film. A second product feeder meters an amount of a
second product into the plurality over the amount of the first
product. A lid film supply roll supplies a lid film to the
plurality of cavities. The first feeder and the second feeder may
include an auger feed system that directs product into the
cavities. The first feeder and the second feeder may also include
multiple hoppers supplying multiple conveyor belts that deposit the
product into the cavities. The system may include a drum, a belt, a
flat-bed, or platens that move the cavities.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 is a schematic view of the system to form the dual
layer water soluble packets using the laser.
[0023] FIG. 2 is a schematic view of the system to form the dual
layer water soluble packets using the sprayer.
[0024] FIG. 3 is a schematic view of the system to form the dual
layer water soluble packets using the piercing member.
[0025] FIG. 4 is a perspective view of the system to form dual
layer water soluble packets.
[0026] FIG. 5 is a perspective view of the system to form the dual
layer water soluble packets with the laser forming openings in the
base layer of film in the cavities.
[0027] FIG. 6 is a perspective view of the system to form dual
layer water soluble packets with the laser forming openings in the
base layer of film coming off of the supply roll.
[0028] FIG. 7 is a perspective view of the system to form the dual
layer water soluble packets using the sprayer to form the
openings.
[0029] FIG. 8A is a perspective view of the dual layer packet.
[0030] FIG. 8B is a side view of the dual layer packet.
[0031] FIG. 9 is a view of the cavities and the vacuum openings in
the cavities.
[0032] FIG. 10 is a perspective view of the horizontal form fill
seal machine incorporating the laser.
[0033] FIG. 11 is a perspective view of the auger fill
assembly.
[0034] FIG. 12 is a view of the auger fill assembly over the
plurality of cavities.
[0035] FIG. 13 is a perspective view of the auger fill assembly
over the drum system.
[0036] FIG. 14 is a perspective view of the auger fill assembly
over the horizontal form fill seal machine.
DETAILED DESCRIPTION OF INVENTION
[0037] FIG. 1 is a schematic view of a dual layer water soluble
packet forming system 10, which is used to form dual layer water
soluble packets 50. An example of the dual water soluble packet 50
is shown in FIGS. 8A and 8B. The system 10 forms openings 90 in a
base film 200 and/or a base layer 70 of the water soluble packets
50. As described below, the base layer 70 is formed from the base
film 200.
[0038] In FIGS. 1, 5, and 6, the openings 90 are formed by a laser
410a or a laser 410b. The laser 410a/410b may be positioned at any
of a number of different alternate positions about the system 10.
For example, the laser 410a forms the openings 90 after the base
film 200 is over a drum 110. For example, the laser 410b forms the
openings 90 in the base film 200 before the base film 200 reaches
the drum 110. Although the drum 110 is shown, the laser 410a/410b
may be incorporated into other packet forming assemblies that use
an endless belt, a flat-bed arrangement, or platens that move
cavities that form the packets.
[0039] In FIGS. 2 and 7, the openings 90 are formed by a sprayer
413, which sprays a water mist onto the base layer 70. The water
mist dissolves the base layer 70 to form the openings 90. The
sprayer 413 may include a spray bar with one or more nozzles. The
sprayer 413 may include any of a variety of nozzles, dispensers, or
misters that emit fluid. The sprayer 413 may also spray other
solvents or solutions that dissolve the openings 90 into the base
layer 70.
[0040] In FIG. 3, the openings 90 are formed by a mechanical
piercing member. For example, the mechanical piercing member may
include a roller 416 with a plurality of pins 418 that physically
poke the openings 90 into the base film 200.
[0041] The water soluble packets 50 include a first product 62 and
a second product 64 sealed between the base layer 70 and a lid
layer 80. The first product 62 and the second product 64 may
include cleaning agents of different colors. For example, the first
product 62 may have a whitish color and the second product 64 may
have a bluish color. Of course, any different or similar colored
cleaning agents may be used for the first product 62 and the second
product 64.
[0042] The base layer 70 is formed from the base film 200, while
the lid layer 80 is formed from a lid film 300. The openings 90
include holes, perforations, voids, vents, etc. in the base layer
70. As described below, the laser 410a/410b may direct its pulses
at the base film 200.
[0043] FIG. 4 is a perspective view of a packet forming assembly
100, which includes a rotating drum 110 operatively engaged to a
motor 120 for rotation of the drum 110. The packet forming assembly
100 forms the water soluble packets 50. The drum 110 includes a
plurality of cavities 130. The packet forming assembly 100 may also
include flat-bed platen and/or other endless belt systems instead
of the drum 110. The flat-bed platen and/or other endless belt
systems also include a plurality of cavities 130 to form the water
soluble packets 50.
[0044] A bulk amount of the first product 62 is placed in a first
feed hopper 152, which is generally positioned above a first
conveyor 162. A bulk amount of the second product 64 is placed in a
second feed hopper 154, which is generally positioned above a
second conveyor 164. The first feed hopper 152 supplies the first
conveyor 162 with the first product 62. The first conveyor 162
deposits the first product 62 into the cavities 130 on top of the
base film 200. The second feed hopper 154 supplies the second
conveyor 164 with the second product 64. The second conveyor 164
deposits the second product 64 over the first product 62. The first
conveyor 162 and the second conveyor 164 are in a staggered
arrangement. For example, an end 163 of the first conveyor 162 may
be positioned, for example, at an approximately 1 o'clock position,
while an end 165 of the second conveyor 164 may be positioned, for
example, at an approximately 12 o'clock position with respect to
the drum 110. Wipers 168 are positioned between the conveyors 162
and 164 to remove and/or clear extra product from the drum 110 in
order improve sealing.
[0045] As the drum 110 rotates, the first conveyor 162 meters an
amount of the first product 62 into the cavities 130 on top of the
base film 200. As the drum 110 further rotates, the cavities 130
containing the first product 62 are positioned under the end 165 of
the second conveyor 164, which meters an amount of the second
product 64 into the cavities 130 on top of the first product 62. As
such, the second product 64 is layered over the first product 62.
The second product 64 may fully cover, partially cover, or
substantially cover the first product 62. Generally, the second
product 64 will be metered or deposited in an amount sufficient to
fully cover the first product 62, such that two distinct layers are
formed in the water soluble packets 50. Next, the lid film 300 is
sealed to the base film 200, and the water soluble packets 50 are
separated.
[0046] In greater detail, the base film 200 is directed to the drum
110 from the base film supply roll 220. A base film roller 230
presses the base film 200 against a surface 115 of the drum 110.
The base film 200 generally covers a plurality of the cavities 130.
Guide rollers 240 and 242 assist in directing and transferring the
base film 200 to the drum 110.
[0047] The lid film 300 is directed to the drum 110 from the lid
film supply roll 320. A lid film roller 330 presses the lid film
300 against the base film 200 to cover the first product 62 and the
second product 64 in base film 200 lining the cavities 130. A guide
roller 340 assists in directing and transferring the lid film 300
to the drum 110.
[0048] The drum 110 includes multiple rows 142 of the cavities 130.
Generally, the surface 115 of the drum 110 is covered with the
cavities 130. The laser 410a may simultaneously pulse groups 144 of
the cavities 130. The groups 144 may cover multiple rows 142 of the
cavities 130.
[0049] With reference to FIGS. 1-3, each of the cavities 130
includes a vacuum opening 133 that is in fluidic communication with
a vacuum passage 136. The packet forming assembly 100 draws a
vacuum through the vacuum passage 136 and the vacuum opening 133.
The packet forming assembly 100 draws a vacuum through the opening
133 and through the openings 90 of the base film 200. The vacuum
pulls and/or draws the first product 62 and the second product 64
against the base film 200. The vacuum pulls and/or draws air
through the openings 90, the first product 62, and/or the second
product 64.
[0050] With reference to FIG. 1, the packet forming assembly 100
includes a cutting assembly 180 to separate the water soluble
packets 50 from each other. The cutting assembly 180 may include a
vertical cutter 183 to make vertical separation cuts and a
horizontal cutter 186 to make horizontal separation cuts. After the
water soluble packets 50 are separated, the drum 110 drops the
water soluble packets 50 onto a take away conveyor 190.
[0051] With continued reference to FIG. 1, a laser assembly 400
includes the laser 410a and/or the laser 410b to form the openings
90 in the base film 200. The laser assembly 400 also includes a
controller 420 and an encoder 430. The controller 420 and the
encoder 430 register and time the pulses from the laser 410a/410b
to strike the base layer 70 or the base film 200 at the appropriate
interval and time.
[0052] The laser 410a/410b may be integrated with the packet
forming assembly 100 in any of a variety of configurations or
positions. The laser 410a may form the openings 90, as shown in
FIG. 5, after the base film 200 is over the cavities 130. The laser
410b, as shown in FIG. 6, may form the openings 90 in the base film
200 before base film 200 reaches the drum 110.
[0053] With reference to FIG. 5, the openings 90 are formed when
the base film 200 is over or drawn into the cavities 130. The
openings 90 are formed at a pre-fill stage. The laser 410a forms
the openings 90 in the base film 200, while the base film 200 is
positioned over the drum 110 or after the base film 200 has been
drawn into the cavities 130 by the vacuum. In this aspect, the
openings 90 are formed before the products 62 and 64 are added to
the base film 200. The laser 410a is positioned proximate to the
drum 110, and the laser 410a is focused toward the individual
cavities 130 of the drum 110. The drum 110 provides the vacuum
through the vacuum passage 136 that conforms the base film 200 to
the drum 110 and into the individual cavities 130. Air is drawn
into the vacuum passage 136 through the vacuum opening 133 in the
bottom of the cavity 130. The vacuum draws and stretches the base
film 200 into the individual cavities 130. The base film 200 forms
a receptacle shape in the individual cavities 130 to receive the
products 62 and 64. Before the products 62 and 64 are added to the
base film 200 positioned in the cavities 130, the laser 410a forms
the openings 90 in the base film 200. Notably, the openings 90 are
formed by the laser 410a after the base film 200 has been stretched
into the cavities 130 by the vacuum of the drum 110. The openings
90 are formed in the base film 200 after the base film 200 has been
stretched, so the openings 90 will generally maintain their
dimension as the base film 200 is not generally further stretched
during the formation of the water soluble packet 50.
[0054] In this aspect, the vacuum is also drawing air through the
openings 90 in the film, which sucks the products 62 and 64 against
the base film 200. The products 62 and 64 are deposited on the base
film 200 in the cavities 130 while the vacuum force is drawing the
base film 200 into the cavity 130 and air is passing through the
openings 90 and into the vacuum opening 133. This assists in
increasing the density of the products 62 and 64 within the packet
50. The products 62 and 64, in the water soluble packets 50, are
more tightly packed and less likely to mix as compared to
conventional packets. A boundary 63 is more defined between the
products 62 and 64. Without the openings 90 and the drawing of air
through the openings 90 by the vacuum, the water soluble packet 50
will have a softer feel and the products 62 and 64 will be more
loosely contained in the water soluble packet 50 and are more prone
to mix--resulting in a less distinct boundary between the different
colors.
[0055] With reference to FIGS. 8A and 8B, an example of the packet
50 is shown. The base layer 70 (formed from the base film 200)
includes the one or more openings 90. First, the product 62 was
metered onto an upper side 201 of the base film 200 while applying
a vacuum to a lower side 202 of the base film 200. The second
product 64 was metered onto the first product 62 while the vacuum
was applied to the lower side 202 of the base film 200. The
boundary 63 separates the products 62 and 64.
[0056] With reference to FIG. 6, the openings 90 in the base film
200 are formed before base film 200 reaches the drum 110. The
openings 90 are formed at the pre-fill stage. The laser 410b forms
openings 90 in the base film 200 that forms the packet 50. The
laser 410b is positioned to form openings 90 in the base film 200
before the base film 200 reaches the drum 110. The laser 410b is
positioned proximate to the base film supply roll 220. As the sheet
of the base film 200 is unrolled and directed to the drum 110, the
laser 410b may form the openings 90. One or more lasers 410b may be
configured to intermittently form openings 90 in the entire width
of the base film 200 used to cover the cavities 130. In this
aspect, the openings 90 are formed before the products 62 and 64
are added to the base film 200 and before the base film 200 and the
lid film 300 are sealed together. The openings 90 may be formed in
portions of the base film 200 which will become the sides or a
periphery of the finished water soluble packet 50. These areas of
the base film 200 are subjected to less stretching than the areas
of the base film 200 film which will become the central portions of
the water soluble packet 50. By forming the openings 90 at the
sides or periphery, the openings 90 are not generally stretched
during the filling process, and the openings 90 maintain their
desired shape.
[0057] The laser 410a/410b will now be described. The laser
410a/410b forms one or more openings 90 in the base film 200
forming the water soluble packet 50. In some aspects, the laser
410a/410b is programmed to form four openings 90 in each water
soluble packet 50. The openings 90 may have various sizes and
shapes. For example, the openings 90 may have a size up to
approximately 1000 um. The openings 90 should be sized to allow air
to be pulled through the openings 90, but not allow powder to leak
out.
[0058] The system 10, laser assembly 400, and/or the processes
described herein may be incorporated into water soluble packet
forming systems and equipment from Cloud Packaging Solutions of Des
Plaines, Ill. Such equipment is commercially available under the
tradename HYDRO-FORMA.
[0059] The laser 410a/410b may be configured to provide enough
power to generally only cut the openings 90 into the base film 200.
The pulses will not damage the cavities 130, belts, rollers, or
other components of the water soluble packet forming system 10.
Although the laser 410a/410b will not hurt a worker with
incidental, momentary exposure to the laser 410a/410b, the system
10 and its equipment may be provided with a protective shield
and/or barriers to prevent accidental exposure of workers to the
laser 410a/410b.
[0060] The laser assembly 400 also includes the controller 420 and
the encoder 430. Existing water soluble packet forming systems may
be retrofitted to include the laser assembly 400. The laser
410a/410b may be electronically linked to the controller 420, which
registers the pulses from the laser 410a/410b with the moving base
film 200. The encoder 430 may measure the speed of the take away
conveyor 190, the drum 120, or any of the films 200 and 300. The
encoder 430 is in electrical communication with the controller 420
to provide the controller 420 with data regarding the speed. The
laser 410a/410b may be positioned stationary with respect to the
moving films 200 or the drum 110. The controller 420 may time the
laser 410a/410b to intermittently pulse the laser 410a/410b as the
film 200 moves past a focus point of the laser 410b or the drum 110
rotates under the laser 410a. The controller 420 may be
electronically linked to sensors or additional encoders that
monitor the movement of the film or the belt carrying the water
soluble packets 50. The controller 420 times the pulses from the
laser 410a/410b to impact the base film 200 at the appropriate
interval.
[0061] Any of a variety of lasers may be used with the system 10
and the processes described herein. One suitable laser for the
laser 410a/410b is a commercially available laser as Model 3320
from Videojet Technologies, Inc. of Wood Dale, Ill. This laser is a
30 watt CO2 laser.
[0062] The laser 410a/410b and/or the controller 420 may be
programmed to modulate any of a number of parameters and attributes
of the laser pulses, for example, the timing of the laser pulses,
the frequency of the laser pulses, the shape of the laser pulse,
the pattern of the laser pulses, the area of coverage of the laser
pulses, etc. The laser 410a/410b and/or the controller 420 may
include user-input controls, such as a touch screen, keyboard,
etc.
[0063] The laser 410a/410b may simultaneously emit an array of
pulses that simultaneously forms multiple openings 90. For example,
the laser 410a may be configured to simultaneously form openings 90
in the base film 200 covering multiple rows 142 and groups 144 of
the cavities 130 of the drum 110. Likewise, the laser 410b may be
configured to simultaneously form openings 90 across a web of the
base film 200 in multiple columns and rows. For example, the laser
410b may be configured to simultaneously form openings 90 across a
portion of the base film 200 that is approximately 24 inches wide
by approximately 0.25 to 1 inches deep. For example, the laser 410b
may be configured to simultaneously form openings 90 in a base film
200 covering approximately 12 cavities 130 of the drum 110.
Further, multiple lasers 410 may be used together to fully cover a
width of the drum 110 or the film 200.
[0064] The lid film 300 and base film 200 may be a water soluble
film, such as a polyvinyl alcohol (PVA) film. The films dissolve
with contact of water or other fluids. The films may have a
thickness of approximately 1 millimeter to approximately 5
millimeter. Such films are commercially available from Monosol of
Merrillville, Ind. Other water soluble films for forming the water
soluble packets 50 may include any water-soluble, film-forming
polymer, copolymer, or mixtures of such polymers. The polymers may
include vinyl polymers, including homopolymers and copolymers,
having functionality rendering the polymers water-soluble, such as
hydroxyl and carboxyl groups. Typical water-soluble polymers
include at least one of polyvinyl alcohol, partially hydrolyzed
polyvinyl acetate, polyvinyl pyrrolidone, alkyl celluloses such as
methylcellulose, ethylcellulose, propylcellulose and derivatives
thereof, such as the ethers and esters of alkyl celluloses, and
acrylic polymers such as water-soluble polyacrylates,
polyacrylamides, and acrylic maleic anhydride copolymers. Suitable
water-soluble polymers further include copolymers of hydrolyzed
vinyl alcohol and a nonhydrolyzable anionic comonomer.
[0065] In FIGS. 2 and 7, the openings 90 are formed by the sprayer
413, which sprays the water mist onto the base layer 70. The water
mist dissolves the base layer 70 to form the openings 90. The
sprayer 413 may include a spray bar with one or more nozzles. The
nozzles may be spaced along a width of the spray bar. The sprayer
413 may include any of a variety of nozzles, dispensers, or misters
that emit fluid. The sprayer 413 is in fluidic communication with a
water supply, such as a tap or other reservoir. The sprayer 413 may
also spray other solvents or solutions that dissolve the openings
90 into the base layer 70. The controller 420 and the encoder 430
may be integrated with the sprayer 413. The controller 420 may be
programmed to direct the sprayer 413 to continually or
intermittently spray the fluid onto the base film 200.
[0066] In FIG. 3, the openings 90 are formed by the mechanical
piercing member 416. For example, the mechanical piercing member
may include the roller 416 with the plurality of pins 418 that
physically poke the openings 90 into the base film 200. The roller
416 may include the pins 418 spaced along a width of the roller 416
in order to perforate a width of the base film 200. The roller 416
may be positioned proximate to the base film supply roll 220 such
that the roller 416 forms the openings 90 while the base film 200
is still on the base film supply roll 220. The length of the pins
418 may be adjusted to control the depth of the perforating action
of the roller 416. The distance between the roller 416 and the base
film supply roll 220 may also be adjusted to control the depth of
the perforating action of the roller 416. In other aspects, the
roller 416 may be positioned between the base film supply roll 220
and the base film roller 230 to perforate the base film 200. The
controller 420 and the encoder 430 may be integrated with the
roller 416. The controller 420 may be programmed to continually or
intermittently operate the roller 416.
[0067] In other aspects, the mechanical piercing member may include
linear member, such as a plate or bar with a plurality pins. The
linear member may reciprocate back and forth from the base film
supply roll 220 or the base film 200 to poke the openings 90 into
the base film 200.
[0068] Although the methods, systems, and assemblies described
above are described with respect to laundry and dishwashing water
soluble packets, the methods, the system 10, and/or the laser
assembly 400 may be used to form water soluble packets 50
containing any of a variety of products, such as, for example,
powders, granules, or other solid compositions for any application,
such as, for example, herbicides, fertilizers, lawn chemicals,
rinse-aids, cleaners, etc.
[0069] In addition to the packet forming assembly 100, one or more
lasers, sprayers, or mechanical piercing members may also be used
with or integrated into horizontal form fill seal machines and/or
vertical form fill seal machines in order form openings to vent the
water soluble packets. Horizontal form fill seal machines and
vertical form fill seal machines are also used to make water
soluble packets. As with other aspects, the openings provide for
the compacting of the product in the water soluble packets.
[0070] FIG. 10 is a schematic view of a laser-assisted water
soluble packet forming system 500 using lasers 505a and 505b with a
horizontal form fill seal machine 510. Likewise, a sprayer or
mechanical piercing member may be incorporated into the system 500.
The system 500 includes an endless belt 515 operatively engaged to
a motor 517 for movement of the endless belt 515. The packet
forming assembly 500 forms the water soluble packets 50. The
endless belt 515 includes a plurality of cavities 525. A bulk
amount of the first product 62 is placed in a first feed hopper
552, which is generally positioned above a first conveyor 553. As
the endless belt 515 moves, the first conveyor 553 meters an amount
of the first product 62 into the cavities 525 on top of a base film
520. A second feed hopper 554 supplies a second conveyor 555 with
the second product 64. The second conveyor 555 meters an amount of
the second product 64 on top of the first product 62. Wipers 527
are positioned between the conveyors 553 and 555 to remove and/or
clear extra product from the belt 515 in order improve sealing. A
lid film 530 is sealed to the base film 520, and the water soluble
packets 50 are separated. The base film 520 is directed to the
endless belt 515 from a base film supply roll 560. A base film
roller 565 presses the base film 520 against the endless belt 515.
The lid film 530 is directed to the endless belt 515 from a lid
film supply roll 570. A lid film roller 575 presses the lid film
530 against the base film 520. The endless belt 515 includes
multiple rows of the cavities 525. Generally, a surface 518 of the
endless belt 515 is covered with the cavities 525. The cavities 525
include a vacuum opening 533 that is in fluidic communication with
a vacuum passage 536. The packet forming assembly 500 includes a
cutting assembly 580 to separate the water soluble packets 50 from
each other. The cutting assembly 580 may include a vertical cutter
583 to make vertical separation cuts and a horizontal cutter 586 to
make horizontal separation cuts. In other aspects, a punch press
may be used to separate the water soluble packets 50. After the
water soluble packets 50 are separated, the endless belt 515 drops
the water soluble packets 50 onto a take away conveyor 590.
[0071] The lasers 505a and 505b may be integrated with the packet
forming assembly 500 in any of a variety of configurations or
positions. Although FIG. 10 shows the use of multiple lasers, only
one of the lasers 505a and 505b needs to be employed. For example,
the laser 505a may form the openings 90 in the base film 520 before
the base film 520 reaches the endless belt 515. The laser 505b may
form the openings 90 when the base film 520 is over or drawn into
the cavities 525.
[0072] The system 500 may also include the controller 420 to
program and/or modulate any of a number of parameters and
attributes of the laser pulses. The system 500 may also include the
encoder 430 to register and time the pulses from the lasers 505a
and 505b to strike the films or packets at the appropriate interval
and time.
[0073] With reference to FIGS. 10 and 11, an auger fill assembly
600 is shown. As shown in FIG. 13, two auger fill assemblies 600
may be incorporated into the packet forming system 10. As shown in
FIG. 14, two auger fill assemblies 600 may be incorporated into the
packet forming system 500.
[0074] The auger fill assembly 600 includes an infeed opening 610
to load product. The infeed opening 610 leads to a hopper 620 that
holds the product. Independent servo motor 630 drives augers 635
inside of the assembly 600. The gearbox 645. A lower end of the
assembly 600 includes a plurality of funnels 650 that feed the
cavities 130. Generally, the assembly 600 includes a funnel 650 for
each cavity 130 in the row. For example, if the cavities 130 are
provided in rows of twelve, then the assembly 600 may include
twelve funnels 650 to fill the cavities 130. As shown in FIGS. 13
and 14, two similar auger fill assemblies 600 are incorporated into
each of the packet forming systems 10 and 500, with each auger fill
assembly 600 providing a different product.
* * * * *