Note: Descriptions are shown in the official language in which they were submitted.
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IMPROVEMENTS TO CONTINUOUS MOTION ROTATABLE
FORMING OF SOLUBLE POUCHES
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.
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.
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
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different products, and it is difficult to envisage how a folding mechanism
can allow a number of compartments greater than two.
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.
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.
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.
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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.
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.
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.
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.
It may be that a device is provided for perforating one or more of the base
webs.
It may be that the one or more base webs are perforated prior to forming
open compartments or pouches.
It may be that the one or more base webs are perforated while forming
open compartments or pouches.
It may be that the one or more base webs are perforated subsequent to
forming open compartments or pouches.
It may be that different levels of vacuum can be applied at different
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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.
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.
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.
It may be that the method uses a machine according to the preceding
aspect of the invention.
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.
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.
It may be that lidding webs of the pouches are only partially sealed or
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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.
5 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.
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.
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.
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.
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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.
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.
It may be that the pouches are only partially sealed or bonded together in
order to enhance dissolution.
It may be that a solid component is inserted between the two pouches prior
to the two pouches being sealed or bonded together.
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.
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
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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.
The thickness of each water-soluble substrate may vary according to:
1. The depth of forming of each base web and the volume of each
compartment
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
3. The desired dissolution time of each pouch
4. The quantity and/or pattern of solvent applied to each lidding web
prior to sealing of each compartment
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
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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.
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
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registration may be achieved by use of a separate servo drive on each
former, one being a master and one being a slave.
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.
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.
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
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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.
5
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
10 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.
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.
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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.
It may be that the two pouches are sealed or bonded together by means of
a partial perimetric seal.
It may be that the two pouches are sealed or bonded together by means of
a complete perimetric seal.
It may be that at least one of the compartments of the first or second
water-soluble pouch is perimetric.
It may be that the seal pressure exerted between the first and second
water-soluble pouches is adjustable.
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,
The invention will now be described in more detail by way of example
with reference to the accompanying drawings wherein:
Figure 1 shows a machine according to a first embodiment of the
invention;
Figure 2 shows a machine according to a second embodiment of the
invention;
Figure 3 shows a machine according to a third embodiment of the
invention;
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Figures 4a and 4b are plan and sectional views of a multi-compartment
pouch produced by the machines of Figures 1 to 3;
Figure 5 shows a machine for producing multi-compartment pouches
according to a fourth embodiment of the invention;
Figures 6a and 6b are plan and sectional views of a multi-compartment
pouch produced by the machine of Figure 5;
Figures 7a, 7b show plan and sectional views of an alternative multi-
compartment pouch according to the invention;
Figures 8a, 8b show plan and sectional views of an alternative multi-
compartment pouch according to the invention;
Figures 9a, 9b show plan and sectional views of an alternative multi-
compartment pouch according to the invention;
Figures 10a, 10b, 10c, 10d show plan, perspective and sectional views of
an alternative multi-compartment pouch according to the invention;
Figures 11a, lib show plan and sectional views of an alternative multi-
compartment pouch according to the invention;
Figures 12a, 12b show plan and sectional views of an alternative multi-
compartment pouch according to the invention;
Figures 13a, 13b show plan and sectional views of an alternative multi-
compartment pouch according to the invention;
Figures 14a, 14b, 14c show plan, perspective and sectional views of an
alternative multi-compartment pouch according to the invention;
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Figures 15a, 15b show plan and sectional views of an alternative multi-
compartment pouch according to the invention;
Figures 16a, 16b, 16c show plan, perspective and sectional views of an
alternative multi-compartment pouch according to the invention;
Figures 17a, 17b, 17c show an alternative method of wetting the lidding
webs;
Figures 18a, 18b show an alternative method of wetting the lidding webs;
Figures 19a, 19b show an alternative method of wetting the lidding webs;
and
Figures 20a and 20b shows a method of inserting a solid object between
the lidding webs and a pouch so formed.
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.
In the exemplary embodiment of Figure 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 la, 3a that is
circular, for example a continuously rotating drum containing
pockets lb, 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 W02011/061628 to which the reader is directed and only
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features necessary for an understanding of the present invention are
described in the following description.
As shown in Figure 1, a plurality of open compartments or pouches is
formed in the pockets or recesses lb in the circular forming surface la 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.
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
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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
5 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
10 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.
15 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.
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
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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.
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.
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:
= the size of the compartments
= the material contained within each compartment
= 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
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released its contents into an aqueous medium into which the multi-
compartment pouch is placed.
= the time to complete dissolution of each compartment.
In Figure 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 Figure 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 Figure 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.
In Figure 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.
In the exemplary embodiment of Figure 2, the same principle as described
above for Figure 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.
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In Figure 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 W02011/061628 to which the reader
is directed and only features necessary for an understanding of the present
invention are described in the following description.
As shown in Figure 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.
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
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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.
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
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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
5 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.
10 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
15 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
Figure 2 the circular forming surface 101a of the donating former 101 is
positioned above the horizontal forming surface 103a of the receiving
20 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.
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:
= the size of the compartments
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= the material contained within each compartment
= 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.
= the time to complete dissolution of each compartment.
In the exemplary embodiment of Figure 3, the same principle as described
above for Figures 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.
In Figure 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 W02011/061628 to which the reader is directed and
only features necessary for an understanding of the present invention are
described in the following description.
As shown in Figure 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
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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.
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
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may be wetted prior to being brought together to provide adhesion
between the combined webs of closed pouches.
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.
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
Figure 3 the horizontal forming surface 201a of the donating former 201 is
positioned above the horizontal forming surface 203a of the receiving
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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.
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:
= the size of the compartments
= the material contained within each compartment
= 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.
= the time to complete dissolution of each compartment.
In an exemplary embodiment, the sealing pressure exerted by the
formers 1, 3 (Figure 1) or 101, 103 (Figure 2) or 201, 203 (Figure 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
The machine preferably has a main frame to which the both formers 1, 3
(Figure 1) or 101, 103 (Figure 2) or 201, 203 (Figure 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
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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.
5 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
10 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
15 above mentioned adjusters, for example micro screws.
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
20 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
25 skew angle of the drum to the chain can be micro-adjusted ¨ to
compensate for (or, in some cases, create) misalignment for appearance
effect.
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
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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.
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.
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.
An example of a multi-compartment pouch 151 formed by the machines
shown in Figures 1, 2 and 3 is shown in Figures 4a and 4b. The materials
contained within the compartments are not shown for convenience and
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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.
In Figure 5, a modification of the machine of Figure 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 Figure 2 are omitted or depicted diagrammatically.
As shown in Figure 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 Figure 2. The open pouches are filled via product feed 113
but, unlike the mode of operation described previously for Figure 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
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to separating the resulting multi-compartment pouches from the combined
webs as described previously for Figure 2. A similar modification may be
employed in the machine shown in Figure 3.
An example of a multi-compartment pouch formed by the machine shown
in Figure 5 is illustrated in Figures 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.
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 Figures 1, 2 and 3 and by the mode of operation of the
machine shown in Figure 5. The reconfiguration of the machine shown in
Figure 2 to provide the mode of operation shown in Figure 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 Figure 2
to a position downstream of the circular forming surface 101a in Figure 5.
Further examples of novel multi-compartment pouches that can be made
using the machine and the method described herein are shown in
Figures 7a, 7b through Figures 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
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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.
In Figures 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.
In Figures 8a, 8b, the construction of the first and second pouches are
similar to those illustrated in Figures 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 Figures 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.
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In Figures 9a, 9b, the construction of the combined pouch is similar to that
illustrated in Figures 7a, 7b but here the first and second pouches
comprise two compartments each, instead of the single compartments
shown in Figures 7a, 7b. The first pouch comprises compartments A
5 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
Figure 7a, 7b. It should be noted that in Figures 9a, 9b, compartments B
and D are perimetric compartments that surround the central
10 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.
In Figures 10a, 10b, 10c, 10d a modification of the pouch illustrated in
15 Figures 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
20 surround the central windows Wl, 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.
25 By the term perimetric compartment in Figures 9a, 9b and
Figures 10a, 10b, 10c, 10d we mean a compartment situated around the
perimeter of, and therefore surrounding, preferably without interruption, a
central compartment, shown in Figures 9b as compartments A and C or a
central window, shown in Figure 10b as windows W1 and W2. Perimetric
30 compartments could be described as annular were they to be circular
in
plan view. Note that the two pouches are again similar in profile
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providing a symmetrical appearance to the combined pouch comprising
five compartments in the case of the combined pouch shown in
Figures 9a, 9b and three compartments in the case of the combined pouch
shown in Figures 10a, 10b, 10c, 10d.
In Figures 11a, 11b, the construction of the combined pouch is similar to
that illustrated in Figures 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.
In Figures 12a, 12b, the construction of the first pouch (the upper pouch
as viewed in the drawing) is similar to that shown in Figure llb 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.
In Figures 13a, 13b, the construction of the first pouch (the upper pouch
as viewed in the drawing) is again similar to that shown in Figure llb
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
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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.
In Figures 7a, 7b through Figures 13a, 13b the first and second pouches
are generally circular or elliptical in plan view. This is not essential.
In Figures 14a, 14b, 14c the first and second pouches are similar to that
shown in Figures 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.
In Figures 15a, 15b the first and second pouches are similar to that shown
in Figures 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.
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.
In Figures 9a, 9b through Figures 15a, 15b, the perimetric compartments
comprise a single compartment that completely surrounds either a central
compartment or a window. This is not essential.
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In Figures 16a, 16b, 16c, the construction of the second pouch is similar to
that shown in Figures 8a, 8b but, in this example, the perimetric
compartment of the first pouch is divided into two semi-perimetric
compartments, B and D. In Figures 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.
Other configurations of perimetric compartments may be employed. For
example the single perimetric compartments shown in Figures 9a, 9b
through Figures 15a, 15b may be divided into two or more partly
perimetric compartments of the same or different shape.
The following table provides a summary of features of the pouches
described herein.
Number Number Component Symmetrical Perimetric Inserted
of WSP of between compartment Component
Webs Compart- Pouches
ments
Figs 4 2 No Yes No
4a, 4b
Figs 4 3 No No No
6a, 6b
Figs 4 3 Yes Yes No A solid object
7a, 7b such as a
tablet or a
water-soluble
pouch or
capsule made
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off line
Figs 4 2, each No Yes No
8a, 8b containing
two
component
Figs 4 5 Yes Yes Yes around A solid object
9a, 9b both pouches such as a
tablet or a
water-soluble
pouch or
capsule made
off line
Figs 4 3 Yes Yes Yes around A solid object
10a, both pouches such as a
10b, tablet or a
10c. water-soluble
10d pouch or
capsule made
off line
Figs 4 4 No Yes Yes around
1 1 a, both pouches
1 lb
Figs 4 3 No No Yes around
12a, first pouch
12b
Figs 4 3 No No Yes around
13a, first pouch
13b
Figs 4 3 No No Yes around
14a, first pouch
14b,
14c
Figs 4 4 No Yes Yes, around
15a, both pouches
15b
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Figs 4 4 No No Yes, around
16a, first pouch but
16b, divided into
16c two
compartments
Referring now to Figures 17a, 17b, 17c, Figures18a, 18b and
Figures 19a, 19b, different methods are illustrated of wetting the external
5 (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
10 obtain the desired adhesivity at the point where the webs are brought
together with the pouches in register.
In Figures 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
15 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
20 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
25 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
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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.
In Figures 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.
In Figures 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.
CA 02876991 2014-12-16
WO 2013/190517
PCT/1B2013/055114
37
Referring now to Figures 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 Figure 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 Figure 20b.
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.
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.
