[0001] This invention concerns improvements in or relating to water-soluble pouches. More
specifically, the invention concerns apparatus and methods for producing multi-compartment
water-soluble pouches from two or more soluble substrates on continuous motion rotatable
forming machines. The invention also concerns multi-compartment water-soluble pouches
made from two or more soluble substrates, and in particular, but not exclusively,
pouches made using the apparatus and methods of the present invention.
[0002] In our earlier applications
WO2011/061628 and
WO2013/190517, continuous motion rotatable formers and pouches made thereon have been described.
In
WO2011/061628, apparatus for making pouches from two water-soluble substrates was described wherein
a rotatable former is provided with cavities into which a base web is formed to create
open pockets in the base web. Once formed, the base web is tightly held by vacuum
within the cavity throughout the process of filling the pockets, sealing the pockets
with a top or lidding web to form pouches in the combined webs and separating the
pouches from the combined web by transverse and web direction knives. In
WO2013/190517, apparatus for making multi-compartment pouches from four water-soluble substrates
via two pouches was described wherein each pouch was made from two water-soluble substrates
on separate rotatable formers similar to the process described in
WO2011/061628 and the web of pouches on one former then joined to the web of pouches on the other
former produce combined pouches before separating the combined pouches from the combined
webs by transverse and web direction knives.
[0003] As described in the above earlier applications, after separating, many water-soluble
substrates, especially those based substantially upon polyvinyl alcohol, are subject
to what is known as shrink-back after forming but by holding the base web tightly
within the cavity throughout the filling, sealing and cutting operations, shrink-back
of the base web is prevented.
[0004] When the machines described in the above earlier applications are used for making
multi-compartment pouches from two water-soluble substrates, a particular difficulty
arises when the number of compartments to be filled is greater than two due to the
lack of space across the web in which to fit the necessary number of filling heads,
and to the lack of time during which to complete the filling operation if the machine
is to operate at its optimal manufacturing capacity. Lack of space across the web
dictates the use of point filling heads such as nozzle injectors for liquids and gels,
and augur fillers for powders and granules. However, even by means of point filling
heads, it can be difficult to accommodate sufficient filling heads across the web,
and particularly to fill powders and granules quickly enough.
[0005] JP-61-73642 discloses a pouch made from a single film wherein the film is folded in half and
sealed on three or four sides. The pouch has a single compartment and is filled from
the top side, opposite to the fold line.
[0006] US 2003 / 021839 A1 discloses a method of manufacturing a two-compartment capsule, each compartment holding
different material.
[0007] It is an object of the present invention to provide apparatus and methods for producing
multi-compartment water-soluble pouches from two or more soluble substrates on continuous
motion rotatable forming machines that address one or more of the aforementioned problems.
[0008] In one aspect, the present invention provides a multi-compartment pouch as defined
in claim 1. Optional features are the subject of claims 2 to 10. It may be that the
pouch comprises at least two compartments and wherein each compartment is formed between
the same two substrates. The compartments may contain different products selected
for example from liquids, gels, powders and granules. At least one compartment may
be empty, i.e.not filled.
[0009] It may be that the pouch comprises three or more compartments.
[0010] It may be that the compartments are disposed within the pouch such that they provide
resistance to planar distortion.
[0011] It may be that the compartments are disposed within the pouch such that any bending
axis arbitrarily laid across the pouch cuts through the body of at least one compartment.
[0012] It may be that the pouch contains a perimetric compartment.
[0013] It may be that the pouch contains a divided perimetric compartment.
[0014] It may be that at least one compartment is filled with a flowable composition, for
example a liquid or gel.
[0015] It may be that at least one compartment is filled with a solid composition, for example
a powder or granules.
[0016] It may be that at least one compartment is filled with more than one composition
wherein the compositions are mutually compatible and not antagonistic to each other.
[0017] It may be that the top lidding web has a thickness of between 50% and 75% of that
of the base web.
[0018] It may be that each compartment is filled to at least 90% of the available volume.
[0019] It may be that the compartments are formed sequentially in the base web and each
compartment is filled before a further compartment is formed and filled until all
compartments have been filled whereupon the compartments are closed by sealing with
a top or lidding web.
[0020] It may be that the pouch is sealed to a second closed multi-compartment pouch such
that the combined pouch comprises four water-soluble substrates.
[0021] It may be that the pouch is sealed to a second open multi-compartment pouch such
that the combined pouch comprises three water-soluble substrates.
[0022] It may be that at least two compartments are filled with a greater weight of a powder
or granular composition than the weight of any compartment filled with a liquid or
gel.
[0023] In another aspect, the present invention provides a method of making a multi-compartment
pouch as defined in claims 11. Optional featutres are the subject of claims 12 to
14.
[0024] It may be that each pocket of the multi-compartment pouch is filled with at least
one product.
[0025] It may be that the former is configured so that at least one open pocket of a pouch
is formed and filled before at least one other open pocket of the pouch is formed
and filled, and only once all open pockets have been filled is the pouch closed by
sealing with a lidding web.
[0026] It may be that a second pouch is affixed to the multi-compartment water-soluble pouch
to form a combined pouch.
[0027] It may be that each pouch comprises two water soluble substrates such that the combined
pouch comprises four water-soluble substrates. The second pouch may be a multi-compartment
pouch.
[0028] It may be that the top or lidding web of the multi-compartment water-soluble pouch
is provided by the second pouch such that the combined pouches comprises three water-soluble
substrates. The second pouch may be a multi-compartment pouch.
[0029] The foregoing is a summary and thus, by necessity, contains simplifications, generalizations,
and omissions of detail. Any or all of the features, limitations, configurations,
components, subcomponents, systems, and/or subsystems described above may be used
in combination. Consequently, those skilled in the art will appreciate that the summary
is illustrative only and is not intended to be in any way limiting. Other aspects,
inventive features, and advantages of the devices and/or processes described herein,
as defined by the claims, will become apparent in the detailed description set forth
herein and taken in conjunction with the accompanying drawings wherein:
Figure 1 shows plan and sectional views of a multi-compartment pouch made from two substrates
according to the present invention;
Figure 2 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 3 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 4 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 5 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 6 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 7 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 8 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 9 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 10 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 11 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 12 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 13 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 14 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 15 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 16 shows plan, sectional and perspective views of a multi-compartment pouch made from
two substrates according to the present invention;
Figure 17 shows plan, sectional and perspective views of of a multi-compartment pouch made
from two substrates according to the present invention;
Figure 18 shows reconfiguration of a formed pouch to a symmetrical configuration;
Figure 19 shows arrangements for filling a multi-compartment pouch comprising two compartments;
Figure 20 shows an arrangement for filling a multi-compartment pouch comprising three compartments;
Figure 21 shows arrangements of the filling heads for filling multi-compartment pouches;
Figure 22 shows an embodiment of a horizontal rotatable forming machine for producing pouches
from two substrates;
Figure 23 shows an embodiment of a horizontal rotatable former machine and a cylindrical rotatable
forming machine for producing pouches from four substrates;
Figure 24 shows an embodiment of a horizontal rotatable former machine and a cylindrical rotatable
forming machine for producing pouches from three substrates;
Figure 25 shows an embodiment of two horizontal rotatable forming machines for producing pouches
from four substrates;
Figure 26 shows an embodiment of two horizontal rotatable forming machines for producing pouches
from three substrates;
Figure 27 shows a pouch with three compartments;
Figures 28 and 29 show a method sequentially forming and filling the pouch of Figure 27
Figure 30 shows apparatus for forming sequentially forming the compartments of the pouch shown
in Figure 27;
Figure 31 shows another apparatus for forming sequentially forming the compartments of the
pouch shown in Figure 27;
Figure 32 shows a method of sequentially forming and filling a pouch with two compartments;
Figure 33 shows a method of sequentially forming and filling a pouch with three compatments;
Figure 34 shows a method of sequentially forming and filling a pouch with four compartments;
[0030] Various multi-compartment pouches 1 are shown in Figures 1 to 17 and summarised in
the following Table :
| Figure Number |
Configuration in Plan View |
Number of Compartments |
| 1 |
Circular or Elliptical with a complete perimetric compartment |
2 |
| 2 |
Circular or Elliptical with a divided perimetric compartment |
3 |
| 3 |
Triangular with rounded corners and a complete perimetric compartment |
2 |
| 4 |
Triangular with rounded corners and a divided perimetric compartment |
3 |
| 5 |
Square or Rectangular with a complete perimetric compartment |
2 |
| 6 |
Square or Rectangular with a divided perimetric compartment and a divided central
compartment |
4 |
| 7 |
Horseshoe |
2 |
| 8 |
Horseshoe with a divided external compartment |
3 |
| 9 |
Central Tee compartment |
3 |
| 10 |
Central H compartment |
3 |
| 11 |
Rectangular with a divided perimetric compartment |
3 |
| 12 |
Rectangular with a divided perimetric compartment |
3 |
| 13 |
L-shaped external compartment |
2 |
| 14 |
Wedge compartments |
2 |
| 15 |
Wedge compartments with a central compartment |
3 |
| 16 |
Shamrock compartments |
4 |
| 17 |
Clover Leaf compartments |
3 |
[0031] Each pouch 1 is formed from two water soluble substrates 2, 3 which may be referred
to as a base web 2 and a top or lidding web 3. Any suitable water soluble substrates
may be employed. Pouches 1 having two compartments 1a, 1b are shown in Figures 1,3,5,7,13,14.
Pouches 1 having three compartments 1a,1b,1c are shown in Figures 2,4,8,9,10,11,12,15,17.
Pouches having four compartments 1,1b,1c,1d are shown in Figures 6,16. Each pouch
1 is symmertical about a weld line 4 between the base web 2 and top lidding web 3.
Each compartment 1a,1b,1c,1d is fomed between the base web 2 and the top or lidding
web 3. The footprint 5 of the pouches 1 and the number, shape and arrangement of the
compartments 1a,1b,1c,1d is exemplary only and other configurations that may be employed
will be apparent to those skilled in the art. The term "footprint" is defined as the
plan view of the pouch 1 as seen from above the top or lidding web 3 of the pouch
1.
[0032] Water-soluble substrates are often by the very nature of the materials, lacking in
rigidity. As a result, when forming a water soluble pouch from two water soluble substrates,
the resulting pouch will itself have a tendency to lack rigidity or planar strength
which will give an unattractive floppy aspect to the pouch when handled by the consumer.
Such a lack of rigidity or planar strength is referred to herein as planar distortion.
Whilst the majority of water-soluble substrates capable of being formed, for example
thermoformed or vacuum formed, are at the present time, made substantially from polyvinyl
alcohol resins, other water-soluble substrates capable of being formed may be used
to practise the present invention.
[0033] Planar distortion of multi-compartment pouches may be overcome or significantly reduced
in this invention by one or more of the following factors:
- i) relative position and/or shape of the compartments 1a,1b,1c,1d within the footprint
5.
- ii) filling each compartment 1a,1b,1c,1d to a level of at least 80%, preferably at
least 90%, of the available volume,
- iii) selecting the relative thicknesses of the top lidding web 3 and the base web
2 in order to utilise the retraction or shrinkback of the base web 2 after the webs
have been sealed together and the pouch ejected from the forming machine or apparatus,
[0034] These factors and their impact on planar distortion of the resulting pouch 1 are
now discussed. It may be that these factors can be employed separately, or in combination
of any two, or preferably in a combination of all three. The invention extends to
and includes pouches 1 so formed. Aspects of the invention referred to herein may
include any of these factors and we do not intend the invention to be limited to those
aspects specifically mentioned.
POSITION AND/OR SHAPE OF COMPARTMENTS
[0035] Planar distortion may be reduced by employing a perimetric compartment as one of
the compartments. The term "perimetric" in this context describes a compartment which
is situated around the perimeter of the pouch. In its simplest form, the perimetric
compartment may be square or rectangular with rounded corners, allowing maximum use
of the area of the footprint, and hence providing maximum possible compartment fill
volumes. When viewed from above the top lidding web, such a square or rectangular
perimetric compartment may follow the cut edges of the pouch with its outer limit
set back from the cut edges of the pouch, for example at least 1.5mm from the cut
edges of the pouch. A square or rectangular perimetric compartment may be rejected
for marketing or other reasons in favour of other shapes, such as triangular with
rounded corners, or pentagonal with rounded corners, or circular or elliptical although
these shapes are by no means limiting. It will be apparent that departing from a square
or rectangular perimetric compartment can reduce the combined fill volume of the compartments
within the pouch and leave a larger flange around the perimetric or semi-perimetric
compartment.
[0036] The perimetric compartment may be divided into two or more separate compartments
in order to increase the number of compartments within a pouch of a given footprint.
However, by subdividing the perimetric compartment, there may be a loss of planar
stability. The invention overcomes this loss of planar stability by compartmental
design. As an example, if the perimetric compartment is divided into two semi-perimetric
compartments, the pouch may, unless corrective design features are introduced to prevent
it, flex about a line joining the seal areas between the semi-perimetric compartments.
A multi-compartment pouch which is able to flex will be less appealing to the consumer
than one which has planar stability.
[0037] One or more of the compartments within the multi-compartment pouch may be left unfilled
in order to provide additional resistance to planar distortion of the pouch.
COMPARTMENT FILL LEVELS
[0038] Planar distortion may be reduced by filling each compartment of the pouch to at least
80%, preferably at least 90%, of its available volume. Such a percentage fill of the
available volume of each compartment has been found to contribute to planar stability
of the pouch.
WEB THICKNESSES
[0039] The thickness of the top lidding web3 may be selected to be between 30% and 90%,
preferably between 50% and 75%, of that of the base web 2. By this means, when, after
the pouches 1 have been sealed and ejected from the machine, the base web 2 retracts
or shrinks back to reduce the internal volume of each compartment. The pressure so
generated within each compartment of the pouch 1 causes the thinner top lidding web
3 to distend, typically to a greater degree than the shrinkage of the base web 2,
thereby increasing the internal volume of each compartment of the pouch 1. This can
result in the formation of a substantially symmetrical pouch 1 about the weld line
5. This reconfiguration of pouches 1 ejected from cavities 6 of a rotable former 7
configured with a cylndrical surface is shown in Figure 18. The former may 7 may be
circular as shown in Figure 18 although this is not essential and other configurations
of former may be employed, for example a rotable former configured with a flat horizontal
surface.. Examples of cylindrical and horizontal formers that may be employed are
shown and described in
WO2011/061628 to which the reader is directed for further details.
[0040] Whilst the reduction in planar distortion provided by any single factor may not be
sufficient to assure planar rigidity of the pouch, when all three factors are combined,
there is an unexpected increase in planar rigidity which in turn provides a marketing
advantage to the multi-compartment pouch of the present invention.
[0041] Referring now to Figures 19 and 20, examples of filling multi-compartment pouches
1 according to the present invention are illustrated although these examples are by
no means limiting. The number of pouches 1 formed, filled and sealed across the web
of a machine is known as the number of tracks or lanes.
[0042] In Figure 19, filling of pouches 1 with two compartments 1a,1b similar to the pouch
shown in Figure 14 is illustrated. The rotatable former 7 of the pouch making machine
may be configured as shown and described in
WO2011/061628 with a cylindrical surface 7a or alternatively with a flat horizontal surface. The
compartments 1a,1b may be filled by heads 8a,8b. The heads 8a,8b may be point fillers.
The heads 8a,8b may be configured to add a liquid, gel, powder or granules, for example
nozzle injectors for liquids or gels or augur fillers for powders or granules. Heads
8a,8b may be connected to a feed for the same or different materials. The heads 8a,
8b may be arranged with a space offset in the direction of movement of the surface
7a and fire simultaneously (option A) or with no space offset and fire at slightly
different set points (option B). A similar arangmeent may be provided for each track
or lane across the web of the machine. Heads in different tracks or lanes may be connected
to the same or different supplies of material. This method is equally applicable where
the multi-compartment pouch comprises more than two compartments. Generally, a filling
head is provided for each compartment.
[0043] In Figure 20, filling of pouches 1 with three compartments 1a,1b,1c similar to the
pouch shown in Figure 15 is illustrated. The rotatable former 7 of the pouch making
machine may be configured as shown and described in
WO2011/061628 with a cylindrical surface 7a or alternatively with a flat horizontal surface. The
compartments 1a,1b,1c may be filled by heads 8a,8b,8c. The heads 8a,8b,8c may be point
fillers. The heads 8a,8b,8c may be configured to add a liquid or gel or a powder or
granules, for example nozzle injectors for liquids and gels or augur fillers for powders
and granules. In this embodiment, the heads 8a,8b are configured to add a liquid or
gel and head 8c is configured to add a powder or granules. Heads 8a,8b may be connected
to a feed for the same or different liquids or gels. A similar arrangement may be
provided for each track or lane across the web of the machine. Heads in different
tracks or lanes may be connected to the same or different supplies of material. Other
arrangements of heads 8a,8b,8c for delivering any combination of liquids, gels, powders
and granules are envisaged. This method is equally applicable where the multi-compartment
pouch comprises two or more compartments. Generally a filling head is provided for
each compartment.
[0044] Referring now to Figure 21, methods of arranging the heads are illustrated. The heads
may be arranged to create space for a plurality of heads within the confined space
available. In one arrangement, the heads may be inclined to each other. For example,
a head 8a for a liquid or gel and a head 8b for a powder or granules may be inclined
to each other. In another arrangement, a head 8b for a powder or granules may be provided
with a chute 9. The liquid or gel filling head 8a and chute 9 may be inclined to each
other. The heads 8a, 8b may be arranged to follow the cavity 6 of the former 7 as
it advances so that the time available for completion of the filling operation is
thereby increased and the product being filled is spread more evenly along the compartment
in the base web.
[0045] By use of the above filling arrangements and/or by the programming of the software
integrating the filling operation with the running speed of the machine, it may be
possible to fill the compartments of a multi-compartment pouch 1 during a time interval
of up to one second. In this way, the machine may be capable of providing an output
of approximately 60 pouches per minute for each track or lane of the machine. In the
case of granular or powder solid products, the filling equipment is typically a multi-head
auger filler and in the case of liquid products, the filling equipment is typically
cylinder operated nozzle injectors with a cut off such that no drips arrive on the
base web surrounding the cavities. Such contamination of the base web can subsequently
inhibit good sealing of the base web with the top or lidding web. Hitherto, the filling
operation has not allowed such filling speeds across so many tracks, preventing the
compartments of a multi-compartment pouch from being filled within such a short time
interval.
[0046] Embodiments of pouch forming machines are shown in Figures 22 to 26 wherein like
reference numerals are used to indicate the same or similar parts such that the operation
of the same or similar parts will be understood from a description of any emebodiment
without being repeated for other .embodiments.
[0047] An embodiment of a pouch forming machine 20 is shown in Figure 22 comprising a horizontal
rotatable former 21. The term horizontal rotatable former describes a machine wherein
part of the former 21 comprises a horizontal surface or section 21 a. The former 21
may comprise an endless belt (only part of the former is shown in Figure 22). The
machine is configured to form multi-compartment pouches from two water soluble substrates
by sequential forming and filling each compartment of the pouch. In this embodiment,
the former is provided with pouch forming cavities 23 configured to form pouches with
three compartments but it will be understood this is not limiting and the cavities
23 can be configured to form pouches having two or more compartments.
[0048] A base web 24 is unwound from an unwinding station 25 and a first open pocket or
container 26 is formed in the base web at 27 and filled at 28. A second open pocket
or container 29 is formed in the base web at 30 and filled at 31. A third open pocket
or container 32 is formed in the base web at 33 and filled at 34. A lidding web 35
is unwound from an unwinding station 36 and affixed to the base web at 37 thereby
sealing and closing all the open pockets or containers 26, 29, 32 in the base web
to form multi-compartment pouches 38 within the cavities 23. The combined base web
and lidding web is then moved to a cutting station 39 where the pouches 38 are separated
from the combined web. In this embodiment, the top or lidding web 35 is affixed to
the base web 24 by solvent welding by wetting the lidding web 35 at 40. Other methods
of affixing the top or lidding web may be employed such as heat sealing.
[0049] It is important to note that many possible designs of multi-compartment pouches having
at least two compartments may be produced employing the machine 20 by appropriate
design of the pouch forming cavities. For example, the machine 20 may produce any
of the pouches shown in Figures 1 to 17 although this is not limiting on the scope
of the invention. Each compartment may be sequentially formed and filled with different
compositions. Alternatively, where more than one compartment contains the same composition,
these compartment may be formed and filled simultaneously with at least one other
compartment being formed and filled sequentially.
[0050] Further embodiments of a pouch forming machine 20' are shown in Figures 23 and 24
comprising a combination of two rotatable formers wherein one rotatable former is
a horizontal rotatable former 21 similar to Figure 22 and the other rotatable former
is a cylindrical rotatable former 41. The term cylindrical rotatable former describes
a machine where the former 41 comprises a circular surface or section 41 a. The cylindrical
former 41 is positioned above the horizontal section 21a of the horizontal former
21. The former 41 is provided with pouch forming cavities 42 and may comprise a drum.
[0051] In Figure 23, multi-compartment water pouches 38 comprising a water-soluble base
web 24 and a water-soluble top or lidding web 35 are formed on the horizontal rotatable
former 21 as described previously and water-soluble pouches 38' comprising a water
soluble base web 24' and a water soluble top or lidding web 35' are formed on the
cylindrical former 41. The pouches 38,38' are brought together in register and combined
by joining the top or lidding webs 35,35'to each other at 44. The resulting combined
pouch is formed from four water soluble webs or substrates. In this embodiment, the
pouch 38' comprises a single compartment filled at 43. In other embodiments, the pouch
38' may comprise more than one compartment. The pouches 38,38' may comprise any of
the pouches shown in Figures 1 to 17 although this is not limiting on the scope of
the invention. In other embodiments, the pouch 38 may be a single compartment and
the pouch 38' may be multi-compartment.
[0052] In Figure 24, the top or lidding web 35 is omitted and the open pouches or containers
formed by the base web 24 on the former 21 are closed by the top or lidding web 35'
of the pouches 38' on the former 41. The resulting pouch is formed from three water
soluble webs or substrates
[0053] Further embodiments of a pouch forming machine 20" are shown in Figures 25 and 26
comprising a combination of two rotatable formers wherein both rotatable formers are
horizontal rotatable formers 21,21" similar to Figure 22 with a horizontal lower section
21b" of the former 21" positioned above the horizontal upper section 21a of the former
21.
[0054] In Figure 25, multi-compartment pouches 38 comprising a water-soluble base web 24
and a water-soluble top or lidding web 35 are formed on the horizontal rotatable former
21 as described previously and water-soluble pouches 38" comprising a water soluble
base web 24" and a water soluble top or lidding web 35" are formed on the horizontal
former 21". The pouches 38,38" are brought together in register and combined by joining
the top or lidding webs 35,35" to each other at 44. The resulting combined pouch is
formed from four water soluble webs or substrates. An additional cutting station 39"
may be provided in at least the transverse direction so that the closed pouches 38"
produced on the upper horizontal former 21", despite the vacuum holding them within
the cavities 23"of the former 21", are not dislodged as the former 21" passes over
the roller at 45..
[0055] In this embodiment, the pouch 38" is a multi-compartment pouch formed in similar
manner to the pouch 38. In other embodiments, the pouch 38" may comprise a single
compartment or any other design with two or more compartments. The pouches 38,38"
may comprise any of the pouches shown in Figures 1 to 17 although this is not limiting
on the scope of the invention.
[0056] In Figure 26, the top or lidding web 35 is omitted and the open pouches or containers
formed by the base web 24 on the former 21 are closed by the top or lidding web 35"
of the pouches 38" on the former 21". The resulting pouch is formed from three water
soluble webs or substrates
[0057] By way of non-limiting example, a multi-compartment water soluble pouch 60 with three
compartments 60a,60b,60c is shown in Figure 27. The method of sequentially forming
and filling the pouch 60 is illustrated in Figures 28 and 29.
[0058] Referring to Figures 28 and 29, a former 61 has a cavity 62 with three recessed areas
62a,62b,62c corresponding to the compartments 60a.60b,60c of the pouch 60. A base
web 63 is formed into area 62a to form an open pocket or container for compartment
60a. Compartment 60a is then filled for example with a powder or granules by a belt
feeder 64. The feeder 64 may have a scraper blade 66 to prevent overfilling of the
compartment 60a. Next, the base web 63 is formed into area 62b to form an open pocket
or container for compartment 60b. Compartment 60b is then filled for example with
a powder or granules by a belt feeder 64. Finally the base web 63 is formed into area
62c to form an open pocket or container for compartment 60c. Compartment 60c is then
filled for example with a liquid or gel by a nozzle feeder 65. The sequentially formed
and filled compartments 60a,60b,60c can then be closed and sealed by a top or lidding
web (not shown) by any of the methods and machines described previously.
[0059] By means of sequential forming and filling, it may be possible to form and fill open
pockets or containers in a base web to form compartments which, in plan view, "overlap"
each other in the direction of travel of the web. In this way, multi-compartment pouches
containing overlapping compartments can be made employing the sequential forming and
filling method described herein which could not be made by conventional methods employing
contemporaneous forming of the compartments followed by filling due to filling constraints.
The above method may be employed for any design of multi-compartment pouch.
[0060] Sequential forming of the base web 63 may be effected by different methods. One method
involves applying a vacuum to each recessed area 62a,62b,62c of the cavity 62 in turn.
Preferably the vacuum is maintained in each area in which the base web 63 is formed
and filled until the pouch 60 is ejected from the former 61. Sequential forming and
filling offers the advantage of greater space, longer filling times and therefore
ease of filling for powders or granules which do not flow freely from the filling
heads.
- The sequential vacuum supply to the cavities 62 may be provided in various ways. Generally
mechanical methods of vacuum control are preferred as being potentially more reliable
than, for example, an electrical method that would require spinning electrical connections.
Two methods of arranging the vacuum supply for sequential forming the base web 63
to form open pockets or containers corresponding to compartments 60a,60b,60c of the
pouch 60 are described below with reference to Figures 30 and 31, although other methods
will be envisaged by those skilled in the art.
[0061] In Figure 30, a vacuum shoe arrangement for sequential forming of base web 63 is
employed comprising three vacuum slots 66a,66b,66c wherein each slot 66a,66b,66c controls
the vacuum start and stop to each of the three recessed areas 62a,62b,62c respectively,.
The slots 66a,66b,66c are of different lengths and are configured so that stop point
is the same for all recessed areas 62a,62b,62c in order to release the pouch from
the cavity 62. The first slot 66a has the earliest start point, then the second slot
66b and lastly the third slot 66c. In this way the vacuum is applied first to the
area 62a through vacuum slot 66a so that the base web 63 can be drawn into the area
62a only to form an open pocket or container corresponding to compartment 60a which
can then be filled. Whilst the vacuum to the area 62a is maintained, the vacuum is
next applied to the area 62b through vacuum slot 66b so that the base web 63 can be
drawn into the second area 62b to form an open pocket or container corresponding to
compartment 60b which can then be filled. Whilst the vacuum to the areas 62a,62b is
maintained, the vacuum is applied to the area 62c through slot 66c so that the base
web 63 can be drawn into the area 62c to form an open pocket or container corresponding
to compartment 60c which can then be filled... When all the pockets or containers
have been formed and filled, a lidding web (not shown) can be affixed to the base
web 63 around the open pockets or containers to close and seal the compartments to
form the multi-compartment pouch 60. The pouch 60 can then be separated from the combined
web, the vacuum supply to all three recessed areas released and the pouch ejected
from the cavity 62 in the rotatable former either by falling under gravity or by ejection
with compressed air or a combination of both on to a suitable conveyor system.
[0062] In Figure 31, a vacuum valve arrangement for sequential forming of base web 63 is
employed comprising three vacuum valves 67a,67b,67c wherein each valve 67a,67,67c
controls the vacuum start and stop to each of the three recessed areas 62a,62b,62c
respectively. Each valve 67a,67b,67c is mechanically controlled by an actuator 68a,68b,69c
co-operable with a straight cam 69a,69b,69c arranged underneath the valve. The cams
69a,69b,69c are of different lengths and are configured so that the stop point is
the same for all recessed areas 62a,62b,62c in order to release the pouch from the
cavity 62. The first cam 69a is the longest, then the second cam 69b and the third
cam 69c is the shortest.. In this way vacuum valve 67a is actuated first to apply
vacuum to the area 62a so that the base web 63 can be drawn into the area 62a only
to form an open pocket or container corresponding to compartment 60a which can then
be filled. Whilst the vacuum to the area 62a is maintained, the vacuum valve 67b is
next actuated to apply vacuum to the area 62b so that the base web 63 can be drawn
into the second area 62b to form an open pocket or container corresponding to compartment
60b which can then be filled. Whilst the vacuum to the areas 62a,62b is maintained,
the vacuum valve 67c is actuated to apply vacuum to the area 62c so that the base
web 63 can be drawn into the area 62c to form an open pocket or container corresponding
to compartment 60c which can then be filled... When all the pockets or containers
have been formed and filled, a lidding web (not shown) can be affixed to the base
web 63 around the open pockets or containers to close and seal the compartments to
form the multi-compartment pouch 60. The pouch 60 can then be separated from the combined
web, the vacuum supply to all three recessed areas released and the pouch ejected
from the cavity 62 in the rotatable former either by falling under gravity or by ejection
with compressed air or a combination of both on to a suitable conveyor system.
[0063] In arrangement of Figure 31, a simple vacuum shoe or some kind of a vacuum manifold
for the initial vacuum connection to the valve block 70 is required. However, the
cams 69a,69b,69c can be configured to be adjustable to alter the vacuum start and/or
stop points to change the valve timing. For example the cams 69a,69b,69c may be made
of two pieces (dove tailed, for example) which allows for length adjustment. Such
adjustment may be effected remotely. This may allow easier adjustment of the valve
timing compared to the arrangement of Figure 30 where the vacuum shoe has to be removed
and either replaced by a vacuum shoe with different length slots or the slots cut
to change the length and the shoe refitted.
[0064] A further advantage of the arrangement of Figure 31 is that there is only one vacuum
line going to the valve block for the valves 67a,67b,67c for each of the recessed
areas 62a,62b,62c. In the arrangement of Figure 30, individual lines from the vacuum
shoe to each recessed area 62a,62b,62c are required.
[0065] In some embodiments the cavities 62 in the former may be heated by internal and/or
external heaters to assist forming the base web 63 into the cavities. In some embodiments
the base web 63 may pass over a heated roller prior to being drawn into the first
recessed area 62a. In some embodiments, the base web 63 may be heated prior to be
drawn into the second and/or third recessed areas to maintain flexibility of the web
and assist forming into the recessed areas. Such heating may be effected from above
for example by means of externally mounted hot air jets or externally mounted infra-red
heaters.
[0066] Figure 32 illustrates an example, which is by no means limiting, of a two compartment
pouch 70 that can be produced on a machine similar to Figure 22 wherein a first open
pocket or container 71 is formed in a base web and in this example filled using a
belt feeder 72 or similar type area filler and only once the first container 71 has
been filled, is a second open pocket or container 73 sequentially formed in the base
web and in this example, filled using a point feeder 74. The feeders 72,74 may be
replaced by any other feeders to suit the product added to the containers 71,73.
[0067] Figure 33 illustrates an example, which is by no means limiting, of a three compartment
pouch 80 that can be produced on a machine similar to Figure 22 wherein a first open
pocket or container 81 is formed in a base web and in this example filled using a
belt feeder 82 or similar type area filler and only once the first container 81 has
been filled is a second open pocket or container 83 sequentially formed in the base
web and in this example filled using a belt feeder 84 or similar type area filler
and only once the second container 83 has been filled, is a third container 85 sequentially
formed in the base web and in this example filled using a point feeder 86. The feeders
82,84,86 may be replaced by any other feeders to suit the product added to the containers
81,83,85. In a modification, containers 81 and 83 may be formed and filled simultaneously
and container 85 formed and filled sequentially.
[0068] Figure 34 illustrates an example, which is by no means limiting, of a four compartment
pouch 90 that can be produced on a machine similar to Figure 22 wherein a first container
91 is formed in a base web and in this example filled using a belt feeder 92 or similar
type area filler and only once the first container 91 has been filled, is a second
container 93 sequentially formed in the base web and in this example filled using
a belt feeder 94 or similar type area filler and only once the second container 93
has been filled are a third container 95 and a fourth container 96 formed simultaneously
in the base web and in this example, filled simultaneously using point feeders 97
and 98 respectively. The feeders 92,94,97,98 may be replaced by any other feeders
to suit the product added to the containers 91,93,95,96. In other arrangements, containers
91, 93, 95 and 96 may each be formed and filled sequentially. In other arrangements,
containers 91 and 93 may be formed and filled simultaneously and containers 95 and
96 may be formed and filled sequentially. Other combinations of simultaneous and sequential
forming and filling of the containers will be apparent to those skilled in the art.
[0069] Figure 35 illustrates examples, which are by no means limiting, of pouch designs
which may be produced by means of the present invention.
[0070] Figure 35(i) illustrates a two compartment pouch 100 where typically, although the
nature of each composition as described hereafter is by no means limiting, open pocket
or container 101 is formed first in a base web and filled with a powder or granular
composition by means of a belt feeder or similar type area feeder, and container 102
is formed second and filled with a liquid or gel composition filled by means of a
point feeder. The pouch 100 is then closed by means of a lidding web.
[0071] Figures 35(ii), 35(v), and 35(ix) illustrate different three compartment pouches
110 where typically, although the nature of each composition as described hereafter
is by no means limiting, an open pocket or container 111 is formed first in a base
web and filled with a powder or granular composition by means of a belt feeder or
similar type area feeder, open pocket or container 112 is formed second and filled
with a powder or granular composition by means of a belt feeder or similar type area
feeder, and container 113 is formed third and filled with a liquid or gel composition
filled by means of a point feeder. The pouch 110 is then closed by means of a lidding
web.
[0072] Figures 35(iii), 35(iv), 36(vi) and 35(vii) illustrate different four compartment
pouches 120 where typically, although the nature of each composition as hereafter
described is by no means limiting, an open pocket or container 121 is formed first
in a base web and filled with a powder or granular composition by means of a belt
feeder or similar type area feeder, container 122 is formed second and filled with
a powder or granular composition by means of a belt feeder or similar type area feeder,
containers 123 and 124 are formed and filled either sequentially or contemporaneously
with the same or different liquid or gel composition(s) filled by means of point feeders.
The pouch 120 is then closed by means of a lidding web.
[0073] Figure 35(viii) illustrates a six compartment pouch 130 where typically, although
the nature of each composition as hereafter described is by no means limiting, container
131 is formed first in a base web and filled with a powder or granular composition
by means of a belt feeder or similar type area feeder, container 132 is formed second
and filled with a powder or granular composition by means of a belt feeder or similar
type area feeder, and containers 133, 134, 135, and 136 are formed and filled either
sequentially or contemporaneously and filled with the same or different liquid or
gel composition(s) by means of point feeders. The pouch is then closed by means of
a lidding web.
[0074] For the two compartment pouch illustrated in Figure 35(i), the method of fill may
be as follows:
1. Vacuum is applied to form container 101 in the base web
2. Container 101 is filled by a belt feeder or similar type area filler
5. Whilst maintaining the vacuum to form container 101, vacuum is applied to form
container 102
6. Container 102 is filled with a point type filler, i.e auger or liquid nozzle.
[0075] For the remaining pouches illustrated in Figure 35 the method of fill may be the
same wherein:
- 1. Vacuum is applied to form container 111,121,131 only in the base web
- 2. Container 111,121,131 is filled by a belt feeder or similar type area filler
- 3. Whilst maintaining the vacuum to form container 111,121,131, vacuum is applied
to form container 112,122,132 in the base web
- 4. Container 112,122,132 is filled by similar means as container 111,121,131
- 5. Whilst maintaining the vacuum to form containers 111,112,121,122,131,12, vacuum
is applied to form containers 113,123,133 and above (134, 135, 136) in the base web
- 6. Containers 113,123,133 and above (134,135,136) are filled with a point type filler,
i.e auger, or liquid nozzle.
[0076] The construction and arrangement of the elements as shown in the exemplary embodiments
are illustrative only. Although only a few embodiments of the present disclosure have
been described in detail, those skilled in the art who review this disclosure will
readily appreciate that many modifications are possible (e.g., variations in sizes,
dimensions, structures, shapes and proportions of the various elements, values of
parameters, mounting arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the subject matter
recited. The elements and assemblies may be constructed from any of a wide variety
of materials that provide sufficient strength or durability, in any of a wide variety
of colors, textures, and combinations. Additionally, in the subject description, the
word "exemplary" is used to mean serving as an example, instance, or illustration.
Any embodiment or design described herein as "exemplary" is not necessarily to be
construed as preferred or advantageous over other embodiments or designs. Rather,
use of the word "exemplary" is intended to present concepts in a concrete manner.
Accordingly, all such modifications are intended to be included within the scope of
the present disclosure. Other substitutions, modifications, changes, and omissions
may be made in the design, operating conditions, and arrangement of the preferred
and other exemplary embodiments without departing from the scope of the appended claims.
[0077] For purposes of this disclosure, references to the orientation of the elements in
this description are merely used to identify the various elements as they are oriented
in the FIGURES. These terms are not meant to limit the element which they describe,
as the various elements may be oriented differently in various applications. Further,
the order or sequence of any process or method steps may be varied or re-sequenced
according to alternative embodiments. Any means-plus-function clause is intended to
cover the structures described herein as performing the recited function and not only
structural equivalents but also equivalent structures. Other substitutions, modifications,
changes and omissions may be made in the design, operating configuration, and arrangement
of the preferred and other exemplary embodiments without departing from the scope
of the appended claims. For example, the methods and apparatus described herein may
be adapted to produce multi-compartment pouches wherein all compartments of the pouch
are filled with a composition or wherein at least one compartment is filled and at
least one compartment is empty (i.e. not filled). All combinations of filled and empty
compartments may be produced by the method and apparatus described herein. Multi-compartment
pouches may have the compartments formed simultaneously or sequentially or a combination
of simultaneous and sequentially formed compartments may be produced by the method
and apparatus described herein.
1. Ein Mehrkammer-Beutel (1), der aus zwei wasserlöslichen Substraten (2,3) geformt ist,
wobei der Beutel im Wesentlichen symmetrisch zu einer Liniennaht (4) zwischen den
beiden Substraten ist, wobei eines der wasserlöslichen Substrate ein Top oder Lidding
Web (3) und das andere wasserlösliche Substrat ein Base Web (2) darstellt und das
Top oder Lidding Web dünner ist als das Base Web, und wobei das Top Lidding Web eine
Dicke von 30% bis 90% der Dicke des Base Web hat und wobei jede Kammer (1a;1b;1c;1d)
mit mindestens 80% des verfügbaren Volumens gefüllt ist.
2. Der Beutel gemäß Anspruch 1, wobei der Beutel mindestens zwei Kammern aufweist und
wobei jede Kammer zwischen denselben beiden Substraten geformt ist.
3. Der Beutel gemäß Anspruch 2, wobei die Kammern verschiedene Produkte enthalten.
4. Der Beutel eines der vorhergehenden Ansprüche, wobei der Beutel drei oder mehr Kammern
aufweist.
5. Der Beutel gemäß eines der Ansprüche 2 bis 4, wobei die Kammern so im Beutel angeordnet
sind, dass sie einen Widerstand gegen flächige Ausbeulung bieten und/oder so dass
jede Biegeachse, die beliebig über den Beutel gelegt wurde, durch den Hauptteil mindestens
einer Kammer schneidet.
6. Der Beutel gemäß eines der vorhergehenden Ansprüche, der eine perimetrische Kammer
und/oder eine geteilte perimetrische Kammer aufweist.
7. Der Beutel gemäß eines der vorhergehenden Ansprüche, wobei mindestens eine Kammer
mit einer fließfähigen Zusammensetzung oder einer festen Zusammensetzung oder mehr
als einer Zusammensetzung gefüllt ist, wobei die Zusammensetzungen kompatibel zueinander
und nicht entgegenwirkend zueinander sind.
8. Der Beutel gemäß eines der vorhergehenden Ansprüche, wobei das Top Lidding Web eine
Dicke zwischen 50% und 75% der Dicke des Base Web hat.
9. Der Beutel gemäß eines der vorhergehenden Ansprüche, wobei jede Kammer zu mindestens
90% des verfügbaren Volumens gefüllt ist.
10. Der Beutel gemäß eines der vorhergehenden Ansprüche, wobei der Beutel gegenüber einem
zweiten geschlossenen Mehrkammer-Beutel oder gegenüber einem zweiten offenen Mehrkammer-Beutel
versiegelt ist, um einen kombinierten Beutel zu bilden.
11. Ein Verfahren für die Herstellung eines Mehrkammer-Beutels aus zwei wasserlöslichen
Substraten, die aus einem Base Web (3) und einem Top Lidding Web (2) bestehen, das
Verfahren schließt dabei die Bereitstellung eines Formers (21; 41; 61) ein, mit einer
Vielzahl von Mehrkammer-Beutel formenden Vertiefungen (23; 42; 62) auf einer peripheren
Fläche des Formers, das Hineinziehen des Base Web in die Vertiefungen, um eine Vielzahl
von Taschen in jedem Beutel zu bilden, das Füllen einer oder mehrerer Taschen mit
mindestens einem Produkt, das Schließen der Taschen im Base Web mit dem Top Lidding
Web, um eine Vielzahl von versiegelten Mehrkammer-Beuteln (20; 38; 60) zu bilden,
und die Trennung der versiegelten Mehrkammer-Beutel vom kombinierten Base Web und
Top Lidding Web, wobei das Top Lidding Web dünner ist als das Base Web, so dass, wenn
sich das Base Web zusammenzieht oder schrumpft, sobald der Beutel den Former verlassen
hat, der dadurch im Beutel erzeugte Druck dazu führt, das Top Lidding Web in größeren
Maße aufzublähen als sich das Base Web zusammenzieht, wodurch sich das Innenvolumen
des Beutel ausreichend erhöht, um einen Mehrkammer-Beutel zu bilden, der im Wesentlichen
symmetrisch zur Liniennaht zwischen den beiden Substraten ist.
12. Das Verfahren gemäß Anspruch 11, wobei jede Tasche des Mehrkammer-Beutels mit mindestens
einem Produkt gefüllt ist.
13. Das Verfahren gemäß Anspruch 11 oder Anspruch 12, wobei der Former so gestaltet ist,
dass mindestens eine offene Tasche eines Beutels geformt und gefüllt wird bevor mindestens
eine andere offene Tasche des Beutels geformt und gefüllt wird, und erst wenn alle
offenen Taschen gefüllt sind, der Beutel durch Versiegelung mit einem Lidding Web
geschlossen wird.
14. Das Verfahren gemäß eines der Ansprüche 11 bis 13, wobei ein zweiter Beutel an dem
wasserlöslichen Mehrkammer-Beutel befestigt wird, um einen kombinierten Beutel zu
bilden.