CONSUMER PRODUCT

Abstract

 A consumer product including at least one water-soluble unit dose article, a first container, and a second container. The first container has a first container internal compartment in which the at least one water-soluble unit dose article is contained. The second container has a second container internal compartment in which the first container is contained.

Description

FIELD OF THE INVENTION

[0001] The invention is directed to a consumer product comprising a first container comprising at least one water-soluble unit dose article and a second container for containing the first container.

BACKGROUND OF THE INVENTION

[0002] Water-soluble unit dose articles are liked by consumers due to their convenience and ease of use. Without wishing to be bound by theory, water-soluble unit dose articles comprise a water-soluble film shaped to form at least one internal compartment which houses a single use dose of a detergent. Upon addition of the water-soluble unit dose article to water, the water-soluble film dissolves and/or disintegrates releasing the detergent into the surrounding water to produce a wash liquor.

[0003] Such water-soluble unit dose articles are stored and transported in rigid or flexible plastic containers. Without wishing to be bound by theory, consumers purchase containers comprising a plurality of water-soluble unit dose articles. The containers are shipped from the place of manufacture to supermarkets and once purchased are stored in consumers' homes.

[0004] An issue is during transport and storage the container comprising water-soluble unit dose articles can be subjected to extreme variations in temperature. Such environmental changes can as such result in structural failure of the water-soluble unit dose article. Structural failure can result in the unit dose article prematurely rupturing and leaking the internal contents (hereinafter "leakers"). Such leaked content can hence further contaminate other water-soluble unit dose article co-stored in the container. A further issue is that such environmental changes can also result in multiple water-soluble unit dose articles sticking together, causing inconvenience to the consumer having to re-separate them prior to dosing, and in a worse case even causing structural failure of the water-soluble unit dose article upon efforts to separate them. The container is generally made of plastic rigid material to prevent humidity in the environment from entering the container.

[0005] To address the above issue, the container is placed in a secondary package (carton box), to reduce the risk of leakers. However, when the container is removed from the secondary package and bought by the consumer for use at home, consumer habits of putting the product in hot/cold environments may cause leakers. Specifically, in use, humidity in the environment can still enter the container and therefore this can result in condensation of moisture in the container and the unit dose articles thereby causing the unit dose articles to stick together.

[0006] Therefore, there is a need for a container comprising a water-soluble unit dose article which prevents moisture from condensing within the container.

SUMMARY OF THE INVENTION

[0007] The present invention relates to a consumer product comprising at least one water-soluble unit dose article, a first container, and a second container;

wherein the at least one water-soluble unit dose article comprises at least one water-soluble film orientated to create at least one unit dose internal compartment, wherein the at least one unit dose internal compartment comprises a detergent composition; and

wherein the first container comprises a first container internal compartment in which the at least one water-soluble unit dose article is contained; wherein the first container comprises a first container interior surface and a first container exterior surface; wherein the first container interior surface faces the first container internal compartment; wherein at least part of the first container interior surface is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article directly contacts the paper-based material of said first container interior surface; and

wherein the second container comprises a second container internal compartment in which the first container is contained; wherein the second container comprises a second container interior surface and a second container exterior surface; wherein the second container interior surface faces the second container internal compartment and the first container exterior surface of the first container; wherein at least part of the second container interior surface is constructed from a plastic-based material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] 

FIG.1A is a perspective view of a consumer product according to the present invention;

FIG. 1B is a side view of the consumer product of FIG. 1A;

FIG. 2 is a schematic view of components of the consumer product of FIG. 1A;

FIG. 3 is a side cross section view of the consumer product of FIG. 1B taken at line A-A;

FIG. 4 is a perspective view of a first container according to the present invention;

FIG. 5 is a schematic side view of a second container according to the present invention; and

FIG. 6 is a planar view of a blank for making a first container according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0009] The present invention is to a consumer product comprising at least one water-soluble unit dose article, a first container and a second container. Specifically, the at least one water-soluble unit dose article comprises at least one water-soluble film orientated to create at least one unit dose internal compartment, wherein the at least one unit dose internal compartment comprises a detergent composition.

[0010] The first container comprises a first container internal compartment in which the at least one water-soluble unit dose article is contained. The first container further comprises a first container interior surface and a first container exterior surface. The first container interior surface and the first container exterior surface are arranged such that the first container interior surface faces the first container internal compartment. At least part of the first container interior surface is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article directly contacts the paper-based material of said first container interior surface.

[0011] The second container comprises a second container internal compartment in which the first container is contained. Specifically, the second container comprises a second container interior surface and a second container exterior surface; wherein the second container interior surface faces the second container internal compartment and the first container exterior surface of the first container; wherein at least part of the second container interior surface is constructed from a plastic-based material.

[0012] The consumer product can be sold ' as is', in other words the consumer product is the item that the consumer picks up from the shelf. Alternatively, the consumer product could be housed as one unit of a multi-component product. For example, more than one consumer product could be housed within an outer package and the multiple packaged consumer products sold together in a single purchase.

[0013] The consumer product may comprise aesthetic elements, for example shrink sleeves or labels attached to the second container. Alternatively, the first container and/or the second container may be coloured or printed with aesthetic elements or informative print such as usage instructions.

[0014] In the following description, the consumer product described is constructed as a reusable item so that it is replenished with unit-dose articles.

[0015] Specifically, the unit-dose articles are water-soluble unit dose articles, each of the water-soluble unit dose articles comprising a detergent composition that can be directly added into an automatic dishwashing machine or a washing machine, without the bother or mess of measuring and which can be dissolved in the water during a wash cycle. However, it is contemplated that the consumer product may be configured for use in a variety of applications to contain unit-dose articles containing substances whereby it is important to protect the substances herein from moisture to preserve an intended function or activity of the substances before use and the consumer product may include but is not limited to consumer products, such as, for example, laundry detergent products, automatic dishwasher detergent products.

[0016] Prior to describing the present invention in detail, the following terms are defined for clarity. Terms not defined should be given their ordinary meaning as understood by a skilled person in the relevant art.

[0017] "Paper-based material" as used herein, refers to a material comprising paper. The paper-based material may be a laminate comprising paper, cardboard, or a mixture thereof, wherein preferably, cardboard comprises paper-board, corrugated fibre-board, or a mixture thereof, and at least a second material.

[0018] "Paper" as used herein, refers to a material made from a cellulose-based pulp. Preferably, the paper-based material comprises paper, cardboard, or a mixture thereof, wherein preferably, cardboard comprises paper-board, corrugated fibre-board, or a mixture thereof.

[0019] "Plastic-based material" as used herein, refers to a material comprising plastic. Preferably, the plastic-based material comprises polyethylene, polyethylene terephthalate, polypropylene, polyvinylalcohol or a mixture thereof. The plastic-based material may be a biaxially orientated polypropylene, a metallised polyethylene terephthalate or a mixture thereof.

[0020] For the purposes of illustrating the present invention in detail, the invention is described below as a consumer product comprising laundry water-soluble unit dose articles, such as for example a laundry consumer product. However, the consumer product may be configured for use with other unit dose articles such as, for example, automatic dishwashing water-soluble unit dose articles.

[0021] FIG. 1A is a perspective view of a consumer product 1 according to the present invention and FIG. 1B is a side view of the consumer product 1. FIG. 2 is an exploded assembly view of components of the consumer product 1 of FIG. 1 and FIG. 3 is a side cross section view of the consumer product 1 of FIG. 1B taken at line A-A.

[0022] Referring to FIGS. 1A and 2, the consumer product 1 comprises a first container 10 containing at least one water-soluble unit dose article 11, a second container 12 containing the first container 10. Referring to FIG. 2, the second container 12 has a second container opening 13. The consumer product 1 may comprise a second container lid 2 for covering the second container opening 13. The second container lid 2 may be hinged to the second container 12 or may be completely separated from the second container 12.

[0023] Referring to FIG. 2, the second container 12 comprises a second container internal compartment 23 in which the first container 10 is attached. The first container 10 comprises a first container internal compartment 15 in which the at least one water-soluble unit dose article 11 can be contained. Preferably the first container internal compartment 15 may comprise at least two water-soluble unit dose articles 11. The first container internal compartment 15 may comprise water-soluble unit dose articles in a quantity from 1 to 80, from 1 to 60, from 1 to 50, from 1 to 40, from 1 to 30, from 1 to 20 or different combinations of any integers in the ranges listed above. The volume of the first container internal compartment 15 may be between 500ml and 5000ml, preferably between 800ml and 4000ml.

[0024] The first container internal compartment 15 is accessible through a first container opening 17. Those skilled in the art will be aware of a suitable size for the first container opening 17. Without wishing to be bound by theory, the first container opening 17 should be of sufficient size to retrieve at least a single water-soluble unit dose article at a time. Alternatively, the first container opening 17 may be shaped to allow the unit dose articles to be poured out from the first container 10. Therefore, it should be dimensioned to be big enough for at least a single unit dose article 11 to fit through the first container opening 17. Preferably, the first container opening 17 should be big enough for a user to fit their hand through to retrieve at least one water-soluble unit dose article 11.

[0025] The first container 10 may comprise a rim 26 around the periphery of the first container opening 17. The rim 26 may engage a supporting surface 27 on the second container 12 such that the first container 10 is connected to and supported by the second container 12. The rim 26 may engage the supporting surface in a mating relationship.

[0026] Referring to FIG. 3, the first container 10 further comprises a first container interior surface 20 and a first container exterior surface 21. The first container interior surface 20 faces the first container internal compartment 15 wherein at least part 22 of the first container interior surface 20 is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article 11 directly contacts the paper-based material of said first container interior surface 20. A technical effect of direct contact of the at least one unit dose article 11 with the paper-based material is that any moisture present on the at least one unit dose article 11 can be transferred to the paper-based material thereby minimizing sticking with adjacent unit dose articles 11, and consequently reducing damage to the film and minimizing leakers. Without being bound by theory, this minimizes condensation from forming in the first container 10, and thereby preventing the unit dose articles from sticking together (due to moisture) because paper-based material (used to make the first container 10) is porous and enables air ventilation (improved air flow) within the first container 10. As a result, air containing moisture enters and exits the carton cartridge interior freely through pores in the paper-based material. Having improved air flow in the first container internal compartment prevents moisture retention or concentration of moisture is very low in the first container internal compartment and as such, minimizes the unit dose articles from sticking together and leaking. The reduction in the number of leakers is shown in the Examples described hereinafter.

[0027] The second container 12 further comprises a second container interior surface 24 and a second container exterior surface 25. The second container interior surface 24 faces the second container internal compartment 23 and the first container exterior surface 21 of the first container 10. At least part 28 of the second container interior surface 24 is constructed from a plastic-based material. Specifically, the at least part 28 of the second container interior surface 24 may be in contact with the first container exterior surface 21.

[0028] There is a gap 30 between at least a part of the first container exterior surface 21 and the second container interior surface 24. Without wishing to be bound by theory, having the gap 30 between the first container exterior surface 21 and the second container interior surface 24 reduces temperature effects from the atmosphere on the unit dose articles 11 in the first container 10. Specifically, the gap 30 increases a time for heat to be transferred from the environment to the first container compartment and consequently the unit dose articles 11, thereby increasing a heat transfer time between the environment and the first container compartment. Consequently, by minimizing temperature effects by having the gap 30 and minimizing moisture within the first container internal compartment by having direct contact of the at least one unit dose article 11 with the paper-based material, the present invention achieves a reduced leakage in the unit dose articles as described hereinafter in the Examples.

PLASTIC-BASED MATERIAL

[0029] Further, for ease of manufacturability of the second container 12, the entire second container interior surface 24 may be constructed from a plastic-based material, preferably, the second container 12 consists essentially of a plastic-based material. The plastic-based material may comprise polyethylene, polyethylene terephthalate (PETG), polypropylene (PP), polyvinylalcohol or a mixture thereof. Preferably, the second container 12 may comprise a thickness of between 10 micron and 40 micron, more preferably between 10 micron and 35 micron.

[0030] Specifically, the second container 12 may comprise a plastic-based material that is rigid and durable. The plastic-based material may include but is not limited to PP, PETG and mixtures thereof. Preferably the plastic-based material for forming at least a part of the second container 12 may be partially transparent or transparent. The second container lid 2 may be formed of an opaque plastic-based material similar to the plastic-based material as the second container. Preferably the second container 12 and the second container lid 2 may be formed of PP.

PAPER BASED MATERIAL

[0031] The entire first container interior surface 20 of the first container 10 may be constructed from a paper-based material. For ease of manufacturability and recycling, the first container 10 may consists essentially of a paper-based material. The paper-based material may be paper carton, such as for example, 400g virgin white board, Kraft paper board, or mixtures thereof.

[0032] The paper-based material may be a laminate comprising paper, cardboard, or a mixture thereof, wherein preferably, cardboard comprises paper-board, corrugated fibre-board, or a mixture thereof, and at least a second material.

[0033] Wherein the paper-based material is a laminate, then the first container internal surface comprises paper, cardboard, or a mixture thereof, wherein preferably, cardboard comprises paper-board, corrugated fibre-board, or a mixture thereof, and preferably the first container external surface comprises the second material. Alternatively, the second material might also be laminated in-between two paper-based material layers.

[0034] FIG. 4 is a perspective view of a first container 40 according to the present invention. The first container 40 of FIG. 4 comprises substantially the same features as the first container 10 of FIG. 2 except that the first container 40 comprises a first container cover 41 on the top of the first container 10 for covering a first container opening. The first container cover 41 is configured for opening the first container 40 and may comprise two partial die cut or perforation lines 42a, 42b spaced apart to define a peel-away cover using techniques well known in the art. It will be appreciated that the arrangement of the peel-away cover is not limited to the configuration and design as shown in FIG. 4 but can be modified in any configuration according to the function of the first container cover.

[0035] The second container 12 may comprise at least one ventilation opening. A technical effect of having at least one ventilation opening is that moisture can exit the second container 12 quickly in an unintended event that moisture is generated in the second container 12 during thermal shock cycles (i.e. sudden change in temperatures). FIG. 5 is a schematic side view of a second container 50 according to the present invention. The second container 50 comprises substantially the same features as the second container 12 of FIG. 2 except that the second container 50 comprises a bottom wall 51 between a second container interior surface 54 and a second container exterior surface 55. At least one ventilation opening 52 is disposed in the bottom wall 51. A technical effect of positioning the at least one ventilation opening 52 in the bottom wall 51 for ease in manufacturing.

[0036] Alternatively, the second container comprises a side wall between the second container interior surface and the second container exterior surface, wherein the at least one ventilation opening is disposed in the side wall.

Water-soluble unit dose article

[0037] The at least one water-soluble unit dose article 11 comprises at least one water-soluble film orientated to create at least one unit dose internal compartment, wherein the at least one unit dose internal compartment comprises a detergent composition. The water-soluble film and the detergent composition are described in more detail below.

[0038] The consumer product 1 comprises at least one water-soluble unit dose article 11, preferably at least two water-soluble unit dose articles 11.

[0039] A water-soluble unit dose article 11 is generally in the form of a pouch. It comprises a unitary dose of a composition as a volume sufficient to provide a benefit in an end application.

[0040] The water-soluble unit dose article 11 comprises at least one water-soluble film shaped such that the unit-dose article 11 comprises at least one internal compartment surrounded by the water-soluble film. The at least one compartment comprises a cleaning composition. The water-soluble film is sealed such that the cleaning composition does not leak out of the compartment during storage. However, upon addition of the water-soluble unit dose article 11 to water, the water-soluble film dissolves and releases the contents of the internal compartment into the wash liquor.

[0041] The unit dose article 11 may comprise more than one compartment, even at least two compartments, or even at least three compartments, or even at least four compartments, or even at least five compartments. The compartments may be arranged in superposed orientation, i.e. one positioned on top of the other. Alternatively, the compartments may be positioned in a side-by-side orientation, i.e. one orientated next to the other. The compartments may even be orientated in a 'tyre and rim' arrangement, i.e. a first compartment is positioned next to a second compartment, but the first compartment at least partially surrounds the second compartment, but does not completely enclose the second compartment. Alternatively, one compartment may be completely enclosed within another compartment.

[0042] Wherein the unit dose article 11 comprises at least two compartments, one of the compartments may be smaller than the other compartment. Wherein the unit dose article 11 comprises at least three compartments, two of the compartments may be smaller than the third compartment, and preferably the smaller compartments are superposed on the larger compartment. The superposed compartments preferably are orientated side-by-side.

[0043] Each individual unit dose article 11 may have a weight of between 10g and 40g, or even between 15g and 35g.

[0044] The film of the present invention is soluble or dispersible in water. Prior to be being formed into a unit dose article 11, the water-soluble film preferably has a thickness of from 20 to 150 micron, preferably 35 to 125 micron, even more preferably 50 to 110 micron, most preferably about 76 micron.

[0045] Preferred film materials are preferably polymeric materials. The film material can, for example, be obtained by casting, blow-moulding, extrusion or blown extrusion of the polymeric material, as known in the art.

[0046] Preferably, the water-soluble film comprises polyvinyl alcohol polymer or copolymer, preferably a blend of polyvinylalcohol polymers and/or polyvinylalcohol copolymers, preferably selected from sulphonated and carboxylated anionic polyvinylalcohol copolymers especially carboxylated anionic polyvinylalcohol copolymers, most preferably a blend of a polyvinylalcohol homopolymer and a carboxylated anionic polyvinylalcohol copolymer.

[0047] Preferably, the water-soluble film comprises a polymer wherein the polymer comprises a homopolymer, copolymer, or mixture thereof selected from polyvinyl alcohols, polyvinyl pyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts, polyaminoacids or peptides, polyamides, polyacrylamide, copolymers of maleic/acrylic acids, polysaccharides including starch and gelatine, xanthum, carragum or a mixture thereof, preferably, polyvinylalcohol homopolymers and/or anionic polyvinylalcohol copolymers preferably selected from sulphonated and carboxylated anionic polyvinylalcohol copolymers especially carboxylated anionic polyvinylalcohol copolymers.

[0048] Preferred films are those supplied by Monosol under the trade references M8630, M8900, M8779, M8310.

[0049] The film may be opaque, transparent or translucent. The film may comprise a printed area.

[0050] The area of print may be achieved using standard techniques, such as flexographic printing or inkjet printing.

[0051] The film may comprise an aversive agent, for example a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octaacetate, quinine hydrochloride, denatonium benzoate, or mixtures thereof. Any suitable level of aversive agent may be used in the film. Suitable levels include, but are not limited to, 1 to 5000ppm, or even 100 to 2500ppm, or even 250 to 2000ppm.

[0052] The water-soluble film or water-soluble unit dose article or both may be coated with a lubricating agent. Preferably, the lubricating agent is selected from talc, zinc oxide, silicas, siloxanes, zeolites, silicic acid, alumina, sodium sulphate, potassium sulphate, calcium carbonate, magnesium carbonate, sodium citrate, sodium tripolyphosphate, potassium citrate, potassium tripolyphosphate, calcium stearate, zinc stearate, magnesium stearate, starch, modified starches, clay, kaolin, gypsum, cyclodextrins or mixtures thereof.

Detergent Composition

[0053] The detergent composition may be a laundry detergent composition, an automatic dishwashing composition, a hard surface cleaning composition, or a combination thereof. The detergent composition may comprise a solid, a liquid or a mixture thereof. The term liquid includes a gel, a solution, a dispersion, a paste, or a mixture thereof.

[0054] The solid may be a powder. By powder we herein mean the detergent composition may comprise solid particulates or may be a single homogenous solid. Preferably, the powder detergent composition comprises particles. This means the powder detergent composition comprises individual solid particles as opposed to the solid being a single homogenous solid. The particles may be free-flowing or may be compacted, preferably free-flowing.

[0055] Preferably, the detergent composition is a laundry detergent composition, most preferably a liquid laundry detergent composition.

[0056] The laundry detergent composition can be used in a fabric hand wash operation or may be used in an automatic machine fabric wash operation, preferably an automatic machine fabric wash operation.

[0057] The laundry detergent composition comprises a non-soap surfactant, wherein the non-soap surfactant comprises an anionic non-soap surfactant and a non-ionic surfactant. Preferably, the laundry detergent composition comprises between 10% and 60%, more preferably between 20% and 55% by weight of the laundry detergent composition of the non-soap surfactant.

[0058] The weight ratio of non-soap anionic surfactant to nonionic surfactant is from 1:1 to 20:1, preferably from 3:1 to 17.5:1, more preferably from 5:1 to 15:1, most preferably from 7.5:1 to 12.5:1.

[0059] The non-soap anionic surfactant comprises linear alkylbenzene sulphonate, alkyl sulphate or a mixture thereof. The weight ratio of linear alkylbenzene sulphonate to alkyl sulphate is from 1:2 to 9:1, preferably from 1:1 to 7:1, more preferably from 1.25:1 to 5:1, most preferably from 1.4:1 to 3:1.

[0060] Exemplary linear alkylbenzene sulphonates are C10-C16 alkyl benzene sulfonic acids, or C11-C14 alkyl benzene sulfonic acids. By 'linear', we herein mean the alkyl group is linear. Alkyl benzene sulfonates are well known in the art.

[0061] The alkyl sulphate anionic surfactant may comprise alkoxylated alkyl sulphate or non-alkoxylated alkyl sulphate or a mixture thereof. The alkoxylated alkyl sulphate anionic surfactant preferably is an ethoxylated alkyl sulphate anionic surfactant.

[0062] The alkyl sulphate anionic surfactant may comprise an ethoxylated alkyl sulphate anionic surfactant, preferably with a mol average degree of ethoxylation from 1 to 5, more preferably from 1 to 3, most preferably from 2 to 3.

[0063] The alkyl sulphate anionic surfactant may comprise a non-ethoxylated alkyl sulphate and an ethoxylated alkyl sulphate wherein the mol average degree of ethoxylation of the alkyl sulphate anionic surfactant is from 1 to 5, more preferably from 1 to 3, most preferably from 2 to 3.

[0064] The alkyl fraction of the alkyl sulphate anionic surfactant can preferably be derived from fatty alcohols, oxo-synthesized alcohols, guerbet alcohols, or mixtures thereof.

[0065] Preferably, the laundry detergent composition comprises between 10% and 50%, more preferably between 15% and 45%, even more preferably between 20% and 40%, most preferably between 30% and 40% by weight of the laundry detergent composition of the non-soap anionic surfactant.

[0066] Preferably, the non-ionic surfactant is selected from alcohol alkoxylate, an oxo-synthesised alcohol alkoxylate, Guerbet alcohol alkoxylates, alkyl phenol alcohol alkoxylates, or a mixture thereof.

[0067] The laundry detergent composition comprises between 0.01% and 10%, preferably between 0.01% and 8%, more preferably between 0.1% and 6%, most preferably between 0.15% and 5% by weight of the liquid laundry detergent composition of a non-ionic surfactant.

[0068] Preferably, the laundry detergent composition comprises between 1.5% and 20%, more preferably between 2% and 15%, even more preferably between 3% and 10%, most preferably between 4% and 8% by weight of the laundry detergent composition of soap, preferably a fatty acid salt, more preferably an amine neutralized fatty acid salt, wherein preferably the amine is an alkanolamine more preferably selected from monoethanolamine, diethanolamine, triethanolamine or a mixture thereof, more preferably monoethanolamine.

[0069] Preferably, the laundry detergent composition is a liquid laundry detergent composition, more preferably the liquid laundry detergent composition comprises less than 15%, more preferably less than 12% by weight of the liquid laundry detergent composition of water.

[0070] Preferably, the laundry detergent composition is a liquid laundry detergent composition comprising a non-aqueous solvent selected from 1,2-propanediol, dipropylene glycol, tripropyleneglycol, glycerol, sorbitol, polyethylene glycol or a mixture thereof. Preferably, the liquid laundry detergent composition comprises between 10% and 40%, preferably between 15% and 30% by weight of the liquid laundry detergent composition of the non-aqueous solvent.

[0071] Preferably the laundry detergent composition comprises a perfume.

[0072] Preferably, the laundry detergent composition comprises an adjunct ingredient selected from the group comprising builders including enzymes, citrate, bleach, bleach catalyst, dye, hueing dye, brightener, cleaning polymers including alkoxylated polyamines and polyethyleneimines, soil release polymer, surfactant, solvent, dye transfer inhibitors, chelant, encapsulated perfume, polycarboxylates, structurant, pH trimming agents, and mixtures thereof.

[0073] Preferably, the laundry detergent composition has a pH between 6 and 10, more preferably between 6.5 and 8.9, most preferably between 7 and 8, wherein the pH of the laundry detergent composition is measured as a 10% product concentration in demineralized water at 20°C.

[0074] When liquid, the laundry detergent composition may be Newtonian or non-Newtonian. Preferably, the liquid laundry detergent composition is non-Newtonian. Without wishing to be bound by theory, a non-Newtonian liquid has properties that differ from those of a Newtonian liquid, more specifically, the viscosity of non-Newtonian liquids is dependent on shear rate, while a Newtonian liquid has a constant viscosity independent of the applied shear rate. The decreased viscosity upon shear application for non-Newtonian liquids is thought to further facilitate liquid detergent dissolution. The liquid laundry detergent composition described herein can have any suitable viscosity depending on factors such as formulated ingredients and purpose of the composition.

[0075] Those skilled in the art will know how to formulate and make a suitable detergent composition using known knowledge and techniques.

Manufacture

[0076] Those skilled in the art will be aware of standard techniques and methods to make the consumer product according to the present invention. Those skilled in the art will be aware of methods to make the at least one water-soluble unit dose article 11.

[0077] A method of providing water-soluble unit dose articles in a container to form a consumer product according to the present invention may comprise the steps of:

(i) providing a first container comprising at least one water-soluble unit dose article;

(ii) providing a second container;

(iii) attaching the first container to the second container; and

(iv) covering the second container with a second container lid;

wherein the at least one water-soluble unit dose article comprises at least one water-soluble film orientated to create at least one unit dose internal compartment, wherein the at least one unit dose internal compartment comprises a detergent composition; and
wherein the first container comprises a first container internal compartment in which the at least one water-soluble unit dose article is contained; wherein the first container comprises a first container interior surface and a first container exterior surface; wherein the first container interior surface faces the first container internal compartment; wherein at least part of the first container interior surface is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article directly contacts the paper-based material of said first container interior surface.

[0078] Those skilled in the art will be aware of standard methods to make the first container 10 and the second container 12. Preferably, the first container 10 is constructed from a paper-based blank. Preferably, a first container 10 made from a blank according to the present invention is foldable. An advantage is that once the first container 10 is empty, it can be flattened into a flat carton for ease of disposing and recycling.

[0079] FIG. 6 illustrates an embodiment of a cardboard blank 100 suitable for making a first container 10 for a consumer product 1. Folding lines 101 may be pre-formed on the cardboard blank 100, e.g. by printing, perforating or scoring. Graphics 102 may be printed on the blank 100 to provide marketing information and/or visual cues to the consumer. The cardboard blank 100 may have an outer length of 500 mm and an outer width of 240 mm such that upon assembly, the first container 10 is sized and shaped to be held by a user for ease of opening the first container 10 in a handheld position. The first container 10 may comprise a length of 170 mm, a width of 70 mm and a height of 100 mm.

Method of Refilling

[0080] The present invention also relates to a method of refilling water-soluble unit dose articles for a consumer product, the method may comprise the steps of:

(i) providing a consumer product 1;

(ii) removing the first container 10 from the second container 12;

(iii) providing a third container comprising at least one water-soluble unit dose article; and

(iv) attaching the third container to the second container 12.

[0081] The first container 10 and the second container 12 are able to move relative to one another. This relative movement allows the first container 10 to be removed from the second container 12 in step (ii) when the user wishes to refill water-soluble unit dose articles for the consumer product 1. Without wishing to be bound by theory, the user controls the movement of the first and second containers 10, 12 relative to one another to achieve this.

[0082] The movement of the first container 10 and the second container 12 relative to one another can be achieved via any suitable means. Those skilled in the art will be aware of suitable means. The first container 10 may slide within the second container 12. The third container may be configured to be substantially the same as the first container 10 of FIG. 3. Specifically, the third container comprises a third container internal compartment in which the at least one water-soluble unit dose article is contained; wherein the third container comprises a third container interior surface and a third container exterior surface; wherein the third container interior surface faces the third container internal compartment; wherein at least part of the third container interior surface is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article directly contacts the paper-based material of said third container interior surface.

[0083] The following examples are intended to more fully illustrate the present invention and are not to be construed as limitations of the present invention since many variations thereof are possible without departing from the scope of the present invention. All parts, percentages and ratios used herein are expressed as percent weight unless otherwise specified.

TEST METHODS

Thermal Shock Test Method

[0084] Leakers are an ongoing complaint for laundry soluble unit dose article consumers. Temperature shocks, especially strong temperature drops during storage exposure, have been identified as a core driver of unit dose article leakage in a storage container.

[0085] The Thermal Shock Test Method is used to evaluate whether a first and/or a second container material is capable of preventing leakage of a unit dose article contained in a container made of a container material. The Thermal Shock Test Method comprises the following steps and test conditions:

Step 1: Test samples are made by putting unit dose articles into a container made of a container material.

Step 2: Each of the test samples are subjected to 5 thermal shock cycles (one cycle: 7 hours in 50°C climate room, followed by 15 minutes in 20°C climate room).

Step 2: At the end of each cycle of the 5 thermal shock cycles, the test samples are visually checked for leakers.

Step 3: An average number of leakers for each of the test samples is recorded at the end of each cycle.

50°C - 80°C Relative Humidity (RH) Disaster Test Method ("RH Disaster Test Method")

[0086] The RH Disaster Test Method is conducted to evaluate leakage risk in unit dose articles under high temperature and high moisture conditions in an environment of use of a consumer product according to the present invention.

[0087] The RH Disaster Test Method comprises the following steps:

Step 1: Detach a top lid of each of test samples from the test samples to create an opening in each test sample to simulate opening of a consumer product by a consumer upon first use.

Step 2: Cover the opening of each test sample with the top lid to simulate closing of a consumer product by a consumer after use.

Step 3: Store test samples under 50 degrees C at Relative Humidity (RH) of 80% in a room.

EXAMPLES

Example I: Impact of Consumer Product having First Container, Second Container and Gap

[0088] In this example, comparative consumer products comprising unit dose articles (Test Samples 1, 2, 3, 4, 5) are evaluated according to the Thermal Shock Test Method described hereinbefore to show a technical effect of providing a first container in a second container wherein there is a gap between the first and second containers according to the present invention. Table 1 below shows a percentage of leakers for each of the Test Samples. The unit dose articles in each of the Test Samples 1, 2, 3, 4 and 5 is made of a PVA film and a laundry detergent composition.

Table 1

	Reference
	Test Sample 1	Test Sample 2	Test Sample 3	Test Sample 4	Test Sample 5
Test Leg	First Container (Cylinder plastic tub with 14 unit dose articles) In Second Container (Basket) Gap between First Container and Second Container	First Container (Cylinder tub with 14 unit dose articles) In Second Container (open shipper carton box made of paper-based material) Gap between First Container and Second Container	First Container (Cylinder tub with 14 unit dose articles) In First Container (sealed shipper carton box- made of paper based material) Gap between First Container and Second Container	Plastic Pouch with 48 unit dose articles (No Gap)	Plastic Pouch with 96 unit dose articles (No Gap)
Total # of packs	6	6	12	2	2
# of packs with leakers	5	3	0	2	2
% of Leakers/ pack	83%	50%	0	100%	100%

[0089] Referring to Table 1, the above results for each of Test Samples 1, 2, and 3 demonstrate that providing a first container of unit-dose articles (cylinder tub) in a second container having a gap therebetween results in an improved reduction in the number of leakers relative to pouches of unit-dose articles (Test Samples 3 and 4 which show 100% leakers).

Example II: Impact of First Container Material

[0090] Inventive Samples 1 and 2 are prepared using the test materials shown in Table 2 below and are evaluated according to the steps of Thermal Shock Test Method and differs in that it is conducted in four test groups under the following test conditions set out in Table 3 below.

Table 2

Test Group	First Container (Carton volume)	Paper Based Material (Carton type)	Unit Dose Articles (Quantity)	Unit Dose Article Material(s)
1, 3	Ranging from 500ml to 5000ml	400gsm White Folding Box Board (FBB)	30	PVA Film
2,4		350g virgin board+ Polyethylene (PE) inside		Laundry detergent composition

Table 3

Delta T	Start Temperature	End Temperature
Δ: 30°C	45°C - 24 hours	15°C - 24 hours

[0091] No leaker is observed in each of Inventive Samples 1 and 2.

Example III

[0092] Two different paper-based materials for making a first container interior surface and a first container is evaluated for leakers according to the RH Disaster Test Method described hereinbefore for a test period of 11 days. Table 4 shows materials for Inventive Sample 3 and Comparative Sample 4 and the corresponding results.

Table 4

			Test Period (11 Days)
Sample #	Unit Dose Articles	First Container Paper-Based Material	After 3 days from the start of Test Period, daily check Lid open during the test period from Day 1-11	After 7 days from the start of Test Period than daily check Lid open during the test period from Day 1-11
Inventive Sample 3	30 unit dose articles, each having a PVA Film and Laundry Detergent Composition	400gsm White FBB	No leakage	No leakage
		First Container Interior Surface - White FBB (Paper board)
Comparative Sample 4	30 unit dose articles, each having a PVA Film and Laundry Detergent Composition	350gsm virgin board plus PE laminated inside the virgin board	1 leaker on 5th day	1 leaker on 11th day
		First Container Interior Surface (PE laminated layer)

[0093] The above results show no leakage for a first container made from 400 gsm White FBB, specifically, having a first container interior surface paper may enable moisture to be transferred away from the unit-dose articles and out into the environment external of the first container therefore eliminating leakage.

Example IV: Impact of container material

[0094] Paper-based containers were single variably compared versus traditional in market plastic type containers according to the Thermal Shock Test Method.

[0095] Therefore closed packages of similar dimensions comprising 38 water soluble unit dose articles are exposed to 5 thermal shock cycles (one cycle: 7 hrs in 50°C climate room, followed by 15 minutes in 20°C climate room). A commercial plastic bag has also been added into the comparison. No additional mechanical action (vibration) was added during the testing. After every cycle packages were visually checked for leakers. 5 replicates of each container type were tested and the average number of leakers is reported.
Materials:

• Water soluble unit dose article: Ariel 3 in 1 Pods, as commercially available in the UK in April 2019
• Plastic tub & lid: Ariel 3 in 1 Pods Polypropylene tubs & lids, as commercially available in the UK in April 2019 (dimensions: Length=250mm; Height=135mm; width=106mm, count size: 38)
• Plastic bags: Fairy Platinum multi-laminate (Polyethelene/Polyethylene Terephtalate) bag, as commercially available in the UK in April 2019 (dimensions: length=278mm; height=214 mm; width = 87mm, count size: 38)
• Paper-board container (dimensions: Length=245mm; Height=135mm; width=96mm, material 100% virgin fiber GN4 480gsm commercially available from BillerudKorsnas Carry ref. BKC480, count size: 38)
• Corrugated fibre-board container (dimensions: Length=245mm; Height=135mm; width=96mm, material: E-flute corrugated board 382 gsm KW2 135 / RF1 90 / Board KW2 135, count size: 38)

[0096] The leakage results in Table 5 clearly show that unlike plastic tubs or bags, a first container 10 comprising a paper-based material according to the invention show absence of leakers under influence of a thermal shock exposure.

Table 5:

Average number leaked water soluble unit dose articles upon thermal shock cycling
# leakers	Cycle 1	Cycle 2	Cycle 3	Cycle 4	Cycle 5
Plastic tub	1.4	3.4	4	4.2	4.6
Plastic bag	2	4.6	7	8.5	9.5
Plainboard tub	0	0	0	0	0
Corrugated paper tub	0	0	0	0	0

Example V: Impact of lamination

[0097] The impact of lamination on leaker formation upon thermal shock exposure was tested by adding a paper layer (A4 - 80gsm paper glued on the surface) respectively over the entire inside and over the entire outside of a 38 ct plastic polypropylene tub (as in Example IV). Both legs are as such designed to have the same thermal inertia upon a thermal shock with the intent of evaluating single variable the role of a lamination layer. Both tubs were again filled with 38 pouches and exposed through 5 thermal shock cycles as described above.

[0098] Results: The leakage results in table 6 clearly show that while lamination of a paper based material with a secondary plastic material does not obsolete the learning ex Example IV above, it is critical when laminating to have the paper based material on the inside of the storage container.

Table 6:

Average # leaked water soluble unit dose articles upon thermal shock cycling
# leakers	Cycle 1	Cycle 2	Cycle 3	Cycle 4	Cycle 5
Paper lamination outside	2	4	4	4	5
Paper lamination inside	0	0	0	0	0

[0099] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

Claims

1. A consumer product (1) comprising at least one water-soluble unit dose article (11), a first container (10), and a second container (12, 50);

wherein the at least one water-soluble unit dose article (11) comprises at least one water-soluble film orientated to create at least one unit dose internal compartment, wherein the at least one unit dose internal compartment comprises a detergent composition; and

wherein the first container (10) comprises a first container internal compartment (15) in which the at least one water-soluble unit dose article (11) is contained; wherein the first container (10) comprises a first container interior surface (20) and a first container exterior surface (21); wherein the first container interior surface (20) faces the first container internal compartment (15); wherein at least part (22) of the first container interior surface (20) is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article (11) directly contacts the paper-based material of said first container interior surface (20); and

wherein the second container (12, 50) comprises a second container internal compartment (23) in which the first container (10) is contained; wherein the second container (12) comprises a second container interior surface (24) and a second container exterior surface (25); wherein the second container interior surface (24) faces the second container internal compartment (23) and the first container exterior surface (21) of the first container (10); wherein at least part (28) of the second container interior surface (24) is constructed from a plastic-based material.

2. The consumer product (1) according to claim 1, wherein the entire second container interior surface (24) is constructed from a plastic-based material, preferably, wherein the second container (12) consists essentially of a plastic-based material.

3. The consumer product (1) according to claim 1, wherein the second container (50) comprises at least one ventilation opening (52).

4. The consumer product (1) according to claim 3, wherein the second container (50) comprises a side wall between the second container interior surface and the second container exterior surface, wherein the at least one ventilation opening is disposed in the side wall.

5. The consumer product (1) according to claim 3, wherein the second container (50) comprises a bottom wall (51) between the second container interior surface (54) and the second container exterior surface (55), wherein the at least one ventilation opening (52) is disposed in the bottom wall (51).

6. The consumer product (1) according to claim 1, wherein the entire first container interior surface (20) of the first container (10) is constructed from a paper-based material, preferably, wherein the first container (10) consists essentially of a paper-based material.

7. The consumer product (1) according to claim 1, wherein the first container (10) comprises a first container opening for accessing the first container internal compartment, and a first container cover covering the first container opening, preferably said first container cover is a peel-away cover.

8. The consumer product (1) according to claim 1, wherein the first container (10) comprises a first container opening (17) for accessing the first container internal compartment (15), and a rim (26) around the periphery of the first container opening (17), wherein the rim (26) engages a supporting surface (27) on the second container (12) so that the first container (10) is connected to and supported by the second container (12).

9. The consumer product (1) according to claim 8, wherein the rim (26) engages the supporting surface (27) in a mating relationship.

10. The consumer product (1) according to any one of the preceding claims, wherein the plastic-based material comprises polyethylene, polyethylene terephthalate, polypropylene, polyvinylalcohol or a mixture thereof.

11. The consumer product (1) according to any one of the preceding claims, wherein the paper-based material comprises paper, cardboard, or a mixture thereof, wherein preferably, cardboard comprises paper-board, corrugated fibre-board, or a mixture thereof.

12. The consumer product (1) according to any one of the preceding claims wherein the volume of the first container internal compartment (15) is between 500ml and 5000ml, preferably between 800ml and 4000ml.

13. The consumer product (1) according to any one of the preceding claims, wherein the water-soluble film comprises a polymer wherein the polymer comprises a homopolymer, copolymer, or mixture thereof selected from polyvinyl alcohols, polyvinyl pyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts, polyaminoacids or peptides, polyamides, polyacrylamide, copolymers of maleic/acrylic acids, polysaccharides including starch and gelatine, xanthum, carragum or a mixture thereof, preferably, polyvinylalcohol homopolymers and/or anionic polyvinylalcohol copolymers preferably selected from sulphonated and carboxylated anionic polyvinylalcohol copolymers especially carboxylated anionic polyvinylalcohol copolymers.

14. A method of providing water-soluble unit dose articles in a container to form a consumer product (1), the method comprising the steps of:

(i) providing a first container (10) comprising at least one water-soluble unit dose article;

(ii) providing a second container (12, 50);

(iii) 1ttaching the first container (10) to the second container (12); and

(iv) covering the second container (12, 50) with a second container lid (2);

wherein the at least one water-soluble unit dose article comprises at least one water-soluble film orientated to create at least one unit dose internal compartment, wherein the at least one unit dose internal compartment comprises a detergent composition; and
wherein the first container (10) comprises a first container internal compartment (15) in which the at least one water-soluble unit dose article (11) is contained; wherein the first container (10) comprises a first container interior surface (20) and a first container exterior surface (21); wherein the first container interior surface (20) faces the first container internal compartment (15); wherein at least part (22) of the first container interior surface (20) is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article directly contacts the paper-based material of said first container interior surface (20).

15. A method of refilling water-soluble unit dose articles for a consumer product (1), the method comprising the steps of:

(i) Providing a consumer product (1) according to claim 1;

(ii) Removing the first container (10) from the second container (12, 50); and

(iii) Providing a third container comprising at least one water-soluble unit dose article;
wherein the at least one water-soluble unit dose article comprises at least one water-soluble film orientated to create at least one unit dose internal compartment, wherein the at least one unit dose internal compartment comprises a detergent composition; and wherein the third container comprises a third container internal compartment in which the at least one water-soluble unit dose article is contained; wherein the third container comprises a third container interior surface and a third container exterior surface; wherein the third container interior surface faces the third container internal compartment; wherein at least part of the third container interior surface is constructed from paper-based material, so that the at least one water-soluble film of the at least one unit dose article directly contacts the paper-based material of said third container interior surface; and

(iv) attaching the third container to the second container (12).

Drawing