US20230138404A1 - Systems and methods for forming openings in water soluble packet - Google Patents
Systems and methods for forming openings in water soluble packet Download PDFInfo
- Publication number
- US20230138404A1 US20230138404A1 US18/089,032 US202218089032A US2023138404A1 US 20230138404 A1 US20230138404 A1 US 20230138404A1 US 202218089032 A US202218089032 A US 202218089032A US 2023138404 A1 US2023138404 A1 US 2023138404A1
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- base film
- cavities
- laser
- water soluble
- openings
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- 238000007789 sealing Methods 0.000 description 5
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- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 1
- 239000001856 Ethyl cellulose Substances 0.000 description 1
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B9/00—Enclosing successive articles, or quantities of material, e.g. liquids or semiliquids, in flat, folded, or tubular webs of flexible sheet material; Subdividing filled flexible tubes to form packages
- B65B9/02—Enclosing successive articles, or quantities of material between opposed webs
- B65B9/04—Enclosing successive articles, or quantities of material between opposed webs one or both webs being formed with pockets for the reception of the articles, or of the quantities of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B47/00—Apparatus or devices for forming pockets or receptacles in or from sheets, blanks, or webs, comprising essentially a die into which the material is pressed or a folding die through which the material is moved
- B65B47/08—Apparatus or devices for forming pockets or receptacles in or from sheets, blanks, or webs, comprising essentially a die into which the material is pressed or a folding die through which the material is moved by application of fluid pressure
- B65B47/10—Apparatus or devices for forming pockets or receptacles in or from sheets, blanks, or webs, comprising essentially a die into which the material is pressed or a folding die through which the material is moved by application of fluid pressure by vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B61/00—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages
- B65B61/02—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for perforating, scoring, slitting, or applying code or date marks on material prior to packaging
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B61/00—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages
- B65B61/04—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for severing webs, or for separating joined packages
- B65B61/06—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for severing webs, or for separating joined packages by cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B9/00—Enclosing successive articles, or quantities of material, e.g. liquids or semiliquids, in flat, folded, or tubular webs of flexible sheet material; Subdividing filled flexible tubes to form packages
- B65B9/02—Enclosing successive articles, or quantities of material between opposed webs
- B65B9/04—Enclosing successive articles, or quantities of material between opposed webs one or both webs being formed with pockets for the reception of the articles, or of the quantities of material
- B65B2009/047—Rotary pocket formers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B2220/00—Specific aspects of the packaging operation
- B65B2220/06—Cutting webs along their longitudinal direction
Definitions
- the present invention relates to systems and methods for forming openings in water soluble packets involving the use of a laser.
- Water soluble packets also commonly referred to as pouches or sachets, provide a single dose of a product in one convenient unit.
- the water soluble packets include a water soluble film sealed around a pre-measured amount of the product. During exposure or contact with water, the film dissolves and the product mixes with the water.
- the water soluble packets provide many benefits to the consumer. The water soluble packets arc pre-measured, and thus avoid any measuring by the consumer.
- the product is contained by the film, and it not prone to spilling.
- the water soluble packets are commonly used with dishwasher and laundry detergents. During a wash cycle, the water soluble film dissolves when exposed to the wash liquid allowing the detergent to mix with the wash liquid.
- the water soluble packets may also be used in any of a variety of different applications and contain any of a variety of different products. For example, herbicides, fertilizers, lawn chemicals, rinse-aids, cleaners, etc. may all be sealed within the water soluble packets.
- Conventional water soluble packets are formed by using a drum having rows of cavities on its exterior surface.
- a base or bottom layer of film such as a polyvinyl alcohol (PVA) film, is applied over the cavities.
- a vacuum from inside of the drum draws the base layer of film into the cavities to form a receptacle to receive the product.
- a specified amount of the product is next metered onto the base layer of film.
- a lid or an upper layer of film, such as additional PVA film, is then sealed over the base layer of the film.
- the product is now sealed inside of a combination of the base layer and the lid layer of films.
- Rows and rows of water soluble packets are formed as part of a continuous process. As the drum rotates, individual water soluble packets arc cut from the rows of water soluble packets. Such processes and equipment are described in U.S. Pat. No. 3,218,776, which is hereby incorporated by reference.
- air becomes trapped inside of the packet with the product.
- the air forms an air bubble or an air pocket inside of the sealed water soluble packet.
- the air bubble or air pocket may cause inadvertent rupture of the water soluble packet and is not desirable from an aesthetic or packaging perspective.
- a water mist is typically sprayed onto the sealed water soluble packet by a mister.
- the water mist creates passages in the film of the water soluble packet to allow air trapped in the laundry packet to escape.
- the water may also cause much of the film to discolor, which may not be cosmetically desirable from a consumer's or a retailer's perspective.
- the water soluble packets may also become sticky and adhere to one another after being sprayed with the water mist. This causes problems in automated filling processes, which direct the water soluble packets into containers for retail sale. In these automated filling processes, the containers may be filled by weight, and multiple water soluble packets sticking together may interfere with such automated filling processes.
- the laser forms the openings to vent the water soluble packets.
- the openings provide for the escape or release of air trapped in the water soluble packets.
- the laser also forms the openings to assist in the filling of the water soluble packet with detergent or other product.
- the laser burns openings into the water soluble film that forms the water soluble packet.
- the openings provide a number of improvements in the manufacturing process for water soluble packets and the resulting water soluble packets.
- the laser openings do not discolor the entire film of the water soluble packet.
- the laser openings do not make the water soluble packets sticky, which is a problem associated with the use of a conventional water mister.
- the laser openings when applied in a pre-fill stage, assist in forming the water soluble packet with several beneficial aesthetic features that may be more desirable to consumer.
- the product in such water soluble packets is more tightly packed with fewer wrinkles in the film as compared to conventional packets.
- the water soluble packets formed using the laser processes described herein are not generally pliable and do not exhibit a loose feel common to conventional water soluble packets.
- the openings may include holes, perforations, voids, vents, etc. in the film.
- the laser burns the openings in the films.
- the openings permit air to escape from the packets. During the manufacturing process, air may be trapped inside of the packet with the product. The openings provide for the trapped air to escape or vent.
- the air trapped in the water soluble packet is generally under pressure, and the openings allow the interior of the water soluble packet to equilibrate in pressure with the atmosphere.
- the water soluble packet has improved packaging characteristics.
- the water soluble packets are packed more tightly with product. Further, the film does not have bubbles or loose folds of the film. Also, the packets arc not sticky or mostly discolored. Further, the packets tend to have a uniform and consistent appearance. These characteristics may be desirable to a consumer or retailer.
- the laser may be configured to form the openings at any of a variety of stages during the industrial manufacture of the water soluble packets.
- the product is filled into cavities which are lined with a base layer of the film.
- the cavities are in the exterior surface of a rotating drum.
- a lid layer of film is sealed to the base layer over the product.
- the laser may form the openings at a pre-fill stage or at a post-fill stage in the manufacturing process of the water soluble packets.
- a first pre-fill process the laser forms the openings after the base film is positioned over or drawn into the cavities of the drum and before adding the product to the cavities.
- the laser forms the openings before the base film is positioned over the cavities. For example, the laser forms the openings in the base film as the base film is unrolled.
- the laser forms the openings in the lid film before the lid film is sealed to the base film. For example, the laser forms the openings in the lid film as the lid film is unrolled.
- the laser may also form openings in the sealed packets of product, i.e., at a post-fill stage.
- the laser may be positioned over an output or take away conveyor and direct pulses to the sealed packets.
- the laser forms the openings as part of a continuous manufacturing process, i.e., the laser forms the openings while the film or water soluble packets are moving.
- the films or water soluble packets are not intermittently slowed or stopped in order to form the openings with the laser. As such, the use of the laser does not slow down production rates of the water soluble packets.
- the laser may also be used with or integrated into both horizontal and vertical form fill seal machines.
- a system to form openings in water soluble packets includes a packet forming assembly to form water soluble packets.
- the packet forming assembly includes one or more cavities, a base film supply roll that supplies a base film to cover the one or more cavities, a feed hopper meters an amount of a product into the one or more cavities over the base film, and a lid film supply roll supplies a lid film that is sealed to the base film.
- a laser forms one or more openings in the water soluble packets.
- a method of forming openings in water soluble packets includes providing a packet forming assembly to form water soluble packets.
- the packet forming assembly comprises one or more cavities.
- the method includes covering the one or more cavities with a base film.
- the method includes feeding an amount of a product into the one or more cavities over the base film.
- the method includes sealing a lid film to the base film to form the water soluble packets.
- the method includes forming openings in the water soluble packets with a laser.
- FIG. 1 is a schematic view of multiple configurations of the laser-assisted water soluble packet forming system.
- FIG. 2 is a perspective view of the packet forming assembly.
- FIG. 3 is a perspective view of the first configuration of the laser-assisted water soluble packet forming system.
- FIG. 4 is a perspective view of the second configuration of the laser-assisted water soluble packet forming system.
- FIG. 5 is a perspective view of the third configuration of the laser-assisted water soluble packet forming system.
- FIG. 6 is a perspective view of the fourth configuration of the laser-assisted water soluble packet forming system.
- FIG. 7 is a perspective view of the water soluble packet.
- FIG. 8 is close-up view of the drum and its cavities.
- FIG. 9 is a schematic view of the laser with a horizontal form fill seal machine.
- FIG. 10 is a perspective view of the laser with a vertical form fill seal machine.
- FIG. 1 is a schematic view of multiple configurations of a laser-assisted water soluble packet forming system 10 , which is used to form water soluble packets 50 .
- An example of the water soluble packet 50 is shown in FIG. 7 .
- the system 10 forms openings 90 in the water soluble packets 50 .
- the openings 90 are formed by a laser 410 .
- the laser 410 may be positioned at any of a number of different alternate positions about the system 10 .
- the water soluble packets 50 include a product 60 scaled between a base layer 70 and a lid layer 80 .
- the base layer 70 is formed from a base film 200
- the lid layer 80 is formed from a lid film 300 .
- the openings 90 include holes, perforations, voids, vents, etc. in either or both of the base layer 70 and the lid layer 80 .
- the laser 410 may direct its pulses at any of the base film 200 , the lid film 300 , and/or the sealed water soluble packets 50 . Depending upon the set-up, the laser 410 burns the openings 90 in any or all of the base layer 70 , lid layer 80 , base film 200 , or lid film 300 .
- FIG. 2 is a perspective view of a packet forming assembly 100 , which includes a rotating drum 110 operatively engaged to a motor 120 for rotation of the drum 110 .
- the packet forming assembly 100 forms the water soluble packets 50 .
- the drum 110 includes a plurality of cavities 130 .
- a bulk amount of the product 60 is placed in a feed hopper 150 , which is generally positioned above the drum 110 .
- the feed hopper 150 meters an amount of the product 60 into the cavities 130 on top of the base film 200 .
- the lid film 300 is sealed to the base film 200 , and the water soluble packets 50 are separated.
- the base film 200 is directed to the drum 110 from the base film supply roll 220 .
- a base film roller 230 presses the base film 200 against a surface 115 of the drum 110 .
- the base film 200 generally covers a plurality of the cavities 130 .
- Guide rollers 240 and 242 assist in directing and transferring the base film 200 to the drum 110 .
- the lid film 300 is directed to the drum 110 from the lid film supply roll 320 .
- a lid film roller 330 presses the lid film 300 against the base film 200 .
- a guide roller 340 assists in directing and transferring the lid film 300 to the drum 110 .
- the drum 110 includes multiple rows 142 of the cavities 130 . Generally, the surface 115 of the drum 110 is covered with the cavities 130 .
- the laser 410 may simultaneously pulse groups 144 of the cavities 130 . The groups 144 may cover multiple rows 142 of the cavities 130 .
- each of the cavities 130 includes a vacuum opening 133 that is in fluidic communication with a vacuum passage 136 .
- the packet forming assembly 100 draws a vacuum through the vacuum passage 136 and the vacuum opening 133 .
- the packet forming assembly 100 includes a cutting assembly 180 to separate the water soluble packets 50 from each other.
- the cutting assembly 180 may include a vertical cutter 183 to make vertical separation cuts and a horizontal cutter 186 to make horizontal separation cuts.
- the drum 110 drops the water soluble packets 50 onto a take away conveyor 190 .
- a laser assembly 400 includes the laser 410 to form the openings 90 in the water soluble packets 50 .
- the laser assembly 400 also includes a controller 420 and an encoder 430 .
- the controller 420 and the encoder 430 register and time the pulses from the laser 410 to strike the base layer 70 , lid layer 80 , base film 200 , and/or the lid film 300 at the appropriate interval and time.
- the laser 410 may be integrated with the packet forming assembly 100 in any of a variety of configurations or positions. As described below in greater detail, the laser 410 may form the openings 90 , shown in FIG. 7 , at a pre-fill stage or a post-fill stage in the packet forming process.
- Four exemplary configurations of the system 10 are described below and are referred to herein as configurations 10 a , 10 b , 10 c , and 10 d . Of course, one or more lasers 410 may be simultaneously employed at any of the configurations or positions.
- FIG. 3 shows a perspective view of the first configuration 10 a of the system 10 , which forms the openings 90 when the base film 200 is over or drawn into the cavities 130 .
- FIG. 3 shows a perspective view of the first configuration 10 a of the system 10 , which forms the openings 90 when the base film 200 is over or drawn into the cavities 130 .
- FIG. 4 shows a perspective view of the second configuration 10 b , which forms the openings 90 in the sealed water soluble packets 50 after the water soluble packets 50 are formed on the drum 110 and separated by the cutting assembly 180 .
- FIG. 5 shows a perspective view of the third configuration 10 c , which forms the openings 90 in the lid film 300 before the lid film 300 is sealed to the base film 200 .
- FIG. 6 shows a perspective view of the fourth configuration 10 d , which forms the openings 90 in the base film 200 before base film 200 reaches the drum 110 .
- the first configuration 10 a forms the openings 90 when the base film 200 is over or drawn into the cavities 130 .
- the first configuration 10 a forms the openings 90 at a pre-fill stage.
- the laser 410 may form openings 90 in the base film 200 , while the base film 200 is positioned over the drum 110 or after the base film 200 has been drawn into the cavities 130 by the vacuum. In this aspect, the openings 90 are formed before the product 60 is added to the base film 200 .
- the laser 410 is positioned proximate to the drum 110 , and the laser 410 is focused toward the individual cavities 130 of the drum 110 .
- the drum 110 provides the vacuum through the vacuum passage 136 that conforms the base film 200 to the drum 110 and into the individual cavities 130 .
- Air is drawn into the vacuum passage 136 through the vacuum opening 133 in the bottom of the cavity 130 .
- the vacuum draws and stretches the base film 200 into the individual cavities 130 .
- the base film 200 forms a receptacle shape in the individual cavities 130 to receive the product 60 .
- the laser 410 forms the openings 90 in the base film 200 .
- the openings 90 are formed by the laser 410 after the base film 200 has been stretched into the cavities 130 by the vacuum of the drum 110 .
- the openings 90 are formed in the base film 200 after the base film 200 has been stretched, so the openings 90 will generally maintain their dimension as the base film 200 is not generally further stretched during the formation of the water soluble packet 50 .
- the vacuum is also drawing air through the openings 90 in the film, which sucks the product 60 into the base film 200 .
- the product 60 may be deposited on the base film 200 in the cavities 130 while the vacuum force is drawing the base film 200 into the cavity 130 and air is passing through the openings 90 and into the vacuum opening 133 . This assists in increasing the density of the product 60 within the packet 50 .
- the product 60 in such water soluble packets 50 is more tightly packed with fewer wrinkles in the film as compared to conventional packets. Without the openings 90 and the drawing of air through the openings 90 by the vacuum, the water soluble packet 50 will have a softer feel and the product 60 will be more loosely contained in the water soluble packet 50 .
- the second configuration 10 b forms the openings 90 in the sealed water soluble packets 50 after the water soluble packets 50 are formed on the drum 110 and separated by the cutting assembly 180 .
- the second configuration 10 b forms the openings 90 at a post-fill stage.
- the laser 410 may be positioned to form openings 90 in the sealed water soluble packets 50 after the water soluble packets 50 are formed on the drum 110 and separated by a cutting assembly 180 .
- the openings 90 are formed after the lid film 300 and base film 200 are sealed together to contain the product 60 .
- the laser 410 may be positioned over the take away conveyor 190 .
- the laser 410 may be focused on any portion of the water soluble packet 50 .
- the third configuration 10 c forms the openings 90 in the lid film 300 before the lid film 300 is sealed to the base film 200 .
- the third configuration 10 c also forms the openings 90 at the pre-fill stage.
- the laser 410 may form the openings 90 in the lid film 300 that forms the packet 50 .
- the laser 410 may be positioned to form openings 90 in the lid film 300 before the lid film 300 reaches the drum 110 .
- the laser 410 is positioned proximate to the lid film supply roll 320 . As the sheet of the lid film 300 is unrolled and directed to the drum 110 , the laser 410 may form the openings 90 .
- One or more lasers may be configured to intermittently form openings 90 in the entire width of lid film 300 used to cover the cavities 130 .
- the openings 90 may be formed in portions of the lid film 300 which will become the sides or a periphery of the finished water soluble packet 50 . These areas of the lid film 300 are subjected to less stretching than the areas of the base film 200 , which will become the central portions of the water soluble packet 50 . By forming the openings 90 at the sides or periphery, the openings 90 are not generally stretched during the sealing process, and the openings 90 maintain their desired shape.
- the fourth configuration 10 d forms the openings 90 in the base film 200 before base film 200 reaches the drum 110 .
- the fourth configuration 10 d also forms the openings 90 at the pre-fill stage.
- the laser 410 may form openings 90 in the base film 200 that forms the packet 50 .
- the laser 410 may be positioned to form openings 90 in the base film 200 before the base film 200 reaches the drum 110 .
- the laser 410 is positioned proximate to the base film supply roll 220 . As the sheet of the base film 200 is unrolled and directed to the drum 110 , the laser 410 may form the openings 90 .
- One or more lasers 410 may be configured to intermittently form openings 90 in the entire width of the base film 200 used to cover the cavities 130 .
- the openings 90 are formed before the product 60 is added to the base film 200 and before the base film 200 and the lid film 300 arc scaled together.
- the openings 90 may be formed in portions of the base film 200 which will become the sides or a periphery of the finished water soluble packet 50 . These areas of the base film 200 are subjected to less stretching than the areas of the base film 200 film which will become the central portions of the water soluble packet 50 .
- the openings 90 are not generally stretched during the filling process, and the openings 90 maintain their desired shape.
- the laser 410 forms one or more openings 90 in the water soluble packet 50 or the portion of the films 200 and 300 forming the water soluble packet 50 .
- the laser 410 forms four openings 90 in each water soluble packet 50 .
- the openings 90 may have various sizes and shapes.
- the openings 90 may have a size up to approximately 1000 um.
- the system 10 , laser assembly 400 , and/or the processes described herein may be incorporated into water soluble packet forming systems and equipment from Cloud Packaging Solutions of Des Plaines, Ill. Such equipment is commercially available under the tradename HYDRO-FORMA.
- the laser 410 may be configured to provide enough power to generally only burn the openings 90 into the film, and, in post-fill applications, not to burn a significant amount of the product 60 therein.
- the pulses will not damage the cavities 130 , belts, rollers, or other components of the water soluble packet forming system 10 .
- the system 10 and its equipment may be provided with a protective shield and/or barriers to prevent accidental exposure of workers to the laser 410 .
- the laser assembly 400 includes the laser 410 to form the openings 90 in the water soluble packets 50 .
- the laser assembly 400 also includes the controller 420 and the encoder 430 .
- Existing water soluble packet forming systems may be retrofitted to include the laser assembly 400 .
- the laser 410 may be electronically linked to the controller 420 , which registers the pulses from the laser 410 with the moving films 200 and/or 300 or moving water soluble packets 50 .
- the encoder 430 may measure the speed of the take away conveyor 190 , the drum 120 , or any of the films 200 and 300 .
- the encoder 430 is in electrical communication with the controller 420 to provide the controller 420 with data regarding the speed.
- the laser 410 may be positioned stationary with respect to the moving films 200 and/or 300 or the belts carrying the water soluble packets 50 .
- the controller 420 may time the laser 410 to intermittently pulse the laser 410 as the films 200 and/or 300 or the water soluble packets 50 move past a focus point of the laser 410 .
- the controller 420 may be electronically linked to sensors or additional encoders that monitor the movement of the film or the belt carrying the water soluble packets 50 .
- the controller 420 times the pulses from the laser 410 to impact the films or water soluble packets 50 at the appropriate interval.
- lasers Any of a variety of lasers may be used with the system 10 and the processes described herein.
- One suitable laser for the laser 410 is a commercially available laser as Model 3320 from Videojet Technologies, Inc. of Wood Dale, Ill. This laser is a 30 watt CO2 laser.
- the laser 410 and/or the controller 420 may be programmed to modulate any of a number of parameters and attributes of the laser pulses, for example, the timing of the laser pulses, the frequency of the laser pulses, the shape of the laser pulse, the pattern of the laser pulses, the area of coverage of the laser pulses, etc.
- the laser 410 and/or the controller 420 may include user-input controls, such as a touch screen, keyboard, etc.
- the laser 410 may simultaneously emit an array of pulses that simultaneously forms multiple openings 90 .
- the laser 410 may be configured to simultaneously form openings 90 in the base film 200 covering multiple rows 142 and groups 144 of the cavities 130 of the drum 110 .
- the laser 410 may be configured to simultaneously form openings 90 in multiple packets 50 , multiple rows of packets 50 , and/or or multiple groups 144 of packets 50 .
- the laser 410 may be configured to simultaneously form openings 90 across a web of the films 200 and 300 in multiple columns and rows.
- the laser 410 may be configured to simultaneously form openings 90 in approximately 12 water soluble packets 50 .
- the laser 410 may be configured to simultaneously form openings 90 across a portion of the films 200 and/or 300 of approximately 24 inches wide by approximately 0.25 to 1 inches deep.
- the laser 410 may be configured to simultaneously form openings 90 in a base film 200 covering approximately 12 cavities of the drum 110 .
- multiple lasers 410 may be used together to fully cover a width of the drum 110 , films 200 and/or 300 , or the take away conveyor 190 .
- the lid film 300 and base film 200 may be a water soluble film, such as a polyvinyl alcohol (PVA) film.
- PVA polyvinyl alcohol
- the films dissolve with contact of water or other fluids.
- the films may have a thickness of approximately 1 millimeter to approximately 5 millimeter.
- Such films are commercially available from Monosol of Merrillville, Indiana.
- Other water soluble films for forming the water soluble packets 50 may include any water-soluble, film-forming polymer, copolymer, or mixtures of such polymers.
- the polymers may include vinyl polymers, including homopolymers and copolymers, having functionality rendering the polymers water-soluble, such as hydroxyl and carboxyl groups.
- Typical water-soluble polymers include at least one of polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, polyvinyl pyrrolidone, alkyl celluloses such as methylcellulose, ethylcellulose, propylcellulose and derivatives thereof, such as the ethers and esters of alkyl celluloses, and acrylic polymers such as water-soluble polyacrylates, polyacrylamides, and acrylic maleic anhydride copolymers.
- Suitable water-soluble polymers further include copolymers of hydrolyzed vinyl alcohol and a nonhydrolyzable anionic comonomer.
- water soluble packets 50 containing any of a variety of products 60 such as, for example, powders, granules, or other solid compositions for any application, such as, for example, herbicides, fertilizers, lawn chemicals, rinse-aids, cleaners, etc.
- the water soluble packets 50 will contain a dry product 60 .
- one or more lasers may also be used with or integrated into horizontal form fill seal machines and/or vertical form fill seal machines in order form openings to vent the water soluble packets.
- Horizontal form fill seal machines and vertical form fill seal machines are also used to make water soluble packets.
- the openings provide for the escape or release of air trapped in the water soluble packets.
- the laser also forms the openings to assist in the filling of the water soluble packet with detergent or other product.
- FIG. 9 is a schematic view of a laser-assisted water soluble packet forming system 500 using one or more of lasers 505 a , 505 b , 505 c , 505 d , and 505 e with a horizontal form fill seal machine 510 .
- the system 500 includes an endless belt 515 operatively engaged to a motor 517 for movement of the endless belt 515 .
- the packet forming assembly 500 also forms the water soluble packets 50 .
- the endless belt 515 includes a plurality of cavities 525 .
- a bulk amount of the product 60 is placed in a feed hopper 550 , which is generally positioned above the endless belt 515 .
- the feed hopper 550 meters an amount of the product 60 into the cavities 525 on top of a base film 520 .
- a lid film 530 is sealed to the base film 520 , and the water soluble packets 50 are separated.
- the base film 520 is directed to the endless belt 515 from a base film supply roll 560 .
- a base film roller 565 presses the base film 520 against the endless belt 515 .
- the lid film 530 is directed to the endless belt 515 from a lid film supply roll 570 .
- a lid film roller 575 presses the lid film 530 against the base film 520 .
- the endless belt 515 includes multiple rows of the cavities 525 . Generally, a surface 518 of the endless belt 515 is covered with the cavities 525 .
- the cavities 525 include a vacuum opening 533 that is in fluidic communication with a vacuum passage 536 .
- the packet forming assembly 500 includes a cutting assembly 580 to separate the water soluble packets 50 from each other.
- the cutting assembly 580 may include a vertical cutter 583 to make vertical separation cuts and a horizontal cutter 586 to make horizontal separation cuts. After the water soluble packets 50 are separated, the endless belt 515 drops the water soluble packets 50 onto a take away conveyor 590 .
- the lasers 505 a , 505 b , 505 c , 505 d , and 505 e may be integrated with the packet forming assembly 500 in any of a variety of configurations or positions. Although FIG. 9 shows the use of multiple lasers, only one of the lasers 505 a , 505 b , 505 c , 505 d , and 505 e needs to be employed.
- the lasers 505 a , 505 b , 505 c , 505 d , and 505 e may form the openings 90 , shown in FIG. 7 , at a pre-fill stage or a post-fill stage in the packet forming process.
- the lasers 505 a , 505 b , 505 c , 505 d , and 505 e may be simultaneously employed at any of the configurations or positions.
- the laser 505 a may form the openings 90 in the base film 520 before the base film 520 reaches the endless belt 515 .
- the laser 505 b may form the openings 90 when the base film 520 is over or drawn into the cavities 525 .
- the laser 505 c may form the openings 90 in the lid film 530 before the lid film 530 is sealed to the base film 520 .
- the laser 505 d may form the openings 90 after the water soluble packets 50 are formed on the endless belt 515 but before the packets 50 are separated by the cutting assembly 580 .
- the laser 505 e may form the openings 90 after the water soluble packets 50 are formed on the endless belt 515 , separated by the cutting assembly 580 , and deposited on the take away conveyor 590 .
- the laser 505 e may be positioned directly over the take away conveyor 590 .
- FIG. 10 is a perspective view of a laser-assisted water soluble packet forming system 600 using one or both of lasers 605 a and 605 b with a vertical form fill seal machine 610 .
- the packet forming assembly 600 generally forms water soluble packets 55 from a single layer of a film 650 .
- a bulk amount of the product 60 is placed in a feed hopper 610 , which is generally positioned above a horn 620 .
- the horn 620 includes an entrance opening 623 and an exit opening 626 .
- the horn 620 also includes an exterior surface 630 .
- Drive rollers 640 pull the film 650 over the exterior surface 630 while the product 60 is metered into an interior of the horn 620 through the entrance opening 623 .
- the film 650 is provided by a supply roller 655 .
- a first sealing device 660 seals opposing vertical edges 652 and 654 of the film 650 .
- a second sealing device 670 seals the other seams.
- a cutting device 680 separates the individual packets 50 and drops the packets 50 onto a take-away conveyor 690 .
- the lasers 605 a and 605 b may be integrated with the packet forming assembly 600 in any of a variety of configurations or positions. Although FIG. 10 shows the use of multiple lasers, only one of the lasers 605 a and 605 b needs to be employed.
- the lasers 605 a and 605 b may form openings 91 in the packets 55 at a pre-fill stage or a post-fill stage in the packet forming process.
- the laser 605 a may form the openings 91 in the film 650 before the film 650 reaches the horn 620 .
- the laser 605 b may form the openings 91 in the packets 55 on the take-away conveyor 690 .
- the laser 605 b may be positioned directly over the take-away conveyor 690 .
- the systems 500 and 600 may also include the controller 420 to program and/or modulate any of a number of parameters and attributes of the laser pulses.
- the systems 500 and 600 may also include the encoder 430 to register and time the pulses from the lasers to strike the films or packets at the appropriate interval and time.
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Abstract
Description
- This application is a continuation of U.S. Nonprovisional application Ser. No. 17/329,067, filed May 24, 2021 which is a continuation of U.S. Nonprovisional application Ser. No. 14/179,878, filed Feb. 13, 2014, which claims the benefit of U.S. Provisional Patent Application 61/764,196 filed Feb. 13, 2013, and which is hereby incorporated by reference.
- The present invention relates to systems and methods for forming openings in water soluble packets involving the use of a laser.
- Water soluble packets, also commonly referred to as pouches or sachets, provide a single dose of a product in one convenient unit. The water soluble packets include a water soluble film sealed around a pre-measured amount of the product. During exposure or contact with water, the film dissolves and the product mixes with the water. The water soluble packets provide many benefits to the consumer. The water soluble packets arc pre-measured, and thus avoid any measuring by the consumer. The product is contained by the film, and it not prone to spilling.
- The water soluble packets are commonly used with dishwasher and laundry detergents. During a wash cycle, the water soluble film dissolves when exposed to the wash liquid allowing the detergent to mix with the wash liquid. The water soluble packets may also be used in any of a variety of different applications and contain any of a variety of different products. For example, herbicides, fertilizers, lawn chemicals, rinse-aids, cleaners, etc. may all be sealed within the water soluble packets.
- Conventional water soluble packets are formed by using a drum having rows of cavities on its exterior surface. A base or bottom layer of film, such as a polyvinyl alcohol (PVA) film, is applied over the cavities. A vacuum from inside of the drum draws the base layer of film into the cavities to form a receptacle to receive the product. A specified amount of the product is next metered onto the base layer of film. A lid or an upper layer of film, such as additional PVA film, is then sealed over the base layer of the film. The product is now sealed inside of a combination of the base layer and the lid layer of films. Rows and rows of water soluble packets are formed as part of a continuous process. As the drum rotates, individual water soluble packets arc cut from the rows of water soluble packets. Such processes and equipment are described in U.S. Pat. No. 3,218,776, which is hereby incorporated by reference.
- During the filling and sealing process, air becomes trapped inside of the packet with the product. The air forms an air bubble or an air pocket inside of the sealed water soluble packet. The air bubble or air pocket may cause inadvertent rupture of the water soluble packet and is not desirable from an aesthetic or packaging perspective.
- In order to get the air out of packet, a water mist is typically sprayed onto the sealed water soluble packet by a mister. The water mist creates passages in the film of the water soluble packet to allow air trapped in the laundry packet to escape. Unfortunately, the water may also cause much of the film to discolor, which may not be cosmetically desirable from a consumer's or a retailer's perspective. Further, the water soluble packets may also become sticky and adhere to one another after being sprayed with the water mist. This causes problems in automated filling processes, which direct the water soluble packets into containers for retail sale. In these automated filling processes, the containers may be filled by weight, and multiple water soluble packets sticking together may interfere with such automated filling processes.
- Systems and methods for forming openings in water soluble packets involving the use of a laser are herein described. The laser forms the openings to vent the water soluble packets. The openings provide for the escape or release of air trapped in the water soluble packets. The laser also forms the openings to assist in the filling of the water soluble packet with detergent or other product. The laser burns openings into the water soluble film that forms the water soluble packet.
- The openings provide a number of improvements in the manufacturing process for water soluble packets and the resulting water soluble packets. First, the laser openings do not discolor the entire film of the water soluble packet. Second, the laser openings do not make the water soluble packets sticky, which is a problem associated with the use of a conventional water mister. Further, the laser openings, when applied in a pre-fill stage, assist in forming the water soluble packet with several beneficial aesthetic features that may be more desirable to consumer. The product in such water soluble packets is more tightly packed with fewer wrinkles in the film as compared to conventional packets. Further, the water soluble packets formed using the laser processes described herein are not generally pliable and do not exhibit a loose feel common to conventional water soluble packets.
- The openings may include holes, perforations, voids, vents, etc. in the film. The laser burns the openings in the films. The openings permit air to escape from the packets. During the manufacturing process, air may be trapped inside of the packet with the product. The openings provide for the trapped air to escape or vent. The air trapped in the water soluble packet is generally under pressure, and the openings allow the interior of the water soluble packet to equilibrate in pressure with the atmosphere. By allowing air to escape, the water soluble packet has improved packaging characteristics. The water soluble packets are packed more tightly with product. Further, the film does not have bubbles or loose folds of the film. Also, the packets arc not sticky or mostly discolored. Further, the packets tend to have a uniform and consistent appearance. These characteristics may be desirable to a consumer or retailer.
- The laser may be configured to form the openings at any of a variety of stages during the industrial manufacture of the water soluble packets. During the manufacturing process, the product is filled into cavities which are lined with a base layer of the film. The cavities are in the exterior surface of a rotating drum. After the filling, a lid layer of film is sealed to the base layer over the product.
- The laser may form the openings at a pre-fill stage or at a post-fill stage in the manufacturing process of the water soluble packets. In a first pre-fill process, the laser forms the openings after the base film is positioned over or drawn into the cavities of the drum and before adding the product to the cavities. In a second pre-fill process, the laser forms the openings before the base film is positioned over the cavities. For example, the laser forms the openings in the base film as the base film is unrolled. In a third pre-fill process, the laser forms the openings in the lid film before the lid film is sealed to the base film. For example, the laser forms the openings in the lid film as the lid film is unrolled.
- The laser may also form openings in the sealed packets of product, i.e., at a post-fill stage. For example, the laser may be positioned over an output or take away conveyor and direct pulses to the sealed packets.
- The laser forms the openings as part of a continuous manufacturing process, i.e., the laser forms the openings while the film or water soluble packets are moving. Typically, the films or water soluble packets are not intermittently slowed or stopped in order to form the openings with the laser. As such, the use of the laser does not slow down production rates of the water soluble packets.
- The laser may also be used with or integrated into both horizontal and vertical form fill seal machines.
- In one aspect, a system to form openings in water soluble packets is described. The system includes a packet forming assembly to form water soluble packets. The packet forming assembly includes one or more cavities, a base film supply roll that supplies a base film to cover the one or more cavities, a feed hopper meters an amount of a product into the one or more cavities over the base film, and a lid film supply roll supplies a lid film that is sealed to the base film. A laser forms one or more openings in the water soluble packets.
- In another aspect, a method of forming openings in water soluble packets is described. The method includes providing a packet forming assembly to form water soluble packets. The packet forming assembly comprises one or more cavities. The method includes covering the one or more cavities with a base film. The method includes feeding an amount of a product into the one or more cavities over the base film. The method includes sealing a lid film to the base film to form the water soluble packets. The method includes forming openings in the water soluble packets with a laser.
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FIG. 1 is a schematic view of multiple configurations of the laser-assisted water soluble packet forming system. -
FIG. 2 is a perspective view of the packet forming assembly. -
FIG. 3 is a perspective view of the first configuration of the laser-assisted water soluble packet forming system. -
FIG. 4 is a perspective view of the second configuration of the laser-assisted water soluble packet forming system. -
FIG. 5 is a perspective view of the third configuration of the laser-assisted water soluble packet forming system. -
FIG. 6 is a perspective view of the fourth configuration of the laser-assisted water soluble packet forming system. -
FIG. 7 is a perspective view of the water soluble packet. -
FIG. 8 is close-up view of the drum and its cavities. -
FIG. 9 is a schematic view of the laser with a horizontal form fill seal machine. -
FIG. 10 is a perspective view of the laser with a vertical form fill seal machine. -
FIG. 1 is a schematic view of multiple configurations of a laser-assisted water solublepacket forming system 10, which is used to form watersoluble packets 50. An example of the watersoluble packet 50 is shown inFIG. 7 . Thesystem 10 forms openings 90 in the watersoluble packets 50. The openings 90 are formed by alaser 410. As shown inFIG. 1 , thelaser 410 may be positioned at any of a number of different alternate positions about thesystem 10. - The water
soluble packets 50 include aproduct 60 scaled between abase layer 70 and alid layer 80. Thebase layer 70 is formed from abase film 200, while thelid layer 80 is formed from alid film 300. The openings 90 include holes, perforations, voids, vents, etc. in either or both of thebase layer 70 and thelid layer 80. As described below, thelaser 410 may direct its pulses at any of thebase film 200, thelid film 300, and/or the sealed watersoluble packets 50. Depending upon the set-up, thelaser 410 burns the openings 90 in any or all of thebase layer 70,lid layer 80,base film 200, orlid film 300. -
FIG. 2 is a perspective view of apacket forming assembly 100, which includes arotating drum 110 operatively engaged to amotor 120 for rotation of thedrum 110. Thepacket forming assembly 100 forms the watersoluble packets 50. Thedrum 110 includes a plurality ofcavities 130. A bulk amount of theproduct 60 is placed in afeed hopper 150, which is generally positioned above thedrum 110. As thedrum 110 rotates, thefeed hopper 150 meters an amount of theproduct 60 into thecavities 130 on top of thebase film 200. Thelid film 300 is sealed to thebase film 200, and the watersoluble packets 50 are separated. - The
base film 200 is directed to thedrum 110 from the basefilm supply roll 220. Abase film roller 230 presses thebase film 200 against asurface 115 of thedrum 110. Thebase film 200 generally covers a plurality of thecavities 130.Guide rollers base film 200 to thedrum 110. - The
lid film 300 is directed to thedrum 110 from the lidfilm supply roll 320. Alid film roller 330 presses thelid film 300 against thebase film 200. Aguide roller 340 assists in directing and transferring thelid film 300 to thedrum 110. - The
drum 110 includesmultiple rows 142 of thecavities 130. Generally, thesurface 115 of thedrum 110 is covered with thecavities 130. Thelaser 410 may simultaneously pulsegroups 144 of thecavities 130. Thegroups 144 may covermultiple rows 142 of thecavities 130. - With reference to
FIGS. 1 and 8 , each of thecavities 130 includes avacuum opening 133 that is in fluidic communication with avacuum passage 136. Thepacket forming assembly 100 draws a vacuum through thevacuum passage 136 and thevacuum opening 133. - With reference to
FIG. 1 , thepacket forming assembly 100 includes a cuttingassembly 180 to separate the watersoluble packets 50 from each other. The cuttingassembly 180 may include avertical cutter 183 to make vertical separation cuts and ahorizontal cutter 186 to make horizontal separation cuts. After the watersoluble packets 50 are separated, thedrum 110 drops the watersoluble packets 50 onto a take awayconveyor 190. - With continued reference to
FIG. 1 , alaser assembly 400 includes thelaser 410 to form the openings 90 in the watersoluble packets 50. Thelaser assembly 400 also includes acontroller 420 and anencoder 430. Thecontroller 420 and theencoder 430 register and time the pulses from thelaser 410 to strike thebase layer 70,lid layer 80,base film 200, and/or thelid film 300 at the appropriate interval and time. - The
laser 410 may be integrated with thepacket forming assembly 100 in any of a variety of configurations or positions. As described below in greater detail, thelaser 410 may form the openings 90, shown inFIG. 7 , at a pre-fill stage or a post-fill stage in the packet forming process. Four exemplary configurations of thesystem 10 are described below and are referred to herein asconfigurations more lasers 410 may be simultaneously employed at any of the configurations or positions. In summary,FIG. 3 shows a perspective view of the first configuration 10 a of thesystem 10, which forms the openings 90 when thebase film 200 is over or drawn into thecavities 130.FIG. 4 shows a perspective view of thesecond configuration 10 b, which forms the openings 90 in the sealed watersoluble packets 50 after the watersoluble packets 50 are formed on thedrum 110 and separated by the cuttingassembly 180.FIG. 5 shows a perspective view of thethird configuration 10 c, which forms the openings 90 in thelid film 300 before thelid film 300 is sealed to thebase film 200.FIG. 6 shows a perspective view of thefourth configuration 10 d, which forms the openings 90 in thebase film 200 beforebase film 200 reaches thedrum 110. - With reference to
FIG. 3 , the first configuration 10 a forms the openings 90 when thebase film 200 is over or drawn into thecavities 130. The first configuration 10 a forms the openings 90 at a pre-fill stage. Thelaser 410 may form openings 90 in thebase film 200, while thebase film 200 is positioned over thedrum 110 or after thebase film 200 has been drawn into thecavities 130 by the vacuum. In this aspect, the openings 90 are formed before theproduct 60 is added to thebase film 200. Thelaser 410 is positioned proximate to thedrum 110, and thelaser 410 is focused toward theindividual cavities 130 of thedrum 110. Thedrum 110 provides the vacuum through thevacuum passage 136 that conforms thebase film 200 to thedrum 110 and into theindividual cavities 130. Air is drawn into thevacuum passage 136 through thevacuum opening 133 in the bottom of thecavity 130. The vacuum draws and stretches thebase film 200 into theindividual cavities 130. Thebase film 200 forms a receptacle shape in theindividual cavities 130 to receive theproduct 60. Before theproduct 60 is added to thebase film 200 positioned in thecavities 130, thelaser 410 forms the openings 90 in thebase film 200. Notably, the openings 90 are formed by thelaser 410 after thebase film 200 has been stretched into thecavities 130 by the vacuum of thedrum 110. The openings 90 are formed in thebase film 200 after thebase film 200 has been stretched, so the openings 90 will generally maintain their dimension as thebase film 200 is not generally further stretched during the formation of the watersoluble packet 50. - In this aspect, the vacuum is also drawing air through the openings 90 in the film, which sucks the
product 60 into thebase film 200. Theproduct 60 may be deposited on thebase film 200 in thecavities 130 while the vacuum force is drawing thebase film 200 into thecavity 130 and air is passing through the openings 90 and into thevacuum opening 133. This assists in increasing the density of theproduct 60 within thepacket 50. Theproduct 60 in such watersoluble packets 50 is more tightly packed with fewer wrinkles in the film as compared to conventional packets. Without the openings 90 and the drawing of air through the openings 90 by the vacuum, the watersoluble packet 50 will have a softer feel and theproduct 60 will be more loosely contained in the watersoluble packet 50. - With reference to
FIG. 4 , thesecond configuration 10 b forms the openings 90 in the sealed watersoluble packets 50 after the watersoluble packets 50 are formed on thedrum 110 and separated by the cuttingassembly 180. Thesecond configuration 10 b forms the openings 90 at a post-fill stage. Thelaser 410 may be positioned to form openings 90 in the sealed watersoluble packets 50 after the watersoluble packets 50 are formed on thedrum 110 and separated by a cuttingassembly 180. In this aspect, the openings 90 are formed after thelid film 300 andbase film 200 are sealed together to contain theproduct 60. Thelaser 410 may be positioned over the take awayconveyor 190. Thelaser 410 may be focused on any portion of the watersoluble packet 50. - With reference to
FIG. 5 , thethird configuration 10 c forms the openings 90 in thelid film 300 before thelid film 300 is sealed to thebase film 200. Thethird configuration 10 c also forms the openings 90 at the pre-fill stage. Thelaser 410 may form the openings 90 in thelid film 300 that forms thepacket 50. Thelaser 410 may be positioned to form openings 90 in thelid film 300 before thelid film 300 reaches thedrum 110. Thelaser 410 is positioned proximate to the lidfilm supply roll 320. As the sheet of thelid film 300 is unrolled and directed to thedrum 110, thelaser 410 may form the openings 90. One or more lasers may be configured to intermittently form openings 90 in the entire width oflid film 300 used to cover thecavities 130. In this aspect, the openings 90 may be formed in portions of thelid film 300 which will become the sides or a periphery of the finished watersoluble packet 50. These areas of thelid film 300 are subjected to less stretching than the areas of thebase film 200, which will become the central portions of the watersoluble packet 50. By forming the openings 90 at the sides or periphery, the openings 90 are not generally stretched during the sealing process, and the openings 90 maintain their desired shape. - With reference to
FIG. 6 , thefourth configuration 10 d forms the openings 90 in thebase film 200 beforebase film 200 reaches thedrum 110. Thefourth configuration 10 d also forms the openings 90 at the pre-fill stage. Thelaser 410 may form openings 90 in thebase film 200 that forms thepacket 50. Thelaser 410 may be positioned to form openings 90 in thebase film 200 before thebase film 200 reaches thedrum 110. Thelaser 410 is positioned proximate to the basefilm supply roll 220. As the sheet of thebase film 200 is unrolled and directed to thedrum 110, thelaser 410 may form the openings 90. One ormore lasers 410 may be configured to intermittently form openings 90 in the entire width of thebase film 200 used to cover thecavities 130. In this aspect, the openings 90 are formed before theproduct 60 is added to thebase film 200 and before thebase film 200 and thelid film 300 arc scaled together. The openings 90 may be formed in portions of thebase film 200 which will become the sides or a periphery of the finished watersoluble packet 50. These areas of thebase film 200 are subjected to less stretching than the areas of thebase film 200 film which will become the central portions of the watersoluble packet 50. By forming the openings 90 at the sides or periphery, the openings 90 are not generally stretched during the filling process, and the openings 90 maintain their desired shape. - The
laser 410 will now be described. Thelaser 410 forms one or more openings 90 in the watersoluble packet 50 or the portion of thefilms soluble packet 50. In some aspects, thelaser 410 forms four openings 90 in each watersoluble packet 50. The openings 90 may have various sizes and shapes. For example, the openings 90 may have a size up to approximately 1000 um. - The
system 10,laser assembly 400, and/or the processes described herein may be incorporated into water soluble packet forming systems and equipment from Cloud Packaging Solutions of Des Plaines, Ill. Such equipment is commercially available under the tradename HYDRO-FORMA. - The
laser 410 may be configured to provide enough power to generally only burn the openings 90 into the film, and, in post-fill applications, not to burn a significant amount of theproduct 60 therein. The pulses will not damage thecavities 130, belts, rollers, or other components of the water solublepacket forming system 10. Although thelaser 410 will not hurt a worker with incidental, momentary exposure to thelaser 410, thesystem 10 and its equipment may be provided with a protective shield and/or barriers to prevent accidental exposure of workers to thelaser 410. - With reference to
FIG. 1 , thelaser assembly 400 includes thelaser 410 to form the openings 90 in the watersoluble packets 50. Thelaser assembly 400 also includes thecontroller 420 and theencoder 430. Existing water soluble packet forming systems may be retrofitted to include thelaser assembly 400. Thelaser 410 may be electronically linked to thecontroller 420, which registers the pulses from thelaser 410 with the movingfilms 200 and/or 300 or moving watersoluble packets 50. Theencoder 430 may measure the speed of the take awayconveyor 190, thedrum 120, or any of thefilms encoder 430 is in electrical communication with thecontroller 420 to provide thecontroller 420 with data regarding the speed. Thelaser 410 may be positioned stationary with respect to the movingfilms 200 and/or 300 or the belts carrying the watersoluble packets 50. Thecontroller 420 may time thelaser 410 to intermittently pulse thelaser 410 as thefilms 200 and/or 300 or the watersoluble packets 50 move past a focus point of thelaser 410. Thecontroller 420 may be electronically linked to sensors or additional encoders that monitor the movement of the film or the belt carrying the watersoluble packets 50. Thecontroller 420 times the pulses from thelaser 410 to impact the films or watersoluble packets 50 at the appropriate interval. - Any of a variety of lasers may be used with the
system 10 and the processes described herein. One suitable laser for thelaser 410 is a commercially available laser as Model 3320 from Videojet Technologies, Inc. of Wood Dale, Ill. This laser is a 30 watt CO2 laser. - The
laser 410 and/or thecontroller 420 may be programmed to modulate any of a number of parameters and attributes of the laser pulses, for example, the timing of the laser pulses, the frequency of the laser pulses, the shape of the laser pulse, the pattern of the laser pulses, the area of coverage of the laser pulses, etc. Thelaser 410 and/or thecontroller 420 may include user-input controls, such as a touch screen, keyboard, etc. - The
laser 410 may simultaneously emit an array of pulses that simultaneously forms multiple openings 90. For example, thelaser 410 may be configured to simultaneously form openings 90 in thebase film 200 coveringmultiple rows 142 andgroups 144 of thecavities 130 of thedrum 110. Thelaser 410 may be configured to simultaneously form openings 90 inmultiple packets 50, multiple rows ofpackets 50, and/or ormultiple groups 144 ofpackets 50. Likewise, thelaser 410 may be configured to simultaneously form openings 90 across a web of thefilms laser 410 may be configured to simultaneously form openings 90 in approximately 12 watersoluble packets 50. For example, in a pre-fill process, thelaser 410 may be configured to simultaneously form openings 90 across a portion of thefilms 200 and/or 300 of approximately 24 inches wide by approximately 0.25 to 1 inches deep. For example, in a pre-fill process, thelaser 410 may be configured to simultaneously form openings 90 in abase film 200 covering approximately 12 cavities of thedrum 110. Further,multiple lasers 410 may be used together to fully cover a width of thedrum 110,films 200 and/or 300, or the take awayconveyor 190. - The
lid film 300 andbase film 200 may be a water soluble film, such as a polyvinyl alcohol (PVA) film. The films dissolve with contact of water or other fluids. The films may have a thickness of approximately 1 millimeter to approximately 5 millimeter. Such films are commercially available from Monosol of Merrillville, Indiana. Other water soluble films for forming the watersoluble packets 50 may include any water-soluble, film-forming polymer, copolymer, or mixtures of such polymers. The polymers may include vinyl polymers, including homopolymers and copolymers, having functionality rendering the polymers water-soluble, such as hydroxyl and carboxyl groups. Typical water-soluble polymers include at least one of polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, polyvinyl pyrrolidone, alkyl celluloses such as methylcellulose, ethylcellulose, propylcellulose and derivatives thereof, such as the ethers and esters of alkyl celluloses, and acrylic polymers such as water-soluble polyacrylates, polyacrylamides, and acrylic maleic anhydride copolymers. Suitable water-soluble polymers further include copolymers of hydrolyzed vinyl alcohol and a nonhydrolyzable anionic comonomer. - Although the methods, systems, and assemblies described above are described with respect to laundry and dishwashing water soluble packets, the methods, the
system 10, and/or thelaser assembly 400 may be used to form watersoluble packets 50 containing any of a variety ofproducts 60 such as, for example, powders, granules, or other solid compositions for any application, such as, for example, herbicides, fertilizers, lawn chemicals, rinse-aids, cleaners, etc. Generally, the watersoluble packets 50 will contain adry product 60. - In addition to the
packet forming assembly 100, one or more lasers may also be used with or integrated into horizontal form fill seal machines and/or vertical form fill seal machines in order form openings to vent the water soluble packets. Horizontal form fill seal machines and vertical form fill seal machines are also used to make water soluble packets. As with other aspects, the openings provide for the escape or release of air trapped in the water soluble packets. The laser also forms the openings to assist in the filling of the water soluble packet with detergent or other product. These aspects are shown inFIGS. 9 and 10 . -
FIG. 9 is a schematic view of a laser-assisted water soluble packet forming system 500 using one or more oflasers endless belt 515 operatively engaged to amotor 517 for movement of theendless belt 515. The packet forming assembly 500 also forms the watersoluble packets 50. Theendless belt 515 includes a plurality ofcavities 525. A bulk amount of theproduct 60 is placed in a feed hopper 550, which is generally positioned above theendless belt 515. As theendless belt 515 moves, the feed hopper 550 meters an amount of theproduct 60 into thecavities 525 on top of abase film 520. Alid film 530 is sealed to thebase film 520, and the watersoluble packets 50 are separated. Thebase film 520 is directed to theendless belt 515 from a basefilm supply roll 560. Abase film roller 565 presses thebase film 520 against theendless belt 515. Thelid film 530 is directed to theendless belt 515 from a lid film supply roll 570. A lid film roller 575 presses thelid film 530 against thebase film 520. Theendless belt 515 includes multiple rows of thecavities 525. Generally, asurface 518 of theendless belt 515 is covered with thecavities 525. Thecavities 525 include avacuum opening 533 that is in fluidic communication with avacuum passage 536. The packet forming assembly 500 includes a cuttingassembly 580 to separate the watersoluble packets 50 from each other. The cuttingassembly 580 may include avertical cutter 583 to make vertical separation cuts and ahorizontal cutter 586 to make horizontal separation cuts. After the watersoluble packets 50 are separated, theendless belt 515 drops the watersoluble packets 50 onto a take awayconveyor 590. - The
lasers FIG. 9 shows the use of multiple lasers, only one of thelasers lasers FIG. 7 , at a pre-fill stage or a post-fill stage in the packet forming process. Of course, one or more of thelasers base film 520 before thebase film 520 reaches theendless belt 515. Thelaser 505 b may form the openings 90 when thebase film 520 is over or drawn into thecavities 525. Thelaser 505 c may form the openings 90 in thelid film 530 before thelid film 530 is sealed to thebase film 520. Thelaser 505 d may form the openings 90 after the watersoluble packets 50 are formed on theendless belt 515 but before thepackets 50 are separated by the cuttingassembly 580. Thelaser 505 e may form the openings 90 after the watersoluble packets 50 are formed on theendless belt 515, separated by the cuttingassembly 580, and deposited on the take awayconveyor 590. Thelaser 505 e may be positioned directly over the take awayconveyor 590. -
FIG. 10 is a perspective view of a laser-assisted water solublepacket forming system 600 using one or both of lasers 605 a and 605 b with a vertical form fillseal machine 610. Thepacket forming assembly 600 generally forms watersoluble packets 55 from a single layer of afilm 650. A bulk amount of theproduct 60 is placed in afeed hopper 610, which is generally positioned above ahorn 620. Thehorn 620 includes an entrance opening 623 and anexit opening 626. Thehorn 620 also includes anexterior surface 630.Drive rollers 640 pull thefilm 650 over theexterior surface 630 while theproduct 60 is metered into an interior of thehorn 620 through the entrance opening 623. Thefilm 650 is provided by a supply roller 655. Afirst sealing device 660 seals opposingvertical edges film 650. Asecond sealing device 670 seals the other seams. Acutting device 680 separates theindividual packets 50 and drops thepackets 50 onto a take-away conveyor 690. - The lasers 605 a and 605 b may be integrated with the
packet forming assembly 600 in any of a variety of configurations or positions. AlthoughFIG. 10 shows the use of multiple lasers, only one of the lasers 605 a and 605 b needs to be employed. The lasers 605 a and 605 b may formopenings 91 in thepackets 55 at a pre-fill stage or a post-fill stage in the packet forming process. For example, the laser 605 a may form theopenings 91 in thefilm 650 before thefilm 650 reaches thehorn 620. For example, the laser 605 b may form theopenings 91 in thepackets 55 on the take-away conveyor 690. The laser 605 b may be positioned directly over the take-away conveyor 690. - The
systems 500 and 600 may also include thecontroller 420 to program and/or modulate any of a number of parameters and attributes of the laser pulses. Thesystems 500 and 600 may also include theencoder 430 to register and time the pulses from the lasers to strike the films or packets at the appropriate interval and time.
Claims (26)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US18/089,032 US20230138404A1 (en) | 2013-02-13 | 2022-12-27 | Systems and methods for forming openings in water soluble packet |
US18/377,014 US20240025582A1 (en) | 2013-02-13 | 2023-10-05 | Systems and methods for forming openings in water soluble packet |
Applications Claiming Priority (4)
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US201361764196P | 2013-02-13 | 2013-02-13 | |
US14/179,878 US20140228194A1 (en) | 2013-02-13 | 2014-02-13 | Systems and methods for forming openings in water soluble packets |
US17/329,067 US20210276742A1 (en) | 2013-02-13 | 2021-05-24 | Systems and methods for forming openings in water soluble packets |
US18/089,032 US20230138404A1 (en) | 2013-02-13 | 2022-12-27 | Systems and methods for forming openings in water soluble packet |
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US17/329,067 Continuation US20210276742A1 (en) | 2013-02-13 | 2021-05-24 | Systems and methods for forming openings in water soluble packets |
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US18/377,014 Continuation US20240025582A1 (en) | 2013-02-13 | 2023-10-05 | Systems and methods for forming openings in water soluble packet |
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US20230138404A1 true US20230138404A1 (en) | 2023-05-04 |
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US14/179,878 Abandoned US20140228194A1 (en) | 2013-02-13 | 2014-02-13 | Systems and methods for forming openings in water soluble packets |
US17/329,067 Abandoned US20210276742A1 (en) | 2013-02-13 | 2021-05-24 | Systems and methods for forming openings in water soluble packets |
US18/089,032 Abandoned US20230138404A1 (en) | 2013-02-13 | 2022-12-27 | Systems and methods for forming openings in water soluble packet |
US18/377,014 Pending US20240025582A1 (en) | 2013-02-13 | 2023-10-05 | Systems and methods for forming openings in water soluble packet |
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Application Number | Title | Priority Date | Filing Date |
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US14/179,878 Abandoned US20140228194A1 (en) | 2013-02-13 | 2014-02-13 | Systems and methods for forming openings in water soluble packets |
US17/329,067 Abandoned US20210276742A1 (en) | 2013-02-13 | 2021-05-24 | Systems and methods for forming openings in water soluble packets |
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Application Number | Title | Priority Date | Filing Date |
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US18/377,014 Pending US20240025582A1 (en) | 2013-02-13 | 2023-10-05 | Systems and methods for forming openings in water soluble packet |
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US (4) | US20140228194A1 (en) |
CA (1) | CA2842774A1 (en) |
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US20140336029A1 (en) * | 2013-05-07 | 2014-11-13 | The Procter & Gamble Company | Process for laser puncturing holes into water-soluble films |
CA2923311C (en) * | 2013-09-06 | 2020-04-14 | The Procter & Gamble Company | Pouches comprising apertured film wall materials and methods for making same |
GB2529431A (en) * | 2014-08-19 | 2016-02-24 | Kraft Foods R & D Inc | Packaging and a method of manufacture |
CN105416638B (en) * | 2015-12-15 | 2019-10-08 | 佛山市博维环保材料有限公司 | A kind of water-soluble film automatic packaging machine and technology of the package |
CN105416636B (en) * | 2015-12-15 | 2018-07-06 | 佛山市博维环保材料有限公司 | A kind of drum type brake mold cavity forming mechanism of water-soluble film packing machine |
CA3047813A1 (en) | 2017-01-04 | 2018-07-12 | Church & Dwight Co., Inc. | A system and a related method for forming a multi-chamber package |
ES2825499T3 (en) * | 2018-02-01 | 2021-05-17 | Procter & Gamble | Process for making a consumer goods product |
WO2019202534A1 (en) * | 2018-04-19 | 2019-10-24 | Church & Dwight Co., Inc. | Apparatus, system, and method for filling a chambered package |
MX2021004246A (en) * | 2018-11-08 | 2021-05-28 | Kwik Lok | Tamper evident packaging and methods of manufacturing the same utilizing a non-contact sealing device. |
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Also Published As
Publication number | Publication date |
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US20210276742A1 (en) | 2021-09-09 |
CA2842774A1 (en) | 2014-08-13 |
US20140228194A1 (en) | 2014-08-14 |
US20240025582A1 (en) | 2024-01-25 |
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