Method and apparatus for making a laundry detergent sheet

• US 10,639,825 B2
• Filed: 09/26/2016
• Issued: 05/05/2020
• Est. Priority Date: 02/06/2014
• Status: Active Grant

• Current Assignee: Dizolve Group Corp.
• Original Assignee: Dizolve Group Corp.
• Inventors: Jalbert, Luc, Miller, Leo, Surette, Marc, Bogdanova, Irina
• Primary Examiner(s): Thomas, Binu
• Application Number:
  US15/276,140
• Publication Number:
  US 20170008199A1
• Time in Patent Office: 1,317 Days
• Field of Search: None
• CPC Class Codes: B05C 5/007 Slide-hopper coaters, i.e. apparatus in which the liquid or other fluent material flows freely on an inclined surface before contacting the work
• CPC Class Codes: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 41/12 Spreading-out the material on a substrate , e.g. on the surface of a liquid
• CPC Class Codes: B29C 41/26 by depositing flowable material on a rotating drum
• CPC Class Codes: B29C 41/28 by depositing flowable material on an endless belt
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 41/38 Moulds, cores or other substrates
• CPC Class Codes: B29C 41/46 Heating or cooling
• CPC Class Codes: B29C 69/001 a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence
• CPC Class Codes: B29K 2029/04 PVOH, i.e. polyvinyl alcohol B29K2031/04 takes precedence
• CPC Class Codes: B29L 2007/002 Panels; Plates; Sheets
• CPC Class Codes: C11D 1/143 Sulfonic acid esters
• CPC Class Codes: C11D 11/00 Special methods for preparing compositions containing mixtures of detergents
• CPC Class Codes: C11D 17/041 Compositions releasably affixed on a substrate or incorporated into a dispensing means
• CPC Class Codes: C11D 3/2065 Polyhydric alcohols
• CPC Class Codes: C11D 3/3753 Polyvinylalcohol; Ethers or esters thereof

Abstract

A method and apparatus for making a laundry detergent sheet. Preferably, the laundry detergent sheet is capable of dissolving in a laundry cycle of an automatic washing machine. The method comprises the steps of preparing a first shelf-stable solution, preparing a second non-shelf-stable solution comprising a portion of the first shelf-stable solution, applying the second non-shelf-stable solution onto a surface, and drying the second non-shelf-stable solution on the surface.

Claims

1. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet; and

a sensor configured to monitor a liquid level of said solution in said applicator reservoir trough.

2. The apparatus as claimed in claim 1, wherein said laundry detergent sheet is substantially dissolvable in water.

3. The apparatus as claimed in claim 1, wherein said solution drying temperature is at least 75°

C.

4. The apparatus as claimed in claim 1, wherein said heater comprises heated oil, steam, infra-red, or direct contact electric heating pads.

5. The apparatus as claimed in claim 1, wherein said solution comprises polyvinyl alcohol.

6. The apparatus as claimed in claim 5, wherein said solution further comprises one or more of α

-olefin sulfonate, preservative, liquid detergent, water, starch, liquid paraffin, and glycerin.

7. The apparatus as claimed in claim 6, wherein said preservative comprises methylisothiazolinone or chloromethylisothiazolinone.

8. The apparatus as claimed in claim 6, wherein said liquid detergent comprises one or more of sodium laureth sulfate, sodium borate, sodium metasilicate, hexylene glycol, cocamidopropyl betaine, citric acid, lauryl glucoside, and laureth-4.

9. The apparatus as claimed in claim 1, further comprising a valve between said supply reservoir and said applicator reservoir trough, said valve being operatively coupled to said sensor to maintain a desired liquid level of said solution in said applicator reservoir trough.

10. The apparatus as claimed in claim 9, wherein said desired liquid level of said solution in said applicator reservoir trough is between one and two inches, inclusive.

19. The apparatus claimed in claim 1, wherein excess solution drains off the rising portion of said rotatable surface to return to said applicator reservoir trough.

11. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet; and

a floating lid resting on top of said solution in said supply reservoir, said floating lid being configured to minimize exposure of said solution to air.

12. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet; and

a gasket disposed between said applicator reservoir trough and said rotatable surface.

13. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet; and

a scraper member positioned adjacent said rotatable surface, above a horizontal plane of said rotatable cylinder.

14. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet; and

a scraper member positioned adjacent said rotatable surface, up to about 180 degrees away from said applicator reservoir trough.

15. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet; and

a scraper member positioned adjacent said rotatable surface, between about 180 degrees and about 330 degrees, inclusive, away from said applicator reservoir trough.

16. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet; and

a gravity feed associated with said supply reservoir, said gravity feed being adapted to allow said solution to flow into said applicator reservoir trough under gravity.

17. An apparatus for making a laundry detergent sheet, said apparatus comprising:

a rotatable cylinder defining a rotatable surface;

a supply reservoir for holding a solution adapted to form said laundry detergent sheet when said solution is dried on said rotatable surface;

an applicator reservoir trough in fluid communication with said supply reservoir, said applicator reservoir trough being positioned adjacent said rotatable cylinder such that movement of said rotatable surface in a rising direction relative to said applicator reservoir trough draws said solution from said applicator reservoir trough directly on to a rising portion of said rotatable surface, and excess solution drains off said rotatable surface in a direction opposite said rising direction by gravity to return to said applicator reservoir trough;

a heater configured to raise a temperature of said rotatable surface to a solution-drying temperature adapted to dry said solution on said rotatable surface to form said laundry detergent sheet;

at least one sensor configured to monitor a liquid level of said solution in said applicator reservoir trough; and

at least one valve operatively coupled to said sensor to maintain a desired liquid level of said solution in said applicator reservoir trough.

18. The apparatus as claimed in claim 17, further comprising a gravity feed associated with said supply reservoir, said gravity feed being adapted to allow said solution to flow into said applicator reservoir trough under gravity.