Powdered pouch and method of making same

• US 9,394,092 B2
• Filed: 03/14/2013
• Issued: 07/19/2016
• Est. Priority Date: 04/16/2012
• Status: Active Grant

• Current Assignee: Monosol LLC (Kuraray Company Limited)
• Original Assignee: Monosol LLC (Kuraray Company Limited)
• Inventors: Lee, David M., Parulekar, Yashodhan S.
• Primary Examiner(s): AUGHENBAUGH, WALTER
• Application Number:
  US13/828,299
• Publication Number:
  US 20130273277A1
• Time in Patent Office: 1,223 Days
• Field of Search: 428/34.8, 428/35.2, 428/35.4, 428/35.5, 428/35.7, 428/36.4, 428/36.6
• US Class Current: 1/1
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 27/28 comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/285 comprising polyethers
• CPC Class Codes: B32B 27/286 comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/306 comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/38 comprising epoxy resins
• CPC Class Codes: B32B 27/42 comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B65D 31/02 with laminated walls
• CPC Class Codes: B65D 37/00 Portable flexible containers not otherwise provided for
• CPC Class Codes: B65D 65/46 Applications of disintegrable, dissolvable or edible materials
• CPC Class Codes: C08J 2300/14 Water soluble or water swellable polymers, e.g. aqueous gels
• CPC Class Codes: C08J 7/042 with two or more layers, where at least one layer of a composition contains a polymer binder
• CPC Class Codes: C08J 7/0423 with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder
• CPC Class Codes: C08J 7/0427 with only one layer of a composition containing a polymer binder with more layers C08J7/042
• CPC Class Codes: C08J 7/06 with compositions not containing macromolecular substances
• CPC Class Codes: C08J 7/065 Low-molecular-weight organic substances, e.g. absorption of additives in the surface of the article
• CPC Class Codes: C09D 1/02 : alkali metal silicates
• CPC Class Codes: C09D 103/02 : Starch; Degradation products thereof, e.g. dextrin
• CPC Class Codes: C11D 17/042 : Water soluble or water disintegrable containers or substrates containing cleaning compositions or additives for cleaning compositions
• CPC Class Codes: C11D 17/043 : Liquid or thixotropic (gel) compositions
• CPC Class Codes: C11D 17/044 : Solid compositions
• CPC Class Codes: C11D 3/505 : encapsulated or adsorbed on a carrier, e.g. zeolite or clay
• CPC Class Codes: Y02W 90/10 : Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics
• CPC Class Codes: Y10T 428/1324 : Flexible food casing [e.g., sausage type, etc.]
• CPC Class Codes: Y10T 428/1334 : Nonself-supporting tubular film or bag [e.g., pouch, envelope, packet, etc.]
• CPC Class Codes: Y10T 428/1341 : Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit
• CPC Class Codes: Y10T 428/1345 : Single layer [continuous layer]
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1372 : Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/1379 : Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit

Abstract

Disclosed herein are water-soluble films and resulting packets including a water-soluble film coated by a powder, wherein the powder includes a mixture of a powdered lubricant and an active agent. Optionally, the active agent may be encapsulated, e.g. microencapsulated, for release of the active agent through mechanisms including, but not limited to, mechanical rupture, melt, ablation, dissolution, diffusion, biodegradation, or pH-controlled release. Active ingredients described include enzymes, oils, flavors, colorants, odor absorbers, fragrances, pesticides, fertilizers, activators, acid catalysts, metal catalysts, ion scavengers, bleaches, bleach components, fabric softeners and combinations thereof. Examples of packet fills include laundry detergents, bleach and laundry additives, fabric care, dishwashing, hard surface cleaning, beauty care, skin care, other personal care, and foodstuffs.

Claims

1. A water-soluble packet, comprising:

a water-soluble film in the form of a packet and coated by a powder, the powder comprising a mixture of

a powdered lubricant and

an active agent, provided that when the active agent is a fragrance the fragrance is microencapsulated, wherein the powder is present in an amount in a range of 0.01 mg/cm² to 10 mg/cm².

2. The water-soluble packet of claim 1, wherein the active agent is microencapsulated.

3. The water-soluble packet according to claim 1, wherein the powdered lubricant is selected from the group consisting of starches, modified starches, silicas, siloxanes, calcium carbonate, magnesium carbonate, clay, talc, silicic acid, gypsum, zeolites, cylclodextrins, calcium stearate, zinc stearate, alumina, magnesium stearate, alumina, zinc oxide and combinations thereof.

4. The water-soluble packet according to claim 1, wherein the active agent is selected from the group consisting of enzymes, oils, flavors, colorants, odor absorbers, fragrances, pesticides, fertilizers, activators, acid catalysts, metal catalysts, ion scavengers, bleaches, bleach components, fabric softeners or combinations thereof.

5. The water-soluble packet of claim 2, wherein the microcapsule is characterized by one or more of the following release mechanisms:

mechanical rupture, dissolution, diffusion, ablation, biodegradation, melt, or a pH triggered release mechanism.

6. The water-soluble packet of claim 1, wherein the powdered lubricant is characterized by a mean particle size in a range of 1 μ

m to 100 μ

m.

7. The water-soluble packet according to claim 2, wherein said microcapsule is selected from one or more of:

melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, poly methyl methacrylate, polystyrene, polysulfone, poly tetrahydrofuran, gelatin, gum arabic, starch, polyvinylpyrrolidone, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly (ethylenevinyl acetate), cellulose nitrate, silicones, poly(lactideco-glycolide), paraffin, carnauba, spermaceti, beeswax, stearic acid, stearyl alcohol, glyceryl stearates, shellac, cellulose acetate phthalate, and zein.

8. The water-soluble packet according to claim 2, wherein the microcapsule is characterized by a mean particle size in a range of 0.1 μ

m to 200 μ

m.

9. The water-soluble packet according to claim 2, wherein the mean particle size of the microcapsule is greater than the mean particle size of the powdered lubricant, wherein the microcapsule is selected from one or more of the group consisting of melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, polymethyl methacrylate, polystyrene, polysulfone, poly tetrahydrofuran, gelatin, gum arabic, starch, polyvinyl pyrrolidone, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly (ethylenevinyl acetate), cellulose nitrate, silicones, poly(lactideco-glycolide), paraffin, carnauba, spermaceti, beeswax, stearic acid, stearyl alcohol, glyceryl stearates, shellac, cellulose acetate phthalate, and zein.

10. The water-soluble packet according to claim 2, wherein microcapsule agglomerates are formed and the mean microcapsule agglomerate size is greater than the mean particle size of the powdered lubricant, wherein the microcapsule is selected from one or more of the group consisting of melamine formaldehyde, polyurethane, urea formaldehyde, chitosan, polymethyl methacrylate, polystyrene, polysulfone, polytetrahydrofuran, gelatin, gum arabic, starch, polyvinyl pyrrolidone, carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, arabinogalactan, polyvinyl alcohol, polyacrylic acid, ethylcellulose, polyethylene, polymethacrylate, polyamide, poly(ethylenevinyl acetate), cellulose nitrate, silicones, poly(lactidoco-glycolide), paraffin, carnauba, spermaceti, beeswax, stearic acid, stearyl alcohol, glyceryl stearates, shellac, cellulose acetate phthalate, or zein.

11. The water-soluble packet according to claim 1, wherein the powder comprises 1 wt % to 99 wt % active agent.

12. The water-soluble packet according to claim 1, wherein the powder comprises 1 wt % to 99 wt % powdered lubricant.

13. The water-soluble packet according to claim 1, wherein the water-soluble film comprises a material selected from the group consisting polyvinyl alcohol, modified polyvinyl alcohols, polyacrylates, water-soluble acrylate copolymers, methylcellulose, carboxymethylcellulose, dextrin, ethylcellulose, hydroxyethylcelleulose, hydroxypropyl methylcellulose, malodextrin, polymethacrylates, polyvinyl alcohol copolymers, hydroxypropyl methyl cellulose, polyvinyl pyrrolidone, polyalkylene oxides, acrylamide, acrylic acid, and combinations thereof.

14. The water-soluble packet according to claim 1, further comprising a solid, liquid, or gel composition enclosed within the water-soluble packet.

15. The water-soluble packet according to claim 14, wherein the enclosed composition comprises laundry detergents, bleach and laundry additives, fabric care, dishwashing, hard surface cleaning, beauty care, skin care, other personal care, or food product compositions.

16. The water-soluble packet according to claim 14, wherein the active agent is capable of a chemical reaction with a component of the composition enclosed in the water-soluble film.

17. The water-soluble packet according to claim 16, wherein the active agent is capable of a chemical reaction with a component of the composition enclosed in the water-soluble film in an aqueous solution.

18. The water-soluble packet according to claim 14, wherein either the active agent is unstable in the presence of a component of the composition enclosed within the water-soluble film, or a component of the composition enclosed within the water-soluble film is unstable in the presence of the active agent, or both the active agent and a component of the composition enclosed within the water-soluble film are unstable in the presence of each other.

19. The water-soluble packet according to claim 17, wherein

the composition enclosed in the water-soluble film comprises a percarbonate;

and

the active agent comprises tetraacytylethylenediamine (TAED).

20. The water-soluble packet according to claim 3, wherein the powdered lubricant is kaolin.

21. A method of providing a water-soluble packet with additional functionality provided by an active agent, comprising:

coating a water-soluble film in the form of a water-soluble packet with a powder comprising

a powdered lubricant and

the active agent, provided that when the active agent is a fragrance the fragrance is microencapsulated, wherein the powder is present in an amount in a range of 0.01 mg/cm² to 10 mg/cm².

22. The method according to claim 21, wherein the active agent is microencapsulated.

23. The method according to claim 21, wherein the water-soluble packet further comprises a solid, liquid, or gel composition enclosed within the water-soluble packet.

24. The method according to claim 21, wherein the powdered lubricant is selected from the group consisting of starches, modified starches, silicas, siloxanes, calcium carbonate, magnesium carbonate, clay, talc, silicic acid, gypsum, zeolites, cyclodextrins, calcium stearate, zinc stearate, magnesium stearate, alumina, zinc oxide and combinations thereof.

25. The method according to claim 21, wherein said active agent is selected from the group consisting of enzymes, oils, flavors, colorants, odor absorbers, pesticides, fertilizers, activators, acid catalysts, metal catalysts, ion scavengers, bleaches, bleach components, fabric softeners and combinations thereof.

26. The method according to claim 21, further comprising preparing the coating powder by a process comprising:

providing a master batch of a first powder comprising a first powdered lubricant; and

mixing the active agent with a portion of the master batch to form a daughter batch of coating powder.

27. The method according to claim 26, wherein a continuous feed of active agent is mixed with a continuous feed of the master batch to form the coating powder.

28. The method according to claim 21, wherein the process of applying the coating powder to the water-soluble film in the form of a water-soluble packet comprises sprinkling, brushing, dusting, or spraying.

29. The method according to claim 24, wherein the powdered lubricant is kaolin.