Injection molded containers

Abstract

A process for the manufacture of single or multi-compartment rigid, water-soluble container, containing a detergent composition wherein the container is at least partially made of injection moulded water soluble polymer; the process comprising the steps of forming the container, keeping the container under substantially anhydrous conditions, filling the container with the detergent composition and sealing, wherein the container is allowed to contact/brought into contact with a plasticiser after sealing.

1 . A process for the manufacture of a single or multi-compartment, rigid, water-soluble container, containing a detergent composition, wherein the container is at least partially formed of injection moulded water soluble polymer; the process comprising the steps of forming the container, filling with the detergent composition and sealing, wherein the container is allowed to contact brought into contact with a plasticiser after sealing.  
   
   
       2 . A process according to  claim 1 , wherein the plasticiser is water.  
   
   
       3 . A process for the manufacture of a single or multi-compartment, rigid, water-soluble container, containing a detergent composition, wherein the container is at least partially formed of injection moulded water soluble polymer; the process comprising the steps of forming the container, keeping the container under substantially anhydrous conditions, filling with the detergent composition and sealing, wherein the container is allowed to contact/brought into contact with a plasticiser after sealing.  
   
   
       4 . A process according to  claim 3 , wherein the container comprises a PVOH polymer or a derivative thereof.  
   
   
       5 . A process according to  claim 4 , wherein the container comprises an additional injection moulded water-soluble polymer, which when dissolved in water is active in detergency.  
   
   
       6 . A process according to  claim 5 , wherein the additional injection moulded water-soluble polymer is poly(vinylpyrrolidone), poly(acrylic acid) or an ester thereof or poly(maleic acid) or an ester thereof, or a copolymer of any thereof.  
   
   
       7 . A process according to  claim 4 ,  5 , or  6 , wherein the first and additional polymer(s) are simultaneously or sequentially injection moulded.  
   
   
       8 . A process according to any one of the preceding claims wherein the container is made from a water-soluble receptacle part and is sealed by a water-soluble closure part, preferably in the form of a film or injection-moulded, rigid closure.  
   
   
       9 . A process according to  claim 8  wherein the closure part comprises a poly(vinyl alcohol) film or closure.  
   
   
       10 . A process according to  claim 8  or  9  wherein the receptacle part has side walls which terminate at their upper end in an outward flange, to which the closure part is sealingly secured.  
   
   
       11 . A process according to  claim 8  wherein the closure part comprises a plastic film.  
   
   
       12 . A process according to any one of the preceding claims wherein the detergent composition comprises a powder, gel, paste or low water liquid formulation.  
   
   
       13 . A process according to any one of  claims 10  to  12  wherein the container comprises a tablet formulated for delayed and/or sustained release of a material.  
   
   
       14 . A process according to  claim 8  wherein the receptacle part comprises an upstanding wall which separates compartments thereof.  
   
   
       15 . A process according to any one of  claims 8  to  14  wherein the closure part is a transparent or translucent material.  
   
   
       16 . A process as claimed in any one of the  claims 1  to  15 , wherein the containers are joined together in an array arrangement, but are readily separable from each other for use.  
   
   
       17 . A method of manufacture of an array as defined in  claim 16 , which method comprises: forming an array of receptacle parts, each receptacle part being connected to adjacent receptacle parts, but being separable from them by a snap or tear action; charging the receptacle parts with washing composition; and sealingly securing a sheet of a water-soluble polymer over the top of the array, to form the closure parts for all the receptacle parts of the array.  
   
   
       18 . A process as claimed in any claim from 1 to 15, which comprises melting the polymer(s), injecting the molten polymer(s) into a mould, removing the rigid water soluble container from the mould and adding the fabric care, surface care, or dishwashing composition into the container.  
   
   
       19 . A process according to  claim 18  wherein a first polymer and an additional polymer(s) are simultaneously or sequentially injected into the mould.  
   
   
       20 . A process according to  claim 19  wherein the first polymer and the additional polymer(s) are sequentially injected into the mould, in any order, by one of the following techniques, multi-component injection moulding or sandwich injection moulding.  
   
   
       21 . A process according to  claim 20  wherein the first polymer and the additional polymer(s) are sequentially injected into the mould, in any order, injection moulding a polymer or molten polymer mix into a mould, removing the solid polymer and inserting into a second mould and injection moulding a second polymer or polymer mix into the second mould.  
   
   
       22 . A process according to  claim 20  wherein the first polymer and the additional polymer(s) are sequentially injected into the mould, in any order, injection moulding a polymer or molten polymer mix into a part of a mould, injection moulding a second polymer or molten polymer mix into a further part of the mould.  
   
   
       23 . A process according to  claim 20  wherein the first polymer and the additional polymer(s) are simultaneously injection moulded into the mould as a molten mix.  
   
   
       24 . A process for the manufacture of a single or multi-compartment rigid, water-soluble container, containing a detergent composition, comprising:—
 (i) Forming an array of containers in an injection moulding process;    (ii) Removing the array from the mould;    (iii) Placing the array in a storage area, substantially free of moisture;    (iv) Filling the array of containers with the detergent composition;    (v) Placing a closure on the array;    (vi) Sealing the containers; and    (vii) Separating the array into individual containers;