Apparatus and method for continuous motion rotatable forming of soluble pouches

Abstract

A machine and method of forming multi-compartment pouches is disclosed in which two pouches formed on separate adjacent formers ( 1, 3 ) are brought together in register and the lidding webs ( 9, 15 ) of the pouches joined to form a combined pouch ( 33 ). The pouches may be held on the formers ( 1, 3 ) by vacuum until the pouches are joined whereupon the vacuum holding one of the pouches on its former ( 1 ) is released while maintaining the vacuum holding the other pouch on its former ( 3 ) so that the combined pouches ( 33 ) are held on that former by the vacuum until the vacuum is released.

1 . A continuous motion machine for producing water-soluble pouches comprising two or more compartments from four water-soluble polymeric webs wherein two pouches are formed, filled and sealed on separate, adjacent donating and receiving formers, each pouch being formed from two water-soluble polymeric webs, and wherein the two such pouches are held by vacuum on their formers until they are joined together in register to form a combined pouch whereupon the vacuum in the donating former is removed releasing its pouch to the receiving former and the combined pouch still held by vacuum in the receiving former is separated from the combined web. 
     
     
         2 . The machine according to  claim 1  wherein the machine is configured to provide a partial perimetric seal between lidding webs of the two pouches. 
     
     
         3 . The machine according to  claim 1  wherein the machine is configured to provide a complete perimetric seal between lidding webs of the two pouches. 
     
     
         4 . The machine according to  claim 2  wherein the machine is configured to place a solid item between the lidding webs of the two pouches before the lidding webs are sealed together, thereby creating a compartment between the lidding webs. 
     
     
         5 . The machine according to  claim 4  wherein the machine is configured such that the solid item is visible through at least one window within both webs of either or both pouches 
     
     
         6 . The machine according to  claim 1  wherein the machine is configured to perforate a base web of at least one of the pouches. 
     
     
         7 . The machine according to  claim 6  wherein the machine is configured to perforate the base web prior to a forming operation. 
     
     
         8 . The machine according to  claim 6  wherein the machine is configured to perforate the base web during a forming operation. 
     
     
         9 . The machine according to  claim 6  wherein the machine is configured to perforate the base web after a forming operation 
     
     
         10 . A method of producing water-soluble pouches comprising two or more compartments by forming, filling and sealing two pouches on separate, adjacent formers each from two water-soluble polymeric webs, bringing the two webs together with the two such pouches in register while they are held by vacuum on their formers and joining the two such pouches together to form a combined web and combined pouch comprising two or more compartments, and removing the vacuum in one former releasing its pouch to the other former so that the combined pouch is still held by vacuum in the other former and separating the combined pouch from the combined web. 
     
     
         11 . (canceled) 
     
     
         12 . The method according to  claim 10  wherein one or more compartments contain a combination of at least two components comprising a granular or powder product, a thickened liquid or gel, and a three dimensional solid item such that all of the components retain their identity and none of the components become mutually antagonistic. 
     
     
         13 . The method according to  claim 10  wherein a partial perimetric seal is formed between lidding webs of the two pouches. 
     
     
         14 . The method according to  claim 10  wherein a complete perimetric seal is formed between lidding webs of the two pouches. 
     
     
         15 . The method according to  claim 13  wherein a solid component is inserted between the lidding webs of the two pouches prior to the two pouches being sealed or bonded together, thereby creating a compartment between the lidding webs. 
     
     
         16 . The method according to  claim 15  wherein the solid component is visible through at least one window within both webs of either or both pouches 
     
     
         17 . The method according to  claim 10  wherein a base web of at least one of the pouches is perforated before, during or after a forming operation. 
     
     
         18 . The method according to  claim 10  including removing the vacuum holding the separated, combined pouch on the other former. 
     
     
         19 . The method according to  claim 10  wherein a sealing pressure between the lidding films of pouches held by vacuum on the donating and receiving formers is adjustable. 
     
     
         20 - 22 . (canceled) 
     
     
         23 . A multi-compartment water-soluble pouch formed by combining two separate pouches, each pouch having one or more sealed compartments, wherein lidding webs of the combined pouches are joined by a perimetric seal to form a further compartment between the lidding webs of the combined pouches. 
     
     
         24 . The multi-compartment water-soluble pouch of  claim 23  wherein the perimetric seal forms a partial seal between the lidding webs of the combined pouches.