Method Of Manufacturing Embedded Water Soluble Film Carrier

Abstract

A water-soluble film (WSF) system comprises at least one active material embedded/entrapped in the film so as to provide precise and desired release of the at least one active material therefrom. The at least one active material includes detergents, enzymes, softeners, perfumes, pesticides, fungicides, active ingredients, dyes, pigments, hazardous chemicals, active agents for cleaning laundry, dishes, floorings, walls, furniture, fluffs, pulp, and combinations thereof. Online and offline processes can be used for the manufacture of multi-layered WSFs with or without liners. The WSFs can be formed in desired shapes to selectively entrap interacting/non-interacting materials and combinations thereof. The process also provides options for the use of a wide range of raw materials, liners such as paper, film, foil, fabric, etc.

We claim: 
     
         1 . A water soluble film (WSF) system comprising a water soluble film having at least one active material embedded/entrapped in said film at a selective concentration and depths/dispositions in said film such that the said active material thus embedded/entrapped in said film is delivered at preselected desired quantities. 
     
     
         2 . The WSF system as claimed in  claim 1  wherein said embedded/entrapped materials are selected active materials. 
     
     
         3 . The WSF system as claimed in  claim 2  wherein said active materials are selected from detergents, enzymes, softeners, perfumes, pesticides, fungicides, active ingredients, dyes, pigments, hazardous chemicals, active agents for cleaning laundry, dishes, floorings, walls, furniture, and combinations thereof embedded in the WSF for delivering in precise and desired quantities. 
     
     
         4 . The WSF system as claimed in  claim 1  wherein said water soluble film comprises multilayered film. 
     
     
         5 . The WSF system as claimed in  claim 1  wherein the water soluble film is made of a material that dissolves in the presence of water and wherein the film is formed by providing a formulation for a water soluble film comprising said at least one active material and wherein a solution of the formulation is cast on an elongate liner to form said water soluble film on said liner with said at least one active material physically incorporated in the water soluble film such that the active material is embedded in the water soluble film of the WSF system. 
     
     
         6 . The water soluble film system as claimed in  claim 5  wherein said at least one active material is selected from the group consisting of detergents, enzymes, softeners, perfumes, pesticides, fungicides, active ingredients, dyes, pigments, hazardous chemicals, active agents for cleaning laundry, dishes, floorings, and walls, and combinations thereof. 
     
     
         7 . The water soluble film system as claimed in  claim 5  wherein the liner is a paper, film, foil or fabric, and the film liner material is preferably selected from the group comprising plain, embossed, metallized, gloss, matte, extrusion coated laminated or release coated. 
     
     
         8 . The water soluble film system as claimed in  claim 7  wherein the liner is a polyester film. 
     
     
         9 . The water soluble film system as claimed in  claim 5  wherein the film is of about 2 microns to about 500 microns thick. 
     
     
         10 . The water soluble film system as claimed in  claim 5  wherein the film is about 10 microns to about 300 microns thick, 
     
     
         11 . The water soluble film system as claimed in  claim 5  wherein the film is about 12 microns to about 250 microns thick. 
     
     
         12 . A product/package comprising the WSF system as claimed in  claim 1  wherein said water soluble film and the at least one active material are selectively embedded or entrapped in the water soluble film such that the at least one active material is protected from environmental factors until the product/package is used. 
     
     
         13 . The product/package as claimed in  claim 12  comprising a carrier liner adapted to be at least partially removed before use for dispensing at least some of said embedded/entrapped active materials from said WSF. 
     
     
         14 . A process for the manufacture of a water soluble film with at least one embedded active material, the method comprising the steps of:
 i) taking up an elongate liner from a liner source;   ii) providing a formulation for the water soluble film, the formulation comprising at least one active material; the at least one active material being selected from the group consisting of detergents, enzymes, softeners, perfumes, pesticides, fungicides, active ingredients, dyes, pigments, hazardous chemicals, active agents for cleaning laundry, dishes, floorings, and walls, and combinations thereof;   iii) casting a solution of the formulation with said at least one active material from step (ii) on the elongate liner to form an elongate water soluble film on said elongate liner with said at least one active material physically incorporated in the water soluble film such that the active material is embedded in the water soluble film;   iv) drying the cast water soluble film with said at least one active material embedded and physically incorporated in said water soluble film on said elongate liner.   
     
     
         15 . The process according to  claim 14  wherein the liner is a polyester film liner. 
     
     
         16 . The process according to  claim 14  further comprising detaching the cast water soluble film from step (iv) from the liner of step (i). 
     
     
         17 . The process according to  claim 14  comprising a further step of casting a solution of a formulation for at least one further water soluble film on the embedded water soluble film from step (iv) at a subsequent casting head to form a multi-layer water soluble film, and drying the multi-layer water soluble film to produce a multi-layer water soluble substrate. 
     
     
         18 . The process according to  claim 17  wherein said at least one active material is an at least one first active material, said process further comprising providing at least one second active material in the formulation for casting said at least one further water soluble film; wherein said at least one second active material is the same as, or different from, the at least one second active material. 
     
     
         19 . The process according to  claim 17 , wherein the multi-layer water soluble film comprises combinations of water soluble films which dissolve at different temperatures in any desired sequence. 
     
     
         20 . The process according to  claim 14  wherein raw materials for the water soluble film are selected from the group consisting of polyvinyl alcohol copolymer ionomers, polyvinyl alcohol homopolymer, non-ionomeric polyvinyl alcohol polymer, polymethacrylate, polyvinyl alcohol, polyacrylamide, polymethacrylamide, polyacrylic acid, and polymethacrylic acid or the group consisting of polyethylene glycols, polyvinylpyrrolidone, proteinaceous binders, gelatin, modified gelatins, phthaloyl gelatin, polysaccharides, starch, gum Arabic and dextrin, water soluble cellulose derivatives, and combinations thereof.