DELAYED RELEASE DELIVERY SYSTEM FOR LAUNDRY AND OTHER APPLICATIONS

Abstract

A delayed release delivery system, comprising: a container for housing contents to be delivered; wherein the container is insoluble in water and sealable and comprises one or more conditionally sealed orifices; and a sealing member for conditionally sealing the one or more conditionally sealed orifices.

Description

TECHNICAL FIELD

The disclosure relates to a delayed release delivery system, and specifically to a container having a conditional sealable orifice, for example, for laundry and other applications.

BACKGROUND

Throughout human history chemical additives, such as detergents, have been used in conjunction with mechanical agitation to clean clothing. More recently the powdered laundry detergents have been losing group to liquid agents and in particular to liquid agents in dissolvable laundry detergent “pods.” However, while these “pods” appear to adequately disperse liquid laundry detergent they are not well suited to applications that require the use of a dry powdered laundry detergent. When applied to a dry powder, the dissolvable pods do not adequately disperse the powder, which can lead to undesired clumping of the detergent and unsightly residue left on clothing. Thus, new and improved technologies are needed to aid in the dispersion of dry powder detergents. Such improved technologies would also benefit other applications and industries where a dried substance needs to be adequately dispersed in a liquid environment.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings and the appended claims. Embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.

FIG. 1 is a schematic showing an example of a delayed release delivery system having a vertical “U” shaped cut, in accordance with embodiments disclosed herein.

FIG. 2 is a schematic showing an example of a delayed release delivery system having a horizontal “U” shaped cut, in accordance with embodiments disclosed herein.

FIG. 3 is a schematic showing an example of a delayed release delivery system having a horizontal “U” shaped cut with stress relief corners, in accordance with embodiments disclosed herein.

FIG. 4 is a schematic showing an example of a delayed release delivery system having a horizontal “X” shaped cut, in accordance with embodiments disclosed herein.

FIG. 5 is a schematic showing an example of a delayed release delivery system having a horizontal “O” shaped cut with stress relief corners, in accordance with embodiments disclosed herein.

FIG. 6 is a schematic showing an example of a delayed release delivery system having a poly bag with fold-over seal, in accordance with embodiments disclosed herein.

FIGS. 7A and 7B are schematic drawings showing an example of a label used for sealing die-cut bags of a delayed release delivery system, in accordance with embodiments disclosed herein.

FIGS. 8A and 8B are schematic drawings showing an example of a multilayer label with water resistant surface and a patterned exposed paper used for sealing die-cut bags of a delayed release delivery system, in accordance with embodiments disclosed herein.

DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS

In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope. Therefore, the following detailed description is not to be taken in a limiting sense.

Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments; however, the order of description should not be construed to imply that these operations are order-dependent.

The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of disclosed embodiments.

The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical contact with each other. “Coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.

For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” means (A), (B), or (A and B). For the purposes of the description, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C). For the purposes of the description, a phrase in the form “(A)B” means (B) or (AB) that is, A is an optional element.

The description may use the terms “embodiment” or “embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous, and are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.).

With respect to the use of any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

The current technology was developed to solve a problem of providing for delayed release of powdered detergents into an aqueous medium, such as in a washing machine mid cycle. Water-soluble packaging such as PVOH films, labels, ties, etc. that are currently used in laundry pods and other products were found to be unsuitable for the delayed release of powdered detergents or other fabric care ingredients. For example the low water temperature soluble bags instantly dissolved, which does not allow for delayed release. The bags rated for higher temperature opened a bit more slowly (not much), and would either take a long time to fully dissolve, which did not adequately disperse the contents, or they would leave behind a nasty wad of PVOH goop.

To overcome these deficiencies, disclosed are systems, articles of manufacture, and methods for the delayed release of a dry powder in a liquid environment, for example for laundry and other applications. The disclosed systems are particularly suited for any surface treatment process for textiles or fabrics, for example, laundry, the application of epoxy-like coatings, dyeing processes, waterproofing, the application of antimicrobial/anti odor ingredients, the application of fire resistant coatings, and the application of mosquito repellant. The disclosed systems are amenable for use with multicomponent systems, such as epoxies, where it would be possible to have more than one container attached together each carrying one part of a multi-part system.

In embodiments, a delayed release delivery system includes a container having one or more conditionally sealed orifices for housing contents to be delivered. These conditionally sealed orifices are configured to open after prolonged contact with an aqueous environment. A sealing member is used for conditionally sealing the one or more conditionally sealed orifices. The sealing member can be selected such that prolonged contact with water causes the sealing member to weaken and allow the contents of the container to breach the seal, for example in conjunction with mechanical agitation of the container, such as might be found in a washing machine or mixing device.

The delayed release delivery system is typically configured so that the contents of the container are released after the system has been exposed to water in a mechanically agitated environment for about 1 minute to about 10 minutes, such as from 4 to 6 minutes, from 2 to 7 minutes, or from 1 to 5 minutes. Although, in some examples the delayed release delivery system is configured so that the contents are delivered at a time greater than 10 minutes. The delivery times can be adjusted based on the application, for example in certain applications, such as laundry, it may be advantageous to release the contents of the system after about 1 to about 5 minutes, while in other applications it may be advantageous to release the contents of the container after a more prolonged time, such as greater than 10 minutes.

A container for a delayed release delivery system is typically water tight and/or water resistant when sealed, for example to keep the contents from getting wet until a desired time, such as after a particular time that the delayed release delivery system is in contact with water. In embodiments, the container is a non-soluble film bag or other soft/flexible water resistant packaging. In embodiments, the container includes a laminate film packaging material, such as a commercially available laminate film packaging material, for example vinyl pouches, low-density polyethylene (LDPE), olefin bags, and the like. In embodiments, the laminate film packaging material comprises of a sandwich of PET/Polyester/Polytheylene/Aluminum/polyethylene/LLDPE.

In embodiments, the container is a bag, sachet, and/or pouch and the sealing member is a pressure sensitive sticker that is applied to seal an orifice in the container. In embodiments, the container includes a front sheet, a back sheet, edges sealing the front sheet to the front sheet such that the container defines a cavity disposed between the front sheet and the back sheet for holding the contents to be delivered. In embodiments, the one or more conditionally sealed orifices include at least one orifice in the front sheet. In embodiments, the one or more conditionally sealed orifices include at least one orifice in the back sheet. In embodiments, the one or more conditionally sealed orifices include at least one orifice in the front sheet and at least one orifice in the back sheet. In embodiments, the one or more conditionally sealed orifices include one or more flaps, which can be held in place by the sealing member, for example to cover the orifice (see, for example, FIGS. 1-5). The sealing member can be applied to the inside and/or the outside of the container as needed. In other embodiments, there is no flap. In embodiments, the one or more conditionally sealed orifices are present on an edge of the container, which can be folded over and held in place by the sealing member (see, for example FIG. 6). In versions of the container having a flap, the flap remains attached to the container after it bursts open and releases the contents.

The size of orifice can be variable relative to the size of the container. In some specific examples, the container has a width of about 4.85 inches and a height of about 6.25 inches. In some specific examples, the orifice has a width of about 2.00 inches and a height of about 2.00 inches. In some specific examples, the sealing member has a width of about 3.00 inches and a height of about 3.00 inches. As can be seen from FIGS. 1-5, there are variations on the shape and or size of the container and/or the orifice, for example an orifice with or without a flap could be generally circular, ellipsoid, or some variation of a polygon. Even irregular shapes are envisioned within the scope of this disclosure.

One of the important factors in the choice of container and/or orifice size and/or relative size to one another. For example the size and shape can be chosen so that when the sealing member is breached substantially all of the contents are released from the container, such is inside of the washing machine. Thus, the orifice should be selected to be large enough to not impede any of the material from getting out.

In embodiments, a sealing member is selected that becomes weakened, for example mechanically, when exposed to water, such that mechanical tumbling, as one might find in a washing machine, facilitates rupture of the sealing member. By selection of the appropriate materials for the sealing member, the timing of this release can be effectively tuned such that the contents of the container are released at a desired time, for example about 1 to about 5 minutes after starting a washing machine. In embodiments, the orifice is configured so that substantially all of the contents of the container are released upon opening of the orifice.

In embodiments, the sealing member includes a sticker and/or label which is at least partially water soluble. In embodiments, the sticker includes a face sheet, a backing material, and an adhesive, for example laid down in that order, wherein the adhesive is configured to couple to the container. In embodiments, the sticker includes a permanent acrylic adhesive, a paper backing, and a surface coat. Typically this film or sticker is not intrinsically water soluble, but the paper backing rapidly loses any mechanical strength upon becoming wet or damp and is essentially abraded off during tumbling, such as might be experienced in a washing machine. In embodiments, the adhesive is not water soluble and stays behind on the container for easy removal. The tumbling action puts enough deformation on the container to cause the sealing member to fail. In embodiments, a combination of mechanical force and solubility of the sticker open the orifice and spill the contents. In embodiments, the sealing member is a sticker or label that comprises a surface finish overlying a paper layer and permanent pressure sensitive adhesive under the paper layer (see, for example FIGS. 7A and 7B). In some embodiments the sticker is a 2 mil thick paper sticker with a permanent acrylic adhesive and a surface top coat, for example that provides a matte finish. In another embodiment, the sealing member is a sticker or label that has a water resistant frame (such as biaxially-oriented polypropylene (BOPP)) surrounding a paper such as vellum whereby the paper may or may not have an adhesive covering the cut, can absorb water to become fragile (see, for example, FIGS. 8A and 8B).

In some embodiments, the top coat present on the top surface of the sticker can be selected to control, at least partially, the rate of disintegration of the label. In some embodiments, the top coat is a varnish, which provides texture, but it also seals/covers the paper temporarily controlling the rate of disintegration. In some embodiments, the top coating is chosen so that the contents are released in the first approximately 5 minutes after addition to the aqueous environment. In some embodiments the topcoat for a matte or glossy finish is on the order of 5-15 μm. These coatings are typically comprised of some polymer binder and clay. The glossiness or matte finish is due to the relative microporosity of the topcoat and can be achieved with a wide variety of materials. In addition, the compression of the paper as it rolls also helps to increase the density of both the paper and the coating.

In embodiments the contents of the container comprise a water soluble or water dispersible powder, such as laundry detergent. In embodiments the contents of the container comprise a bonding agent or activator that would be used as part of a two-part reaction such as an epoxy, dyeing process, textile surface coating process, or other surface treatment. The disclosed systems, and methods are particularly useful for dispersing particles, such as those compositions disclosed in International Patent Application No. PCT/US2016/059579, which is specifically incorporated herein by reference in its entirety. Thus, in some embodiments, a disclosed delayed release delivery system includes one or more of the compositions disclosed in International Patent Application No. PCT/US2016/059579.

In embodiments, the container comprises a first container and the delayed release delivery system comprises one or more additional containers for holding the same or different contents than the first container. In embodiments, the first container and the one or more additional containers are configured to burst at different delay times. In embodiments, the first container and the one or more additional containers are configured to burst at the same delay times.

FIGS. 1-5 depict various examples of a delayed release delivery system, in accordance with embodiments disclosed herein. FIG. 1 shows a delayed release delivery system having a vertical “U” shaped cut. FIG. 2 shows a delayed release delivery system having a horizontal “U” shaped cut. FIG. 3 shows a delayed release delivery system having a horizontal “U” shaped cut with stress relief corners built into the “U” shaped cut. FIG. 4 shows a delayed release delivery system having a horizontal “X” shaped cut. FIG. 5 shows a delayed release delivery system having a horizontal “O” shaped cut with stress relief corners built into the “O” shaped cut. With respect to FIGS. 1-5, a delayed release delivery system 100 includes a container 102, such as a bag, a pouch, or the like, having a height H1 and width W1. In some specific examples, the container has a width W1 of about 4.85 inches and a height H1 of about 6.25 inches. In the embodiments shown, the container includes a front sheet 104, a rear sheet (not visible in these views) opposite the front sheet 104, the front sheet 104 and the rear sheet are sealed at edges 106, so as to create a sealed internal chamber or pocket that can be used to hold contents to be delivered after a delayed time, for example from about 1 minute to about 10 minutes after the delayed release delivery system has contacted water. As shown, to deliver the contents of the container 102, the front sheet includes a conditionally sealed orifice 108, which, in the embodiments shown in FIGS. 1-5 is formed by cutting the front sheet 104 in a desired pattern at cut lines 110, for example by laser cutting the material in the desired pattern. The orifice 108 has a width W2 and a height H2 sized so as to essentially deliver all of the contents of the container 102 almost immediately once the conditionally occluded orifice 108 is opened. In some specific examples, the orifice has a width W1 of about 2.00 inches and a height H2 of about 2.00 inches. In the embodiments shown in FIGS. 1-5, the front sheet 104 is only partially cut to form the orifice 108 and the orifice can be occluded by a flap 112, for example by holding the flap 112 in place for a time until it is desirable to release the contents through the orifice 108. In the embodiments shown the flap 112 is contiguous with the front sheet 104

In the embodiment shown in FIG. 1, the orifice 108 is vertically “U” shaped with rounded over corners. It is envisioned that these corners could be of various shapes, such as round, square, or even angled, such as cut at a 45° or other angle. It is envisioned that in any of the embodiments, such as shown in FIGS. 1-5, that the rear sheet of the container 102 can be identical in to the front sheet 104, for example cut with an orifice 108 that is either identical or different in shape than the orifice 108 of the front sheet 104.

FIG. 2 shows an embodiment where the orifice 108 is oriented with a horizontal “U” shape. Also shown in this view is the presence of a conditional sealing member 120. The conditional sealing member 120 has a width W3 (which in the embodiment shown is the same dimension, although not necessarily, as the height), that is sufficient to cover the orifice 108, such that the conditional sealing member 120 holds the orifice 108 closed, for example during shipping and initial deployment. For example the conditional sealing member 120 can occlude the orifice 108 until such a time as the contents should be delivered, at which time the conditional sealing member 120 ruptures to release the contents of container 102. In some specific examples, the sealing member has a width W3 of about 3.00 inches and a height H3 of about 3.00 inches.

FIG. 3 shows an embodiment where the orifice 108 is oriented with a vertical “U” shape. In this embodiment, the flap 112 further includes stress relief cuts 109 at the corners, for example, to keep the flap 112 from ripping off during mechanical agitation, for example mechanical agitation that may occur in a washing machine, such as a commercial or industrial washing machine.

FIG. 4 shows an embodiment where the orifice 108 is formed from two crossing cuts 110 oriented in an “X” shape. The “X” cut forms four flaps 112 converging at the center of the orifice 108. Also shown in this view is the conditional sealing member 120 (dashed line). The conditional sealing member 120 covers all four flaps 112, keeping them closed until the correct time to deliver the contents.

FIG. 5 shows an embodiment where the orifice 108 has “O” shape. In this embodiment, the flap 112 includes stress relief cuts 109 at the corners, for example, to keep the flap 112 from ripping off during mechanical agitation, for example mechanical agitation that may occur in a washing machine, such as a commercial or industrial washing machine. Also shown in this view is the conditional sealing member 120 (dashed line). The conditional sealing member 120 covers the flap 112, keeping it closed until the correct time to deliver the contents.

FIG. 6 shows an alternate embodiment where the orifice 108 is formed in the top of the container 102. In this view, a rear sheet 105 is visible. In this embodiment, the flap 112 is folded over the top of the container 112 and held in place by the conditional sealing member 120, keeping the top of the container closed until the correct time to deliver the contents.

FIGS. 7A and 7B show a conditional sealing member 120 used for sealing a delayed release delivery system, in accordance with embodiments disclosed herein. FIG. 7A shows an example of a conditional sealing member 120 used for sealing die-cut bags of a delayed release delivery system, such as shown in FIGS. 1-5. FIG. 7B shows a cross-section of a conditional sealing member 120 shown in FIG. 7A. The conditional sealing member 120 has a width W3 and a height H3, that is sufficient to cover an orifice, such that the conditional sealing member 120 holds the orifice closed, for example during shipping and initial deployment, until such a time as the contents should be delivered, at which time the conditional sealing member 120 ruptures to release the contents of a container. The conditional sealing member 120 has a water resistant surface 122, a paper layer 124, and an adhesive layer 126. In some specific examples, the sealing member has a width W3 of about 3.00 inches and a height H3 of about 3.00 inches.

FIGS. 8A and 8B show a conditional sealing member 120 used for sealing a delayed release delivery system, in accordance with embodiments disclosed herein. FIG. 8A, shows a front view of a conditional sealing member 120, in accordance with embodiments disclosed herein. FIG. 8B, shows a cross-section of a conditional sealing member 120 of FIG. 8A. The conditional sealing member 120 has a width W3 and a height H3, that is sufficient to cover an orifice, such that the conditional sealing member 120 holds the orifice closed, for example during shipping and initial deployment, until such a time as the contents should be delivered, at which time the conditional sealing member 120 ruptures to release the contents of a container. In some specific examples, the sealing member has a width of about 3.00 inches and a height of about 3.00 inches. The embodiment shown in includes a “U” shaped region 129 having an overall with W4 and overall height H4. In some specific examples, the “U” shaped region 129 has an overall with W4 of 2.25 inches and an overall height H4 of 2.00. The “U” shaped region 129 also has a channel width W5. In some specific examples, the sealing member has a channel width W5 of about 0.25 inches. The conditional sealing member 120 has a water resistant surface 122, a paper layer 124, and an adhesive layer 126. The multilayer conditional sealing member 120 with water resistant surface 122 and a patterned exposed paper layer 124 that may or may not have adhesive directly over the cut in channel 129 has the advantage of less paper ending up with the clothes and in the dryer filter and not having the bag stick to a particular clothing item.

Although certain embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope. Those with skill in the art will readily appreciate that embodiments may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments be limited only by the claims and the equivalents thereof.

Claims

1. A delayed release delivery system, comprising:

a container for housing contents to be delivered, wherein the container is insoluble in water and sealable and comprises one or more conditionally sealed orifices; and

a sealing member for conditionally sealing the one or more conditionally sealed orifices.

2. The delayed release delivery system of claim 1, wherein the container comprise a front sheet, a back sheet, edges sealing the front sheet to the back sheet and defining a cavity disposed between the front sheet and the back for holding the contents to be delivered.

3. The delayed release delivery system of claim 1, wherein the one or more conditionally sealed orifices comprise one or more flaps.

4. The delayed release delivery system of claim 1, wherein the one or more conditionally sealed orifices comprise at least one orifice in the front sheet.

5. The delayed release delivery system of claim 1, wherein the one or more conditionally sealed orifices comprise at least one orifice in the front sheet.

6. The delayed release delivery system of claim 1, wherein the sealing member comprise a water soluble sticker.

7. The delayed release delivery system of claim 6, wherein the sticker comprises a face sheet, the backing material, and an adhesive.

8. The delayed release delivery system of claim 6, wherein the sticker comprises a permanent acrylic adhesive, a paper backing, and a surface coat.

9. The delayed release delivery system of claim 1, wherein the container comprises a laminate film packaging material.

10. The delayed release delivery system of claim 9, wherein the laminate film packaging material comprises a layered structure of PET/Polyester/Polytheylene/Aluminum/polyethylene/LLDPE.

11. The delayed release delivery system of claim 1, wherein the orifice is configured so that substantially all of the contents of the container are released upon opening of the orifice.

12. The delayed release delivery system of claim 1, wherein a combination of mechanical force and solubility of the sticker open the orifice and spill the contents.

13. The delayed release delivery system of claim 1, wherein the container comprises a first container and the delayed release delivery system comprises one or more additional containers for holding the same or different contents than the first container.

14. The delayed release delivery system of claim 13, wherein the first container and the one or more additional containers are configured to burst at different delay times.

15. The delayed release delivery system of claim 13, wherein the first container and the one or more additional containers are configured to burst at simultaneous delay times.

16. The delayed release delivery system of claim 1, wherein the contents of the container comprise a water soluble or water dispersible powder.

17. The delayed release delivery system of claim 1, wherein the contents of the container comprise a laundry detergent.

18. A method of delayed delivery of a water soluble or water dispersible powder to an aqueous system, comprising:

contacting the aqueous system with a delayed release delivery system, comprising: a container for housing the water soluble or water dispersible powder; wherein the container is insoluble in water and sealable and comprises one or more conditionally sealed orifices; and a sealing member for conditionally sealing the one or more conditionally sealed orifices; and

applying mechanical agitation to the aqueous system.

19. The method of claim 18, wherein the water soluble or water dispersible powder comprises a laundry detergent.