Process for Making Non-Uniform Patterns of Multiphase Compositions

A method of filling a container with a liquid composition, which comprises at least two visually distinct phases, comprising the steps of: a.) transferring said liquid composition to a container using a dispenser which has an initial fill rate; b.) rotating said container during said step a. at an initial speed of rotation and in an initial direction of rotation; c.) changing a feature selected from the group consisting of: the speed of rotation of said container, the fill rate of the dispenser, and the direction of rotation of said container; and mixtures of said features, each independently from the geometry of said container; and d.) completing the transfer of said liquid composition to said container.

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Description
CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application No. 60/873,747, filed Dec. 8, 2006.

FIELD OF THE INVENTION

The present invention relates to a process for making non-uniform patterns in personal care compositions with multiple visually distinct phases.

BACKGROUND OF THE INVENTION

In an increasingly competitive commercial market, it is becoming more and more difficult for manufacturers to distinguish products from those of their competitors. Therefore, it is desirable for products not only to appear aesthetically pleasing to consumers, but also for the products to have a substantially unique appearance from other products in the same market.

In the case of compositions having multiple visually distinct phases, various attempts have been made to create such compositions and to improve known processes for their creation. Processes and apparatuses are known which allow compositions having two or more visually distinct phases to be filled with a spiral configuration into a single container. Each phase may have completely different chemical and physical properties, and each product may have a different function and purpose. Alternately, the visually distinct phases may be substantially the same compositions with only differences in color or texture. Known processes for filling one or more compositions, having two or more visually distinct phases, result uniform patterns.

An attempt at filling spiral compositions involves providing at least two compounds, arranged in separate storage bins each having a pump and a hose attached thereto; rotating a container, for receiving a resulting product formed by the at least two compositions, into position relative to a support and alignment funnel. Then the compounds are pumped through the respective hoses into a nozzle assembly having at least two nozzles for filling the container. Subsequently, predetermined amounts of each of the at least two compositions are combined for creating the resulting product housed in a single container, wherein the resulting product has the at least two compositions formed in a spiral configuration.

A drawback of each of the aforementioned processes is that none of them provide a means for filling personal care compositions having non-uniform patterns into a container. It is desirable, especially for commercial products, to have the latitude of exhibiting as many designs as possible by implementing an economical and efficient process. Therefore, there is a need for a method of filling personal care compositions having non-uniform patterns into a container.

SUMMARY OF THE INVENTION

The present invention relates to a process for making non-uniformed patterned multi-phase liquid compositions that comprise at least two visually distinct liquid phases. The process comprises the steps of:

    • a) placing a plurality of liquid phases in separate vessels equipped with means for transferring said phases from said vessels;
    • b) transferring predetermined amounts of each selected liquid phase from its respective vessel into a combiner;
    • c) combining said liquid phases together to produce a multi-phase liquid composition having predetermined ratios of one phase to another wherein said phases of the liquid composition are visually distinct from one another; and
    • d) transferring said multi-phase liquid phase composition through a dispensing means to an individual product container; wherein said individual product container enters a bottle holding device, therein securing said container to a rotating platform wherein said container is rotated using said rotating platform during transfer of said composition into said container, wherein said dispensing means has an initial fill rate, said holding device has an initial speed of rotation, and wherein said holding device has an initial direction of rotation; and
    • e) changing an element selected from the group consisting of said initial direction of rotation, said initial speed of rotation, said fill rate of said dispensing means, and mixtures thereof, independently from the geometry of said container.

According to one embodiment, during filling, the direction of rotation of the container, the speed of rotation, or the fill rate changes from one speed to another to create non-uniform patterns. For example, during filling, the direction of rotation may be changed once or multiple times during filling to achieve a non-uniform pattern. The direction of rotation could oscillate in some embodiments, back and forth to achieve a desirable pattern. Additionally, during filling, the speed of rotation may be changed, for example, from 2 rpm to 40 rpm or the fill rate may be changed from 100 ml/s to 20 ml/s. Alternately, both the fill rate and the speed of rotation may be changed in order to create non-uniform patterns. Generally, the fill rate is greater than 0 ml/s from the time between the commencement of filling until filling is completed. Therefore, cessation of filling is not considered to be a “change in fill rate” according to this invention. It has been discovered that changes in the direction of rotation, speed of rotation of the container or changes in fill rate, during filling, enables a wide variety of designs and patterns to be created in the composition.

In one embodiment, the visually distinct phases only differ in color, texture, or mixtures thereof Differences in color may include entirely different colors (i.e., a red phase and a blue phase) or differences in color shades (i.e., a royal blue phase and a light blue phase). Specific patterns can be chosen from a wide variety of patterns, including, but not limited to striping, marbling, geometries, spirals, and mixtures thereof. Upon changing either fill rate, speed of rotation, or both, the aforementioned patterns visually appear to be non-uniform. For example, a non-uniform swirled composition may change such that stripes appear to be close to one another at the base of the container, and then appear to spread further from one another towards the top of the container as a result of changing speed of rotation, fill rate, or both.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description below, serve to explain the invention.

FIG. 1 illustrates a perspective view of an apparatus for making visually distinct patterns in a container according to an embodiment of the present invention.

FIGS. 2a-2c illustrate cross-sectional views of typical blender inlet sections which may be used to produce visually distinct patterns.

FIG. 3 illustrates a front view of an apparatus for rotation of containers during filling.

 DETAILED DESCRIPTION OF THE INVENTION

While many variations in the physical characteristics of the present components are possible, i.e., color, rheology, texture, density, etc., variations in color are widely sought. The specific design or pattern achieved (i.e., width, length of stripe or marbling, etc.) in the combination product can be varied by varying a number of additional factors including, but not limited to, rate of speed of rotation of the container or fill rate of the compositions into a rotating container.

As used herein, the term “accelerate” or “acceleration” refers to the increase in the rate of change of velocity with respect to time.

The term “anhydrous” as used herein, unless otherwise specified, refers to those compositions or materials containing less than about 10%, more preferably less than about 5%, even more preferably less than about 3%, even more preferably zero percent, by weight of water.

The term “ambient conditions” as used herein, unless otherwise specified, refers to surrounding conditions at one (1) atmosphere of pressure, 50% relative humidity, and 25° C.

The term “benefit” as used herein, refers to compositions which provide skin, hair or fabric conditioning, fragrance, anti-dandruff, skin moisturizing, skin soothing, skin tanning, skin lightening, anti-acne, anti-wrinkle/anti-atrophy, fabric bleaching, fabric dye transfer inhibition, clay soil removal/anti-redeposition, suds suppression, fabric softening, antibiotics, antimicrobial, anti-inflammatory, dentinal desensitizing, anti-caries, anti-plaque, breath freshening, dental erosion prevension, gingivitis prevention, periodontal disease prevention, teeth whitening, coloring, and flavoring.

As used herein, mixing and blending interchangeably refer to combining and further achieving a relatively greater degree of homogeneity thereafter. However, blending does not in some embodiments confer complete homogeneity of the end product.

As used herein, the term “cleaning composition” includes, unless otherwise indicated, granular or powder-form all-purpose or “heavy-duty” washing agents, especially laundry detergents; liquid, gel or paste-form all-purpose washing agents, especially the so-called heavy-duty liquid types; liquid fine-fabric detergents; hand dishwashing agents; light duty dishwashing agents, especially those of the high-foaming type; machine dishwashing agents, including the various tablet, granular, liquid and rinse-aid types for household and institutional use; liquid cleaning, deodorizing and disinfecting agents, including antibacterial hand-wash types; laundry bars; soap bars; air and fabric deodorizers; mouthwashes; toothpastes; denture cleaners; car or carpet shampoos, bathroom cleaners; hair shampoos; hair-rinses; face wash; skin cleansers; shower gels; body washes; personal cleansing compositions; foam baths; metal cleaners; as well as, cleaning auxiliaries such as fabric enhancers, bleach additives and “stain-stick” or pre-treat types.

As used herein, “combining” refers to adding materials together with or without substantial mixing towards achieving homogeneity.

The term “container” or “package” includes any suitable container for a personal care compositions exhibiting a viscosity from about 1,500 centipoise (cP) to about 1,000,000 cP, of including but not limited to bottle, tottle, tube, jar, non-aerosol pump and mixtures thereof.

As used herein “decelerate” or deceleration refers to the decrease in the rate of change of velocity with respect to time. The deceleration can effect or change the pattern resultant end product. For example, if there is a quick deceleration, the resultant fill pattern may have a sharp transition. Conversely, a slower decceleration may cause a smoother transition in the resultant fill pattern.

By “dentifrice” or “dentifrice composition” as used herein is meant paste, powder, tooth gel, and/or liquid formulations used to clean the surfaces of the oral cavity. The dentifrice is an oral composition that is not intentionally swallowed for purposes of systemic administration of therapeutic agents, but is retained in the oral cavity for a sufficient time to contact substantially all of the dental surfaces and/or mucosal tissues for purposes of oral activity. In addition dentifrice can mean a product which may be intentionally swallowed but not swallowed for the purposes of systemic administration of therapeutic agents.

The term “during filling” as used herein, refers to any time after a composition begins being dispensed into a container and before the composition fills the container to capacity.

The term “flow rate” as used herein, refers to the rate at which a composition is dispensed from a dispenser or nozzle, typically measured in ml/s.

The term “liquid” as used herein, refers to liquid, semi-liquid, cream, lotion or gel compositions, i.e., flowable compositions.

The term “marbling” as used herein, refers to a striped design with a veined and/or mottled appearance similar to marble.

As used herein, the term “multiphase” or “multi-phase”, is meant that the phases of the present compositions occupy separate but distinct physical spaces inside the container or package in which they are stored, but are in direct contact with one another (i.e., they are not separated by a barrier and they are not emulsified or mixed to any significant degree). In one preferred embodiment of the present invention, the “multiphase” cleaning compositions comprise at least two visually distinct phases which are present within the container as a visually distinct pattern. The pattern results from the combination of the “multi-phase” composition by a process herein described. The “patterns” or “patterned” include but are not limited to the following examples: striped, marbled, rectilinear, interrupted striped, check, mottled, veined, clustered, speckled, geometric, spotted, ribbons, helical, swirl, arrayed, variegated, textured, grooved, ridged, waved, sinusoidal, spiral, twisted, curved, cycle, streaks, striated, contoured, anisotropic, laced, weave or woven, basket weave, spotted, and tessellated. Preferably the pattern is selected from the group consisting of striped, geometric, marbled, and combinations thereof. In one aspect, the pattern may be relatively uniform across the dimension of the container; however, the pattern may be uneven, wavy, or non-uniform in dimension. In one aspect, the pattern does not extend across the entire dimension of the container.

By “oral care” as used herein, refers to products meant to treat diseases or conditions of the oral cavity including caries, plaque, breath malodor, dental erosion, gingivitis, and periodontal disease. Oral conditions are further described in WO 02/02096A2, published Jan. 10, 2002, P&G.

The term “personal care composition” as used herein, refers to compositions intended for topical application to the skin or hair. The compositions of the present invention are rinse-off formulations, in which the product is applied topically to the skin or hair and then is subsequently rinsed within minutes from the skin or hair with water, or otherwise wiped off using a substrate with deposition of a portion of the composition. The compositions also may be used as shaving aids. The multiphase personal care composition of the present invention is typically extrudable or dispensible from a package. The multiphase personal care compositions typically exhibit a viscosity of from about 1,500 centipoise (cP) to about 1,000,000 cP, as measured by as measured by the Viscosity Method as described in the commonly owned, patent application published on Nov. 11, 2004 under U.S. Publication No. 2004/0223991A1 entitled “Multi-phase Personal Care Compositions” filed on May 7, 2004 by Wei, et al. The multiphase personal care compositions of the present invention can be in the form of liquid, semi-liquid, cream, lotion or gel compositions intended for topical application to skin. Examples of personal care compositions of the present invention can include but are not limited to shampoo, conditioning shampoo, body wash, moisturizing body wash, shower gels, skin cleansers, cleansing milks, hair and body wash, pet shampoo, shaving preparations and cleansing compositions used in conjunction with a disposable cleansing cloth.

As used herein, the term “phase” as used herein refers to a homogeneous, physically distinct, and mechanically separable portion of matter present in a non-homogeneous physical-chemical system. Phases may be materials considered an intermediate and or a finished product. In one aspect, the phases herein are compositions with different colors. In one aspect, the phases comprise the same chemical compositions but with different colorants and/or rheology modifiers. The phases can be various different colors, and/or include particles, glitter or pearlescent agents in at least one of the phases in order to offset its appearance from the other phase(s) present. The ratio of a first phase to a second phase is preferably from about 90:10 to about 10:90, more preferably from about 80:20 to about 20:80, even more preferably from about 70:30 to about 30:70, still even more preferably from about 60:40 to about 40:60, even still even more preferably about 50:50.

The term “speed of rotation” as used herein, refers to the speed at which a container turns about an axis, typically measured in rotations per minute (rpm). Generally, the container rotates as a result of the rotation of a platform as depicted in FIG. 3.

The term “stripe” as used herein, means that each phase present in the composition occupies separate but distinct physical spaces inside the package in which it is stored, but are in direct contact with one another. In one preferred embodiment, a personal care composition comprises a cleansing phase and a benefit phase that are present within the container as distinct layers or “stripes”. The stripes may be relatively uniform and even across segments of the package. Alternatively the layers may be uneven, i.e. wavy, or may be non-uniform in dimension. The stripes do not necessarily extend across the entire dimension of the package. The “stripe’ can comprise various geometric patterns, various colors and, or glitter or pearlescence, providing that the concentration of said alternative forms visually distinct bands or regions. The striped pattern does not need to necessarily extend across the entire dimension of the package. The size of the stripes can be at least about 0.1 mm in width and 10 mm in length, preferably at least about 1 mm in width and at least 20 mm in length as measured from the package exterior.

The term “stable” as used herein, unless otherwise specified, refers to compositions that maintain visually distinctive phases in physical contact at ambient conditions for a period of at least about 180 days.

The phrase “substantially free of” as used herein, unless otherwise specified means that the composition comprises less than about 5%, preferably less than about 3%, more preferably less than about 1% and most preferably less than about 0.1% of the stated ingredient. The term “free of” as used herein means that the composition comprise 0% of the stated ingredient that is the ingredient has not been added to the composition, however, these ingredients may incidentally form as a byproduct or a reaction product of the other components of the composition.

The term “surfactant component” as used herein means the total of all anionic, nonionic, amphoteric, zwitterionic and cationic surfactants in a phase. When calculations are based on the surfactant component, water and electrolyte are excluded from the calculations involving the surfactant component, since surfactants as manufactured typically are diluted and neutralized.

As used herein “tottle” refers to a bottle which rests on neck or mouth which its contents are filled in and dispensed from, but it is also the end upon which the bottle is intended to rest or sit upon (e.g., the bottle's base) for storage by the consumer and/or for display on the store shelf (this bottle is referred to herein as a “tottle”). Typically, the closure on a tottle is flat or concave, such that the tottle, when stored, rests on the closure. Suitable tottles are described in the co-pending U.S. patent application Ser. No. 11/067,443 filed on Feb. 25, 2005 to McCall, et al, entitled “Multi-phase Personal Care Compositions, Process for Making and Providing, and Article of Commerce.”

As used herein, “visually distinctive” or “visually distinct” describes compositions in the package or upon being dispensed that display visually different phases. These different phases are either distinctively separate or partially mixed as long as the phases of the multiphase liquid composition remains visible to the unaided eye. That is, a region of the multiphase liquid composition has one average composition, as distinct from another region having a different average composition, wherein the regions are visible to the unaided naked eye. In one aspect, the phases may be various different colors, and/or include particles, glitter or pearlescent agents in at least one of the phases in order to offset its appearance from the other phase(s) present. This would not preclude the distinct regions from comprising two similar phases where one phase could comprise pigments, dyes, particles, and various optional ingredients, hence a region of a different average composition. A phase generally occupies a space or spaces having dimensions larger than the colloidal or sub-colloidal components it comprises. A phase can also be constituted or re-constituted, collected, or separated into a bulk phase in order to observe its properties, e.g., by centrifugation, filtration or the like.

The present invention relates to a process for making non-uniformed patterned multi-phase liquid compositions that comprise at least two visually distinct liquid phases. The process comprising the steps of:

    • a) placing a plurality of liquid phases in separate vessels equipped with means for transferring said phases from said vessels;
    • b) transferring predetermined amounts of each selected liquid phase from its respective vessel into a combiner;
    • c) combining said liquid phases together to produce a multi-phase liquid composition having predetermined ratios of one phase to another wherein said phases of the liquid composition are visually distinct from one another; and
    • d) transferring said multi-phase liquid phase composition through a dispensing means to an individual product container; wherein said individual product container enters a container holding means, therein securing said container to a platform wherein said container is rotated by said container holding device during transfer of said composition into said container, wherein said dispensing means begins dispensing said liquid phases at an initial fill rate, said holding device has an initial speed of rotation, and wherein said holding device has an initial direction of rotation; and
    • e) selecting a modification to an element selected from the group consisting of modifying said initial direction of rotation to a second direction of rotation, modifying said initial speed of rotation to a second speed of rotation, modifying said initial fill rate of said dispensing means to a second fill rate, and mixtures of said modifications, independently from the geometry of said container and during step d.

Various devices are known for filling multiple phase compositions. FIG. 1 illustrates a perspective view of one device which may be used to make the multiple visually distinct phase compositions of the present invention and fill the packaging into which it will be sold. This figure represents a single filling station. On a manufacturing scale this alignment of equipment is repeated for as many filling stations as is desired for simultaneously filling of a plurality of containers. Supply lines 1 and 2 are in communication with each phase's supply vessel, not illustrated herein. Said supply lines 1 and 2 can be in the form of hard or flexible piping such as stainless pipes or hoses, useful in transporting said phases from their respective supply vessels. Such supply vessels are typically stainless steel and are equipped with valves at their base wherein flow can be shut off to allow for changing such vessels without shutting down the processing equipment. Said supply lines may be equipped with an inline pump from the supply vessel, thereby pressurizing the supply line to ensure consistent or steady flow from its connected supply vessel. FIG. 1 illustrates a situation wherein supply line 1 is hard plumbed with an in-line pump not shown, whereas supply line 2 is not under pressure and the respective visually distinct phase feeds from the supply vessel into the funnel shown therein. Supply lines 1 and 2 lead to valves 5 that regulate flow of each phase to its respective pump, in this illustration, pumps 3 and 4. In FIG. 1 the pumps are illustrated as positive displacement, piston-type cylinders. Valves 5 are rotary valves that open to allow the flow of each phase from its supply vessel to enter the pump's cylinder as the pump piston is in its back or down stroke. There is a single valve for each pump and all the valves act in unison due to their being linked in a manner wherein one drive mechanism actuates all the valves. Alternately, separate drive mechanisms can be used to achieve a similar effect. Simultaneously to the flow entering the piston cylinders, valves 5 close the outlet of said cylinders to prohibit the phase from flowing directly into supply lines 3a and 4a going to combiner 6. Upon the pumps forward or upstroke, valves 5 reverse position, allowing the contents of each pump cylinder to discharge its contents into the direction of the combiner 6 through supply lines 3a and 4a while prohibiting back flow into the vessel supply lines 1 and 2. Pumps 3 and 4 are used to insure a constant supply of each phase to the combiner section 6. Given the proper flow character of the phase, such piston type pumps may be eliminated. When pumps are utilized, it is preferable that said pumps work in tandem with flow meters to insure consistent flow by the pump. Not illustrated herein, volumetric flow meters, and, or mass flow meters can be utilized to adjust the pumps to insure constant flow. This can also be accomplished by utilizing metering type pumps to deliver the required volume or mass of each phase.

Prior to the phases entering the blender 7, the supply lines 3a and 4a are aligned in such a manner as shown in the cross-sectional views of FIG. 2 in the combiner section 6. FIG. 2 represents a cross-sectional view of the alignment of the phase feeds from line 3a and 4a as they are prepared for entering blender 7. FIG. 2a illustrates an alignment of feeds from 3a and 4a wherein independent feed line 21 is located within feed line 22, thereby injecting the phase coming from 21 into the center of the feed from line 22 prior to going into the blender 7. FIG. 2c is an alternative to FIG. 2a where the feeds are aligned side by side in a common line from the combiner section 6. FIG. 2b similarly illustrates the situation where four feeds are combined together in one line coming from the combiner section 6 going to blender 7.

In some embodiments, the process can further comprises the steps of transferring said liquid phases from the combiner to the blender and blending the liquid phases. After moving through the combiner section 6, the aligned phases are introduced into a blending section 7. The blender section 7 comprises a mixing element that comprises a series of obstructions for diverting the visually distinct phases entering, inducing turbulence and causing the phases to blend together in a way that contributes to forming the composition's eventual in-package pattern. In most cases a static mixer is utilized in the blending section. Static mixers are well know in the art and are generally in the form of a series of repeating or random, interlocking plates and, or fins. Static mixers suitable for use in the process are the Chemineer SSC.75-4R-S (KMA 4 element ¾″) available from Chemineer Inc. P.O. Box 1123, Dayton, Ohio 45401 and the Koch SMX 4 element mixer (¾″ nominal) available from Koch-Glitsch LP Mass Transfer Sales and Engineering, 9525 Kenwood Road, Suite 16-246, Cincinnati, Ohio 45242.

After the blended phases pass through blender section 7, the phases are introduced to the delivery nozzle 8. Delivery nozzle 8 is utilized to deliver the combined phases to the bottle. As previously mentioned, in normal manufacturing operations, a plurality of containers is filled simultaneously. FIG. 3 represents one possible station on such equipment. Container 31 is secured into a puck or bottle holder 32. A rotating platform 33 turns the container 31 at a speed determined by the drive mechanism 34. The drive mechanism 34 for the platform 33 is a variable speed mechanism.

In one embodiment, during filling, the platform 33 rotates, which may initially rotate the container 31, in one direction initially. The direction of rotation can change from the starting position by any degree of 360° and back to the initial starting position. For example, the rotation can occur in one direction by 45° and in the opposite direction returning to the starting position of the rotation. However, the returning to the starting position is unnecessary. For example, the bottle can be rotated 90° in one direction and rotated back in the opposite direction by 180°.

Before the container 31 is full, the platform 33 can change in direction one or more times, which results in variation in the aesthetic pattern or design of the multiple visually distinct phase composition. Designs and patterns created in the personal care composition depend on when and to what amount, during the filling process, as the direction of rotation of the container 31 changes. The direction change of the rotation of the platform 33 and container 31 can be controlled by moving the platform by hand or is accomplished using a servocontroller.

In one embodiment, during filling, the platform 33 rotates, which may initially rotate the container 31, at a substantially constant speed. Before the container 31 is full, the platform 33 accelerates or decelerates, which results in variation in the aesthetic pattern or design of the multiple visually distinct phase composition. Designs and patterns created in the personal care composition depend on when and to what amount, during the filling process, the speed of rotation of the container 31 changes. The initial speed of rotation of the container 31 is generally from about 0 revolutions per minute to about 800 revolutions per minute (rpm). In some embodiments, the process further comprises the step of changing the initial speed of rotation to second speed of rotation. The second speed of rotation differs from the initial speed of rotation by at least 20%. Preferably, the speed of rotation changes by at least about 20%, more preferably by at least about 40%, and most preferably by at least about 50% of the initial speed of rotation. When the initial speed of rotation is 0 revolutions per minute, initiation of rotation at any speed during filling is considered to be a change in speed of rotation. Additionally, the speed of rotation may change continuously during filling to create a continuously changing pattern or design in the composition. The changing initial speed of rotation can comprise a acceleration or deceleration which occurs from an initial speed of rotation to a second speed of rotation. The acceleration/deceleration can affect or change the pattern resultant end product. For example, if there is a quick acceleration/deceleration, the resultant fill pattern may have a sharp transition. Conversely, a slower acceleration/decleration may cause a smoother transition in the resultant fill pattern.

Herein, changes in fill rate and/or speed of rotation are measured in terms of percent change. Changes in fill rate and/or speed of rotation are based on the initial fill rate and/or speeds of rotation (i.e., the fill rate and/or speed of rotation measured prior to changing the fill rate and/or speed of rotation during filling of the container) and the final fill rate and/or speed of rotation (i.e., the fill rate and/or speed of rotation measured either when the fill rate and/or speed of rotation reach(es) a new constant speed or just prior to completion of the filling process). A percent change is calculated based on the difference between the aforementioned initial fill rate and/or speed of rotation and the final fill rate and/or speed of rotation.

In another embodiment, the speed of rotation remains relatively constant and the fill rate changes. Preferably, the fill rate changes by at least about 20%, more preferably by at least about 40%, and most preferably by at least about 50% of the initial fill rate. The fill rate may also change continuously during filling to create a continuously changing pattern or design in the compositions

Known filling techniques often incorporate containers which tend to geometrically narrow towards an orifice. When filling through such an orifice, in order to prevent overflow and to maintain uniformity, either the speed of rotation or fill rate must be adjusted as the composition fills towards the orifice. In contrast to this known technique, the present method creates non-uniform, visually distinct patterns, by changing the fill rate or speed of rotation independently from the geometry of the container.

Additionally, known methods of filling containers generally include filling the container with a liquid product by positioning the dispensing means at or near the orifice of the container. In the process of present invention, the dispensing means may be arranged in such a manner as to position the dispensing means in the bottom of the container. More specifically, the dispensing means may be positioned below half of the volume of the container. Positioning the dispensing means in this position has the advantage of avoiding the “mounding” effect exhibited by filling techniques which employ a dispensing means at or hear the orifice of the container. Mounding may generally be described as the layering or folding of a liquid stream over itself as the container fills. Accordingly, one aspect of this invention is to fill the container with the multiphase liquid phase composition from the bottom of the container.

The transfer of the predetermined amounts of each selected liquid phase from its respective vessel into a combiner is accomplished using a servocontroller. //Add information//

Container 31 is any suitable container for the product. Preferably, container 31 is a transparent bottle wherein the pattern of the finished composition is visible to the consumer. The container preferably comprises a closure and a dispensing orifice. Suitable materials for transparent bottles include, but are not limited to PET or PP.

All percentages, parts and ratios as used herein are by weight of the total composition, unless otherwise specified. All such weights as they pertain to listed ingredients are based on the active level and, therefore, do not include solvents or by-products that may be included in commercially available materials, unless otherwise specified.

In one embodiment, the process is used to produce a cleaning compositions, personal care composition, dentifrice compositions, having a non-uniform, spirally striped, patterns. In some embodiments, one phase can provide one function, such as a cleansing phase, and the second phase can provide an additional function, such as a benefit function. In some embodiments, the phases can provide the same function but be visually distinct from each other. Compositions have been formulated which allow both a cleansing phase and a benefit phase which can comprise a variety of phase types while remaining stable for prolonged periods. Further, one or more of the phases can include stable colorants, resulting in the possibility of non-uniform visual patterns when the personal care compositions are packaged in containers which allow the contents to be viewed.

Suitable surfactants are described in McCutcheon's, Detergents and Emulsifiers, North American edition (1986), published by allured Publishing Corporation; and McCutcheon's, Functional Materials, North American Edition (1992); and in U.S. Pat. No. 3,929,678 issued to Laughlin, et al on Dec. 30, 1975. Suitable surfactants for use herein include any known or otherwise effective cleansing surfactant suitable for application to the hair, skin, teeth and fabric, and which is otherwise compatible with the other essential ingredients in the cleansing phase of the compositions. These cleansing surfactants include anionic, nonionic, cationic, zwitterionic or amphoteric surfactants, or combinations thereof. Preferably, the cleansing phase is structured and/or discrete.

Preferred linear anionic surfactants include ammonium lauryl sulfate, ammonium laureth sulfate, sodium lauryl sulfate, sodium laureth sulfate, potassium laureth sulfate, sodium lauryl sarcosinate, sodium lauroyl sarcosinate, lauryl sarcosine, cocoyl sarcosine, ammonium cocoyl sulfate, potassium lauryl sulfate, and combinations thereof. Branched anionic surfactants and monomethyl branched anionic surfactants suitable for the present invention are described in a commonly owned, patent application published on December, 2006 under U.S. Publication No. 60/680,149 entitled “Structured Multi-phased Personal Cleansing Compositions Comprising Branched Anionic Surfactants” filed on May 12, 2005 by Smith, et al. Branched anionic surfactants include but are not limited to the following surfactants: sodium trideceth sulfate, sodium tridecyl sulfate, sodium C12-13 alkyl sulfate, and C12-13 pareth sulfate and sodium C12-13 pareth-n sulfate.

In one embodiment, the composition can comprise at least one amphoteric surfactant. Amphoteric surfactant suitable for use in the present invention include those that are broadly described as derivatives of aliphatic secondary and tertiary amines in which the aliphatic radical can be straight or branched chain and wherein one of the aliphatic substituents contains from about 8 to about 18 carbon atoms and one contains an anionic water solubilizing group, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate. Examples of compounds falling within this definition are sodium 3-dodecyl-aminopropionate, sodium 3-dodecylaminopropane sulfonate, sodium lauryl sarcosinate, N-alkyltaurines such as the one prepared by reacting dodecylamine with sodium isethionate according to the teaching of U.S. Pat. No. 2,658,072, N-higher alkyl aspartic acids such as those produced according to the teaching of U.S. Pat. No. 2,438,091, and the products described in U.S. Pat. No. 2,528,378. In one aspect, the multiphase personal care composition can comprise an amphoteric surfactant that is selected from the group consisting of sodium lauroamphoacetate, sodium cocoamphoactetate, disodium lauroamphoacetate disodium cocodiamphoacetate, and mixtures thereof. Moreover, Amphoacetates and diamphoacetates can also be used.

Zwitterionic surfactants suitable for use include those that are broadly described as derivatives of aliphatic quaternary ammonium, phosphonium, and sulfonium compounds, in which the aliphatic radicals can be straight or branched chain, and wherein one of the aliphatic substituents contains from about 8 to about 18 carbon atoms and one contains an anionic group, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate. Zwitterionic surfactants suitable for use in the multiphase, personal care composition include betaines, including cocoamidopropyl betaine.

An alkanolamide if present has the general structure of:

wherein R is C8 to C24 or preferably in some embodiments C8 to C22 or in other embodiments C8 to C18 saturated or unsaturated straight chain or branched aliphatic group, R1 and R2 are the same or different C2-C4 straight chain or branched aliphatic group, x=0 to 10; y=1-10 and wherein the sum of x and y is less than or equal to 10. The amount of alkanolamide in the composition is typically about 0.1% to about 10% by weight, and in some embodiments is preferably about 2% to about 5% by weight of the cleansing phase. Some preferred alkanolamides include Cocamide MEA (Coco monethanolamide) and Cocamide MIPA (Coco monoisopropranolamide).

In some aspects, the composition of the present invention is preferably free of alkyl amines and alkanolamide to ensure mildness of the composition to the skin, hair, teeth and fabric.

The composition preferably comprises at least one nonionic emulsifier. Preferably the nonionic emulsifier has an HLB from about 1.5 to 13.0, preferably from about 3.4 to 13.0, more preferably 3.4 to about 9.5, more preferably 3.4 to about 8.0. The composition preferably comprises a nonionic emulsifier at concentrations ranging from about 0.1% to about 10%, more preferably from about 0.25% to about 8%, even more preferably from about 0.5% to about 5%, still even more preferably from about 1.0% to about 3%, and still even still more preferably from about 1.5% to about 2.5%, by weight of the personal care compositions.

The balance between the hydrophilic and lipophilic moieties in a surfactant molecule is used as a method of classification (hydrophile-lipophile balance, HLB). The HLB values for commonly-used surfactants are readily available in the literature (e.g., HLB Index in McCutcheon's Emulsifiers and Detergents, MC Publishing Co., 2004). For example, cocamide monoethanolamine (CMEA) is known in the art to have an HLB value of 16.8. Another way of obtaining HLB values is to estimate by calculations. The HLB system was originally devised by Griffin (J. Soc. Cosmetic Chem., 1, 311, 1949). Griffin defined the HLB value of a surfactant as the mol % of the hydrophilic groups divided by 5, where a completely hydrophilic molecule (with no non-polar groups) had an HLB value of 20. Other examples of how to calculate HLB values are described by Davies in Interfacial Phenomena, 2nd Edition, Academic Press, London, 1963 and by Lin in J. Phys. Chem. 76, 2019-2013, 1972.

Non-limiting examples of preferred nonionic emulsifiers for use herein are those selected form the group consisting of glyceryl monohydroxystearate, isosteareth-2, trideceth-3, hydroxystearic acid, propylene glycol stearate, PEG-2 stearate, sorbitan monostearate, glyceryl laurate, laureth-2, cocamide monoethanolamine, lauramide monoethanolamine, and mixtures thereof.

An electrolyte can be added per se to the composition or it can be formed in situ via the counterions included in one of the raw materials. The electrolyte preferably includes an anion comprising phosphate, chloride, sulfate or citrate and a cation comprising sodium, ammonium, potassium, magnesium or mixtures thereof. Some preferred electrolytes are sodium chloride, ammonium chloride, sodium or ammonium sulfate. The electrolyte is preferably added to the structured surfactant phase of the composition in the amount of from about 0.1% to about 6% preferably from about 1% to about 5%, more preferably from about 2% to about 4%, more preferably from about 3% to about 4%, by weight of composition. Non-limiting examples of other suitable cleansing phase materials are disclosed in U.S. patent application Ser. No. 10/961,719.

The visually distinct phase compositions may further comprise at least one benefit phase selected from the group consisting of a hydrophobic benefit phase, fatty compound gel network, a hydrophobic gel network, a hydrophobic gel network in a fatty compound gel network, a fatty compound gel network in a hydrophobic gel network, a silicone or silicone gel and mixtures thereof. Each benefit phase may act as a delivery vehicle for delivering a conditioning agent or other benefit agent to hair, or itself may act as a conditioning agent or other benefit agent. Non-limiting examples of suitable benefit phase materials are disclosed in U.S. patent application Ser. No. 10/961,719.

The compositions of the present invention comprise a benefit phase. The benefit phase in the present invention may be anhydrous and can be substantially free of water. The benefit phase can be substantially free or free of surfactant.

The benefit phase typically comprises hydrophobic benefit materials. The benefit phase may comprise from about 1% to about 50%, preferably from about 5% to about 30%, more preferably from about 10% to about 30%, by weight of the multiphase personal care composition, of a hydrophobic benefit material.

Hydrophobic benefit materials suitable for use in the present invention preferably have a Vaughan Solubility Parameter of from about 5 (cal/cm3)1/2 to about 15 (cal/cm3)1/2, as defined by Vaughan in Cosmetics and Toiletries, Vol. 103. The Vaughan Solubility Parameter (VSP) as used herein is a parameter used to define the solubility of hydrophobic materials. Vaughan Solubility parameters are well known in the various chemical and formulation arts and typically have a range of from 5 to 25. Non-limiting examples of hydrophobic benefit materials having VSP values ranging from about 5 to about 15 include the following: Cyclomethicone 5.92, Squalene 6.03, Petrolatum 7.33, Isopropyl Palmitate 7.78, Isopropyl Myristate 8.02, Castor Oil 8.90, Cholesterol 9.55, as reported in Solubility, Effects in Product Package, Penetration and Preservation, C. D. Vaughan, Cosmetics and Toiletries, Vol. 103, October 1988.

The hydrophobic benefit materials for use in the benefit phase of the composition have a preferred rheology profile as defined by Consistency value (k) and Shear Index (n). The term “Consistency value” or “k” as used herein is a measure of lipid viscosity and is used in combination with Shear Index, to define viscosity for materials whose viscosity is a function of shear. The measurements are made at 35° C. and the units are poise (equal to 100 cps). The term “Shear Index” or “n” as used herein is a measure of lipid viscosity and is used in combination with Consistency value, to define viscosity for materials whose viscosity is a function of shear. The measurements are made at 35° C. and the units are dimensionless. Consistency value (k) and Shear Index (n) are more fully described in commonly owned and assigned U.S. application Ser. No. 11/312,615 entitled “Shaving Kit, Article of Commerce and Method of Shaving comprising a personal care composition” filed Dec. 20, 2005. Preferred Consistency value ranges are 1-10,000 poise (1/sec)n−1, preferably 10-2000 poise (1/sec)n−1 and more preferably 50-1000 poise (1/sec)n−1. Shear Index ranges are 0.1-0.8, preferably 0.1-0.5 and more preferably 0.20-0.4. These preferred rheological properties are especially useful in providing the personal cleansing compositions with improved deposition of benefit agents on skin.

The benefit phase can be comprised of the hydrophobic benefit materials selected from the group consisting of petrolatum, lanolin, derivatives of lanolin (e.g. lanolin oil, isopropyl lanolate, acetylated lanolin, acetylated lanolin alcohols, lanolin alcohol linoleate, lanolin alcohol riconoleate) hydrocarbon oils (e.g. mineral oil) natural and synthetic waxes (e.g. micro-crystalline waxes, paraffins, ozokerite, lanolin wax, lanolin alcohols, lanolin fatty acids, polyethylene, polybutene, polydecene, pentahydrosqualene) volatile or non-volatile organosiloxanes and their derivatives (e.g. dimethicones, cyclomethicones, alkyl siloxanes, polymethylsiloxanes, methylphenylpolysiloxanes), natural and synthetic triglycerides (e.g. castor oil, soy bean oil, sunflower seed oil, maleated soy bean oil, safflower oil, cotton seed oil, corn oil, walnut oil, peanut oil, olive oil, cod liver oil, almond oil, avocado oil, palm oil, sesame oil) and combinations thereof. In one aspect, at least about 50% by weight of the hydrophobic benefit materials are selected from the groups of petrolatum, mineral oil, paraffins, polyethylene, polybutene, polydecene, dimethicones, alkyl siloxanes, cyclomethicones, lanolin, lanolin oil, lanolin wax. The remainder of the hydrophobic benefit material can be selected from: isopropyl palmitate, cetyl riconoleate, octyl isononanoate, octyl palmitate, isocetyl stearate, hydroxylated milk glyceride and combinations thereof. The benefit phase of the multiphase personal care composition can be comprised a combination of petrolatum and mineral oil.

Alternately, the benefit phase may comprise differing levels of benefit agents as compared to the cleansing phase. Preferably, the benefit phase comprises increased levels of conditioning agents such as silicone conditioning agents, cationic deposition polymers, or volumizing agents (i.e., polyethylene particles) etc.

Suitable detergent compositions filled by the process of the present invention can include base materials listed in Table 1 below. The amount shown is a weight % for each material is the amount in the final product.

TABLE 1 Material Base 1 Base 2 Base 3 C25 AE1.8S 25 17 28 HLAS 6.5 1.5 7.0 Nonionic Surfactant — 1.5 — Amine Oxide 2 — 2.5 Citric Acid 7 4.5 7.5 Fatty Acid 2.5 0.40 2 Borax 4 2.5 4.5 Calcium Formate 0.9 1.00 0.95 DTPA 0.4 0.7 0.45 Brightener 2 0.65 2.5 Propanediol 2.5 0.50 3 NaOH 4 1 5 Viscosity Modifier — 2.5 — Enzymes 1.2 1.4 1.2 Polymers 2.4 0.9 2.4 Water Balance Balance Balance

Suitable body wash or personal cleansing compositions filled by the process of the present invention can include materials listed in Table 2 below, including but not limited to surfactants, humectants, buffer/pH adjusting agents, stabilizing agents, thickening/structuring agents and the like.

TABLE 2 Base Base Base Base Base Materials 2A 2B 2C 2D 2E Ammonium Laureth-3 Sulfate — 9.0  — — — Sodium Sulfate 3.7 — — — Sodium Trideceth Sulfate (Cedepal TD- — — — 8.5  — 407) Sodium Lauryl Sulfate — — — 8.5  — Cocamidopropyl Betaine — 1.43 — — — Sodium Lauroamphoacetate — 0.95 — 5.0  — Guar Hydroxypropyltrimonium Chloride — — 0.6  — — (N-Hance 3196 Aqualon) PEG 90M (Polyox WSR 301 from Dow — — 0.15 0.15 — Chemical) Cationic Polymer (N-Hance 3196)a — — — 0.6  — Trihydroxystearinb — — — — — Trideceth-3 Alcohol — — — 2.0  — Sodium Benzoate — 0.25 — 0.2  — Citric Acid, anhydrous — 0.30 — 0.88 — Polyquaternium-10 — 0.10 — — — Xantham Gum (Keltrol 1000, CP — — 0.22 — — Keltrol) Disodium EDTA — 0.10 0.15 0.15 — Sodium Chloride — — — 4.75 — Titanium Dioxide 328 — — — — — Polyox WSR N-3000c — — — — — Sodium Benzoate —  0.001 —  0.0005 — Kathon CGd — 1.43 0.2  0.36 — Expandcel 091 WE 40 d24 (Expandcel, — — 0.33 0.05 — Inc.) Sodium Hydroxide —50% Solution — — — 0.15 — Water Q.S. Q.S. Q.S. Q.S. — Petrolatum (G2218 WITCO) — — — — 70    Mineral Oil (Hydrobrite 1000 WITCO) — — — — 29.99  Pigment (Red 7) — — — — 0.1 

In one aspect, conventional body wash and/or personal cleansing compositions can be made according to the processes and by the systems of the present invention. Some examples of personal cleansing composition include those more fully described in the co-pending patent applications U.S. Patent Publication No. 2006/0083761A1 entitled Personal care compositions comprising visible beads, cationic polymer, and surfactant filed on Oct. 12, 2005 published on Apr. 20, 2006; U.S. Patent Publication No. 2004/0223991 entitled “Multi-phase Personal Care Compositions” filed on May 7, 2004, published on Nov. 11, 2004; U.S. Patent Publication No. 2004/0057920 A1 entitled “Striped liquid personal cleansing compositions containing a cleansing phase and a separate benefit phase” filed by Focht, et al. on Sep. 18, 2003, published on Apr. 4, 2004, U.S. Patent Publication No. 2004/0092415 A1 entitled “Striped liquid personal cleansing compositions containing a cleansing phase and a separate benefit phase with improved stability” filed by Focht, et al. on Oct. 31, 2003, published on May 13, 2004 and U.S. Patent Publication No. 2004/0219119 A1 entitled “Visually distinctive multiple liquid phase compositions” filed by Weir, et al. on Apr. 30, 2004, published on Nov. 18, 2004 and U.S. Application Ser. No. 60/680,149 entitled “Structured Multi-phased Personal Cleansing Compositions Comprising Branched Anionic Surfactants” filed on May 12, 2004 by Smith, et al.

In another aspect, oral care products may be produced by the processes disclosed herein. Suitable dentifrice bases include base materials listed in Table 3 below, including but not limited to carriers/solvent, humectants, abrasives, tartar control agents, antimicrobials, fluoride sources and anticaries agents, buffer/pH adjusting agents, stabilizing agents, thickening/structuring agents, binders, flavors and sweetening agents and surfactants. The amount shown in weight % for each material is the amount in the final product after addition of finishing and/or reblend materials.

TABLE 3 Base Material 3A 3B 3C 3D 3E 3F 3G Water 38.51  23.26  23.26  8.0  8.95  13.7   — Glycerin — — — 9.00  — 7.750 36.944  Sorbitol 70% soln. 24.21  33.80  32.80  41.0   60.0   24.91  — Polyethylene Glycol 300 — 3.720 3.720 3.00  — 6.00  7.000 Propylene Glycol — — — — — — 7.000 Silica Z-109 — — 7.667 — — — 12.500  Silica Z-119 21.00   17.00  9.333 17.0   15.0   31.0   12.500  Tetrasodium Pyrophosphate — 1.128 1.128 3.850 — 5.045 — Disodium Pyrophosphate — 1.344 1.344 1.0  — — — Tetrapotassium Pyrophosphate — 3.159 3.159 — — — — Sodium Polyphosphate — — — — — — 13.000  Sodium Fluoride 0.32  0.321 0.321 0.243 0.243 0.243 — Stannous Fluoride — — — — — — 0.454 Triclosan/PEG Premix — 0.560 0.560 — — — — Monosodium Phosphate — — — — 0.419 — — Trisodium Phosphate 0.37  — — — 1.10  — 1.100 Sodium Carbonate — — — — — 0.500 — Sodium Bicarbonate — — — — — 1.500 — Sodium Gluconate — — — — — — 0.652 Zinc Lactate Dihydrate — — — — — — 2.500 Xanthan Gum — 0.500 0.500 0.475 — — 0.250 Carbomer 956 0.30  0.300 0.300 0.300 0.300 — — Na Carboxymethylcellulose 1.10  0.700 0.700 — 0.750 0.750 — Carrageenan — — — — — — 0.600 Sodium Saccharin 0.20  0.200 0.200 0.40  0.130 0.350 0.500 Sodium Lauryl Sulfate 28% Soln 2.00  — — 2.0  2.0  5.0  3.400 Poloxamer — — — — — 1.25  —

Suitable base materials for a denture adhesive include bioadhesive materials and a non-aqueous vehicle. Examples of bioadhesive materials include, but are not limited to, karaya gum, guar gum, gelatin, algin, sodium alginate, tragacanth, chitosan, polyethylene glycol, polyethylene oxide, acrylamide polymers, carbopol, polyvinyl alcohol, polyamines, polyquartemary compounds, ethylene oxide polymers, polyvinylpyrrolidone, cationic polyacrylamide polymers, AVE/MA, AVE/MA/IB, mixed salts of AVE/MA, mixed salts of AVE/MA/IB, and mixtures thereof. Non-aqueous vehicle is generally any chemical in any physical form that does not contain water. Examples of non-aqueous vehicle include, but are not limited to, petrolatum, mineral oil, glycerin, natural oils, synthetic oils, fats, silicone, silicone derivatives, polyvinyl acetate, natural waxes, synthetic waxes, animal waves, vegetable oil waxes, vegetable oils, and mixtures thereof. Non-aqueous vehicles for denture adhesive compositions are further described in U.S. Pat. No. 5,561,177, issued on Oct. 1, 1996, Khaledi et al.

Suitable shampoo compositions filled by the process of the present invention can include materials selected from Table 4 below.

TABLE 4 Chem Ingredient Conc. % % Active in Shampoo Sodium Laureth Sulfate (28% active in 28.0 5.0000 5.0000 4.0000 water) Sodium Lauryl Sulfate (29% active in water) 29.0 15.0000 9.0000 8.0000 Polydimethyl siloxane 100.0 1.0000 2.0000 1.0000 Carbopol Aqua SF-1 (Acrylates copolymer) 30.0 1.5000 1.2500 1.2500 (Available from National Starch) Polyquaternium 10 (LR30M) (Available 0.2500 from Americhol) Polyquaternium 10 (KG30M) (Available 100.0 0.5000 0.2500 from Americhol) Mirapol 100 (Polyquaternium 6) 31.5 0.2500 0.2500 Polycare 133 (Polymethacryamidopropyl 0.1000 trimonium CL) cocodimethyl amide 85.0 0.8000 0.8000 0.8000 Brij 30 (Laureth-4) 100.0 1.0000 1.0000 1.0000 NaOH (50%) 50.0 as as needed as needed needed Sodium Benzoate 100.0 0.2500 0.2500 0.2500 Disodium EDTA 100.0 0.1274 0.1274 0.1274 Citric Acid 100.0 0.5000 0.5000 0.5000 NaCl 100.0 as as needed as needed needed Sodium Xylene Sulfonate 41.5 as as needed as needed needed Kathon CG (Methylchloroisothiazolinone 100.0 0.0005 0.0005 0.0005 and Methylisothiazolinone) Perfume/colors/other minors 100.0 as as needed as needed needed Q.S. Water - USP Purified 100.0 as as needed as needed needed

The materials useful in the compositions are described in the Tables above are listed by their cosmetic and/or therapeutic benefit or their postulated mode of action or function. However, it is to be understood that the materials useful, in some instances, provide more than one benefit or function or operate via more than one mode of action. Therefore, descriptions herein are made for the sake of convenience and are not intended to limit an ingredient to the particularly stated application or applications listed.

The compositions herein may further comprise various optional materials. While not essential for the purposes of the present invention, the non-limiting list of materials, in addition to the previously disclosed base materials, optional ingredients are suitable for use in the process disclosed herein to produce compositions, including cleaning compositions, and may be desirably incorporated in certain embodiments, for example to assist or enhance cleaning performance, for treatment of the substrate to be cleaned, or to modify the aesthetics of the composition as is the case with perfumes, colorants, dyes or the like. The precise nature of these additional components, and levels of incorporation thereof, will depend on the physical form of the composition and the nature of the cleaning operation for which it is to be used. The optional ingredients/materials are usually formulated at less than about 15%, less than about 12%, less than about 10%, less than about 9%, less than about 8%, less than about 7%, less than about 6%, less than about 5%, less than about 4%, less than about 3%, less than about 2%, or less than about 1%, of the total cleaning composition.

Suitable optional materials for cleaning composition can include, but are not limited to, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach activators, hydrogen peroxide, sources of hydrogen peroxide, preformed peracids, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, perfumes, structure elasticizing agents, fabric softeners, structurants, carriers, hydrotropes, processing aids, solvents and/or pigments. The aforementioned materials may or may not serve as adjunct ingredients. In addition to the disclosure herein, suitable examples of adjuncts and levels of use are found in U.S. Pat. Nos. 5,576,282, 6,306,812 B1 and 6,326,348 B1.

As stated, the optional materials are not essential to Applicants' compositions. Thus, certain embodiments of Applicants' compositions do not contain one or more of the following adjuncts materials: surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, chelating agents, bleach activators, dye transfer inhibiting agents, hydrogen peroxide, sources of hydrogen peroxide, preformed peracids, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, perfumes, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids, solvents and/or pigments.

Suitable optional materials for the manufacture of personal care/cleansing composition can be materials comprise, but are not limited to, water, anti-dandruff actives (e.g. pyridinethione salts, azoles, selenium sulfide, particulate sulfur, keratolytic agents, and mixtures thereof); thickening agents; low density microspheres (e.g. Expancel 091 WE40 d24, Akzo Nobel and others described in commonly owned and assigned U.S. Patent Publication No. 2004/0092415A1 published on May 13, 2004); preservatives; antimicrobials; fragrances; chelators (e.g. such as those described in U.S. Pat. No. 5,487,884 issued to Bisset, et al.); sequestrants; vitamins (e.g. Retinol); vitamin derivatives (e.g. tocophenyl actetate, niacinamide, panthenol); sunscreens; desquamation actives (e.g. such as those described in U.S. Pat. No. 5,681,852 and 5,652,228 issued to Bisset); anti-wrinkle/anti-atrophy actives (e.g. N-acetyl derivatives, thiols, hydroxyl acids, phenol); anti-oxidants (e.g. ascorbic acid derivatives, tocophenol) skin soothing agents/skin healing agents (e.g. panthenoic acid derivatives, aloe vera, allantoin); skin lightening agents (e.g. kojic acid, arbutin, ascorbic acid derivatives) skin tanning agents (e.g. dihydroxyacteone); polymeric phase structurant (e.g. naturally derived polymers, synthetic polymers, crosslinked polymers, block copolymers, copolymers, hydrophilic polymers, nonionic polymers, anionic polymers, hydrophobic polymers, hydrophobically modified polymers, associative polymers, and oligomers); a liquid crystalline phase inducing structurant (e.g. trihydroxystearin available from Rheox, Inc. under the trade name THIXCIN® R); organic cationic deposition polymer (e.g. Polyquaternium 10 available from Amerchol Corp. Edison, N.J., USA, guar hydroxypropyltrimonium chloride available as Jaguar C-17 from Rhodia Inc., and N-Hance polymer series commercially available from Aqualon); particles providing an increased hair volume benefit (e.g. silicone resins, poly(meth)acrylates, polyethylene, polyester, polypropylene, polystyrene, polyurethane, polyamide (e.g., nylon), epoxy resins, urea resins, acrylic powders, and the like); opacifying agents, suspending agents, propellants, pH regulators (e.g. triethanolamine); anti-acne medicaments; essential oils; sensates; pigments; colorants; pearlescent agents; interference pigments (e.g such as those disclosed in U.S. Pat. No. 6,395,691 issued to Liang Sheng Tsaur, U.S. Pat. No. 6,645,511 issued to Aronson, et al., U.S. Pat. No. 6,759,376 issued to Zhang, et al, U.S. Pat. No. 6,780,826 issued to Zhang, et al.) particles (e.g. talc, kolin, mica, smectite clay, cellulose powder, polysiloxane, silicas, carbonates, titanium dioxide, polyethylene beads) hydrophobically modified non-platelet particles (e.g. hydrophobically modified titanium dioxide and other materials described in a commonly owned, patent application published on Aug. 17, 2006 under Publication No. 2006/0182699A by Taylor, et al.) and mixtures thereof. Other finishing materials can be promotional ingredients, as described in U.S. Patent Publication No. 2004/0116539 entitled “Late variant addition process for personal care products” published on Jun. 17, 2004.

Suitable optional materials for dentifrice bases can include, but are not limited to, surfactants, humectants, mouthwash compositions, water, flavors, extracts, pH adjusting agents, colorants and pigments, binders, cleaning agents, sweeteners, tartar control agents, antisensitivity agents, chelating agents, structurants, processing aids, and/or visual aesthetics such as mica, polyethylene specks, wax prills, and pigmented silica particles.

Suitable optional materials for base denture products include one or more components which provide flavor, fragrance, and/or sensate benefit including but not limited to, natural or artificial sweetening agents, menthol, menthyl lactate, wintergreen oil, peppermint oil, spearmint oil, leaf alcohol, clove bud oil, anethole, methyl salicylate, eucalyptol, cassia, 1-menthyl acetate, sage, eugenol, parsley oil, oxanone, alpha-irisone, marjoram, lemon, orange, propenyl guaethol, cinnamon, vanillin, thymol, linalool, cinnamaldehyde glycerol acetal (CGA), carboxamides, menthol, menthyl, ketals, diols, toxicologically accepted plasticizers, colorants, thickeners, preservatives, iodine, tricolsan, peroxides, sulfonamides, bisbiguanides, phenolics, antibiotics, antimicrobial, anti-inflammatory agents, dentinal desensitizing agents, anesthetic agents, aromatics, benzaldehyde, insulin, steroids, herbal and other plant derived remedies, baking soda, anti-neoplastics, and the like.

The cleansing phase and benefit phase may be present at any ratio with respect to one another. Preferably, the ratio of cleansing phase to benefit phase is at least about 1:1, more preferably at least about 2:1, and most preferably at least about 4:1

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. A process for making non-uniformed patterned multi-phase liquid compositions comprising at least two visually distinct liquid phases said process comprising the steps of:

a) placing a plurality of liquid phases in separate vessels equipped with means for transferring said phases from said vessels;
b) transferring predetermined amounts of each selected liquid phase from its respective vessel into a combiner;
c) combining said liquid phases together to produce a multi-phase liquid composition having predetermined ratios of one phase to another wherein said phases of the liquid composition are visually distinct from one another; and
d) transferring said multi-phase liquid phase composition through a dispensing means to an individual product container; wherein said individual product container enters a container holding means, therein securing said container to a platform wherein said container is rotated by said container holding device during transfer of said composition into said container, wherein said dispensing means begins dispensing said liquid phases at an initial fill rate, said holding device has an initial speed of rotation, and wherein said holding device has an initial direction of rotation; and
e) selecting a modification to an element selected from the group consisting of modifying said initial direction of rotation to a second direction of rotation, modifying said initial speed of rotation to a second speed of rotation, modifying said initial fill rate of said dispensing means to a second fill rate, and mixtures of said modifications, independently from the geometry of said container and during step d.

2. The process of claim 1 wherein said dispensing means is arranged in such a manner as to fill said product container with said multiple liquid phase composition from the bottom of the container.

3. The process of claim 1, wherein said process further comprises the step of transferring said liquid phases from said combiner to said blender.

4. The process of claim 3, wherein said process further comprises the step of blending said liquid phases.

5. The process of claim 1, wherein said rotating platform has an initial speed of rotation.

6. The process of claim 1 wherein said initial speed of rotation is from 0 revolutions per minute to 800 revolutions per minute.

7. The process of claim 5, wherein said process further comprises the step of changing said initial speed of rotation to second speed of rotation.

8. The process of claim 6, wherein said second speed of rotation differs from the initial speed of rotation by at least 20%.

9. The process of claim 7, wherein said step of changing comprises a deceleration occurs from an initial speed of rotation to a second speed of rotation.

10. The process of claim 7, wherein said step of changing comprises an acceleration occurs from an initial speed of rotation to a second speed of rotation.

11. The process of claim 1, wherein said dispensing means has an initial filling rate.

12. The process of claim 11, wherein said process further comprises the step of changing said initial fill rate to a second fill rate.

13. The process of claim 12, wherein said second fill rate differs from said initial fill rate by 20%.

14. The process of claim 1 wherein the transfer of said predetermined amounts of each selected liquid phase from its respective vessel into a combiner is accomplished using a servocontroller.

15. The process of claim 1 wherein said product container is a transparent bottle with a closure comprising a dispensing orifice.

16. The process of claim 1, wherein said phases are visually distinctive relative to at least one attribute selected from the group consisting of color, color shade, texture and mixtures thereof.

17. A method of filling a container with a liquid composition, which comprises at least two visually distinct phases, comprising the steps of:

a.) transferring said liquid composition to a container using a dispenser which has an initial fill rate;
b.) rotating said container during said step a. at an initial speed of rotation and in an initial direction of rotation;
c.) changing a feature selected from the group consisting of: the speed of rotation of said container, the fill rate of the dispenser, and the direction of rotation of said container; and mixtures of said features, each independently from the geometry of said container; and
d.) completing the transfer of said liquid composition to said container.

18. A method according to claim 17, wherein said speed of rotation of said container is changed more than once during filling.

19. A method according to claim 17, wherein said fill rate of said dispenser is changed more than once during filling.

20. A method according to claim 17, wherein said direction of rotation of said container is changed more than once during filling.

Patent History
Publication number: 20080196787
Type: Application
Filed: Dec 7, 2007
Publication Date: Aug 21, 2008
Inventors: Bryan Gabriel Comstock (Mason, OH), Bryce William Wilson (Hamilton, OH), John Eric Vanhook (Cincinnati, OH)
Application Number: 11/952,208
Classifications
Current U.S. Class: Plural Materials (141/9); Rotary Or Oscillating (141/268); With Movement Of Receiver In Horizontal Plane (141/283)
International Classification: B65B 3/04 (20060101);