Method of manufacturing embedded water soluble film carrier

Abstract

This invention relates to a water-soluble film (WSF) system with embedded/entrapped water-soluble films (WSF). More particularly, the invention relates to a WSF system with actives embedded/entrapped therein such as to provide precise and desired release of actives there from and its method of manufacturing for diverse applications, in which a variety of substances such as detergents, enzymes, softeners, perfumes, pesticides, fungicides, active ingredients, dyes, pigments, hazardous chemicals, active agents for cleaning laundry, dishes, floorings, walls, furniture, fluffs, pulp, etc., and the like can be so embedded/entrapped for such purpose. The invention further discloses novel online and offline process for the manufacture of such multi-layered WSF with or without liners and of desired shapes to selectively entrap interacting/non-interacting materials and their combinations. The process also provides options for the use of a wide range of raw materials, liners such as paper, film, foil, fabric, etc.

1 - 52 . (Cancelled).  
     
     
         53 . A water soluble film (WSF) system comprising at least one water soluble film having at least one active material of selective concentration and depth embedded therein such that said active material can be delivered in desired quantity.  
     
     
         54 . A water soluble film system as claimed in  claim 53  wherein said active materials are selected from the group comprising detergents, enzymes, softeners, perfumes, pesticides, fungicides, active ingredients, dyes, pigments, hazardous chemicals, active agents for cleaning laundry, dishes, floorings, walls, furniture.  
     
     
         55 . A water soluble film system as claimed in  claim 53  comprising a removable liner for the water soluble film, for example the liner may be selected from material such as paper, film foil or fabric, such as polyester film and the film line material is preferably selected from the group comprising plain, embossed, metalized, gloss, matte, extrusion coated laminated or release coated.  
     
     
         56 . A water soluble film system according to  claim 53  comprising a plurality of water soluble films having active material embedded therein, and the films are preferably soluble in a selected one of hot and cold water, for example, the system may comprise films that are soluble in cold water only, hot water only or a combination of hot and cold water.  
     
     
         57 . A water soluble film system as claimed in  claim 53  wherein the films range from around 2 microns to around 500 microns, preferably in the range of around 10 microns to around 300 microns, more preferably in the range of around 12 microns to around 250 microns.  
     
     
         58 . A process for the manufacture of a water soluble film system comprising the following steps: 
 providing a formulation of said water soluble film;    casting said formulation to form a water soluble film;    embedding at least one desired active material in said formulation of the said water soluble film prior to and/or after casting the said water soluble film; and    drying the film with the embedded active material.    
     
     
         59 . A process as claimed in  claim 58  further comprising the step of metering said water soluble film onto a casting conveyor or a liner at a casting head, smoothing the film with the embedded active material at a primary station, and stripping the water soluble film from the conveyor or liner.  
     
     
         60 . A process as claimed in  claim 59  further comprising the step of stripping the water soluble film from the liner immediately after drying or after a self-curing ageing period ranging from 1 hrs. to 720 hrs.  
     
     
         61 . A process as claimed in  claim 58  wherein the water soluble film with embedded active material has a percentage of solid content in the range of 3% to 85%, preferably in the range of 4% to 70%, more preferably in the range of 5% to 65%;  
     
     
         62 . A process as claimed in  claim 58  wherein casting is carried out at a temperature in the range from 10° C. to 95° C., preferably 13° C. to 90° C., more preferably 15° C. to 85° C.  
     
     
         63 . A process as claimed in  claim 58  wherein drying is carried out at a temperature in the range from 50° C. to 250° C., preferably from 60° C. to 200° C., more preferably from 55° C. to 170° C.  
     
     
         64 . A process as claimed in  claim 58  wherein active material is added to the formulation of the water soluble film system prior to casting the water soluble film.  
     
     
         65 . A process as claimed in  claim 58  wherein active material is applied to the water soluble film after casting in a controlled dosing by spraying of premeasured material to be embedded onto the cast film prior to drying.  
     
     
         66 . A process as claimed in  claim 58  further comprising the step of casting one or more additional water soluble films with or without embedded active material onto the dried water soluble film at a secondary casting head and smoothing and drying each additional film to form a multilayered water soluble film.  
     
     
         67 . A process as claimed in  claim 66  wherein the additional water soluble film is dried at a temperature in the range from 50° C. to 200° C., preferably 60° C. to 160° C., more preferably 55° C. to 140° C.  
     
     
         68 . A process as claimed in  claim 66  further comprising the step of passing the multilayered water soluble film through a hot/chill device and optionally splitting the multilayered water soluble film prior to collection, for example in sheet or roll form.  
     
     
         69 . A process as claimed in  claim 66  wherein multilayered water soluble film comprises layers selected from one or more of cured film, uncured film, hot water soluble film, cold water soluble film, embedded active material film and liner.  
     
     
         70 . A process as claimed in  claim 58  further comprising the step of entrapping moistened active material between two water soluble films.  
     
     
         71 . A process as claimed in  claim 70  wherein the entrapped active material is provided in selective areas of the water soluble film in desired shapes, for example with the use of dimpled or other embossed or patterned designs.  
     
     
         72 . A water soluble film system for delivering active ingredients in a controlled manner by embedding at least one active material in a single or multilayer water soluble film for releasing the active material at precisely regulated dosages.