Systems and methods for forming openings in water soluble packet

Abstract

Systems and methods to form openings in water soluble packets are described. The system includes a packet forming assembly to form water soluble packets, and a laser to form one or more openings in the water soluble packets. The method includes forming openings in the water soluble packets with a laser. The openings permit air to escape from the packets. By allowing air to escape, the water soluble packets have improved packaging characteristics. The water soluble packets are packed more tightly with a product.

We claim: 
     
         1 . A system for forming openings in water soluble packets, comprising:
 a packet forming assembly which forms water soluble packets having a base film and a lid film containing a product, wherein the packet forming assembly includes one or more cavities, wherein a base film supply roll supplies the base film to cover the one or more cavities, wherein the one or more cavities include vacuum openings in fluidic communication with a vacuum assembly by a vacuum passage, wherein the vacuum assembly draws or stretches a portion of the base film into the one or more cavities, wherein   a feed hopper meters an amount of the product into the one or more cavities over the base film, wherein a lid film supply roll supplies the lid film, and wherein the lid film is sealed to the base film; and   a laser which forms one or more openings in the base film of the water soluble packets, the laser focused at the one or more cavities, and wherein the laser is configured to form the one or more openings in the portion of the base film after it is drawn or stretched into the one or more cavities to form a receptacle shape in the one or more cavities to receive the product and before the feed hopper meters the amount of product into the base film positioned in the cavities.   
     
     
         2 . The system according to  claim 1 , wherein the laser is positioned proximate to the one or more cavities, and wherein the laser is configured to form a plurality of openings arranged in a non-linear pattern in the portion of the base film after the portion of the base film is drawn or stretched into the one or more cavities. 
     
     
         3 . The system according to  claim 1 , wherein the laser is configured to form the one or more openings in the portion of the base film after the portion of the base film is drawn or stretched into the one or more cavities. 
     
     
         4 . The system according to  claim 1 , wherein the laser is configured to form the one or more openings in the portion of the base film before the feed hopper meters the amount of the product into the one or more cavities, wherein each opening has a size up to approximately 1000 um. 
     
     
         5 . The system according to  claim 1 , wherein the packet forming assembly is a rotary drum machine comprising a drum having the one or more cavities. 
     
     
         6 . The system according to  claim 1 , wherein the packet forming assembly is a horizontal form fill seal machine. 
     
     
         7 . The system according to  claim 1 , wherein the product is a powder detergent or a granule detergent. 
     
     
         8 . The system according to  claim 5 , further comprising a controller which controls pulses from the laser. 
     
     
         9 . The system according to  claim 8 , further comprising an encoder, wherein the encoder measures or senses a movement of the drum in order to register the pulses of the laser with the base film. 
     
     
         10 . A system for forming openings in water soluble packets, comprising:
 a rotating drum operatively engaged to a motor for rotating the drum, the drum comprising one or more cavities;   a base film supply roll which supplies a base film to the drum to cover the one or more cavities;   a feed hopper which meters an amount of a product into the one or more cavities over the base film;   a lid film supply roll which supplies a lid film to the drum; and   a laser which forms one or more openings in the base film, the laser positioned proximate to the rotating drum, the laser focused at the one or more cavities;   wherein each of the one or more cavities includes a vacuum opening that is in fluidic communication with a vacuum passage, and a vacuum assembly of the rotary drum draws air through the vacuum opening and draws or stretches a portion of the base film into the one or more cavities, and wherein the laser is configured to form the one or more openings in the portion of the base film after the base film is drawn or stretched into the one or more cavities to form a receptacle shape in the one or more cavities to receive the product and before the feed hopper meters the amount of product into the base film positioned in the cavities.   
     
     
         11 . The system according to  claim 10 , wherein the laser simultaneously pulses the base film after portions of the base film are drawn or stretched into one or more rows of the one or more cavities. 
     
     
         12 . The system according to  claim 10 , further comprising an encoder, wherein the encoder measures or senses a movement of the drum in order to register pulses of the laser with the base film. 
     
     
         13 . The system according to  claim 10 , wherein the laser is positioned between the feed hopper and the locus where a portion of the base film is drawn or stretched into the one or more cavities. 
     
     
         14 . A system for making water soluble packets, comprising:
 a packet forming assembly comprising a rotary drum which forms water soluble packets having a base film and a lid film containing a product, wherein the rotary drum includes one or more cavities, wherein a base film supply roll supplies the base film to cover the one or more cavities, wherein a feed hopper meters an amount of the product into the one or more cavities over the base film, wherein a lid film supply roll supplies the lid film, and wherein the lid film is sealed to the base film,   wherein each of the one or more cavities includes a vacuum opening that is in fluidic communication with a vacuum passage, and a vacuum assembly of the rotary drum draws air through the vacuum opening to draw or stretch a portion of the base film into the one or more cavities and to line the one or more cavities with the portion of the base film; and   a laser which makes one or more openings in the base film of the water soluble packets, the laser directed at the portion of the base film lining the one or more cavities to form a receptacle shape in the one or more cavities to receive the product and before the feed hopper meters the amount of product into the base film positioned in the cavities.   
     
     
         15 . The system for making water soluble packets according to  claim 14 , wherein the vacuum assembly draws or stretches the portion of the base film into the one or more cavities, wherein the laser is configured to make the one or more openings in the portion of the base film while the portion of the base film lines the one or more cavities to form the receptacle shape in the one or more cavities. 
     
     
         16 . The system for making water soluble packets according to  claim 14 , wherein the vacuum assembly draws or stretches the portion of the base film into the one or more cavities, wherein the laser is configured to make a plurality of openings arranged in a non-linear pattern in the portion of the base film after the portion of the base film is drawn or stretched into the one or more cavities. 
     
     
         17 . The system for making water soluble packets according to  claim 14 , wherein the laser is configured to make the one or more openings in the portion of the base film before the feed hopper meters the amount of the product into the one or more cavities, wherein each opening has a size up to approximately 1000 um. 
     
     
         18 . The system for making water soluble packets according to  claim 14 , further comprising an encoder, wherein the encoder measures or senses a movement of the rotary drum in order to register pulses of the laser with the base film. 
     
     
         19 . The system for making water soluble packets according to  claim 14 , wherein the laser is positioned between the feed hopper and the locus where a portion of the base film is drawn or stretched into the one or more cavities. 
     
     
         20 . The system for making water soluble packets according to  claim 14 , further comprising a controller, wherein the controller modulates pulses from the laser to direct the pulses at the portion of the base film lining the one or more cavities. 
     
     
         21 . The system for making water soluble packets according to  claim 20 , comprising an encoder or sensor, wherein the encoder or sensor is in electrical communication with the controller, and the encoder or sensor measures or senses a movement of the rotary drum in order to register the pulses of the laser with the portion of the base film lining the one or more cavities. 
     
     
         22 . The system for making water soluble packets according to  claim 14 , wherein the laser is positioned between the feed hopper and the base film supply roll after an application of the base film into the one or more cavities. 
     
     
         23 . A system for making water soluble packets, comprising:
 a horizontal form, fill and seal machine operatively engaged to a motor for advancing a continuous belt the horizontal form, fill, and seal machine comprising one or more cavities;   a base film supply roll which supplies a base film to the horizontal form, fill and seal machine to cover the one or more cavities;   a vacuum assembly, wherein the one or more cavities are in fluidic communication with the vacuum assembly, wherein the one or more cavities include vacuum openings in fluidic communication with the vacuum assembly by a vacuum passage, wherein the vacuum assembly draws or stretches a portion of the base film into the one or more cavities to line the one or more cavities with the portion of the base film;   a feed hopper which meters an amount of a product into the one or more cavities over the base film;   a lid film supply roll which supplies a lid film to the horizontal form, fill and seal machine; and   a laser which makes openings in the base film, wherein the laser is positioned proximate to the horizontal form, fill and seal machine between the feed hopper and the base film supply roll, the laser configured to make the openings in the portion of the base film while the portion of the base film lines the one or more cavities to form a receptacle shape in the one or more cavities to receive the product and before the feed hopper meters the amount of product into the base film positioned in the cavities.   
     
     
         24 . The system according to  claim 1 , wherein the laser comprises a 30 watt CO 2  laser. 
     
     
         25 . The system according to  claim 10 , wherein the laser comprises a 30 watt CO 2  laser. 
     
     
         26 . The system for making water soluble packets according to  claim 23 , wherein the laser comprises a 30 watt CO 2  laser.