Patent Publication Number: US-2022213416-A1

Title: Active composition delivery system

Description:
FIELD OF THE INVENTION 
     The present invention relates to the fields of fabric care, hard surface cleaners, and personal cleaning products. More particularly, the present invention relates to systems and methods for delivering an active composition in the form of a pre-measured dose sufficient for one or more cleaning or treatment operation. 
     BACKGROUND OF THE INVENTION 
     Cleaning agents, including detergents, are typically provided in liquid or powder forms. However, users find these forms inconvenient because their use requires an additional step of measuring out a correct dose of the detergent. Apart from the inconvenience of measuring out a correct dose is the material cost associated with the need to provide and store a utensil for measuring out the correct dose, and then load the correct dose, for example, into a dishwasher, a washing machine, or other like washing apparatus. Associated with this requirement for measuring a dose is the risk of getting the dose wrong, and either under-dosing (resulting in poor cleaning action), or over-dosing (resulting in wasted detergent, or damage to the item being cleaned). Other problems associated with liquid and powder forms of cleaning agents are that they are messy, They are also not easily transportable in small quantities, which may be desirable when travelling, for example. 
     In light of the above noted problems associated with liquid and powder forms of cleaning agents, many users prefer cleaning agents, such as for example, laundry detergents, that are provided in a form that is simpler to use and less messy than the liquid and powder forms. 
     Attempts have been disclosed In the prior art to overcome some of the above described problems associated with liquid and powder cleaning agents. Some of the attempts included providing a unit dose laundry detergent product, which removed the need to measure out a correct dose of laundry detergent, thereby simplifying for the user the process of loading a washing machine with the correct dose of the laundry detergent. 
     For example, U.S. Pat. No. 4,356,099 to Davies disclosed fabric treatment products for use in washing machines consisting of a bag formed of water-insoluble, water-impermeable synthetic plastics sheet material containing a fabric treatment composition comprising a liquid fabric treatment composition, such as an aqueous or non-aqueous liquid detergent composition. The bag has a weak seal that will be opened by the mechanical action of a washing machine, to release its liquid detergent contents. However, a problem with the fabric treatment products disclosed by Davies is that they are prone to a failure of the weak seal not opening properly in modern day high efficiency (HE) washing machines. This is because opening of the weak seal in a Davies fabric treatment product relies on the mechanical action of the washing machines, and the more gentle mechanical action of HE washing machined may not be enough to open the bag. Additionally, because the bag is made of a water-insoluble material, it remains in the washing machine during the entire wash cycle, and can affect the cleaning performance if it clings to certain areas of the clothing being washed. Furthermore, the format of the fabric treatment products taught by Davies does not allow for partial doses that may be better suited for laundry loads which are smaller than full loads. 
     As another example, U.S. Pat. No. 4,188,304 to Clarke discloses a detergent product which comprises a particulate detergent composition contained within a closed water-Insoluble bag which has a water-sensitive seal, whereby the contents of the bag are discharged on contact of the bag with water. Clarke&#39;s detergent product shares many of the same problems noted above in connection to Davies. However, an additional problem with the Clarke detergent product is that it is difficult to ensure that all of the particulate detergent composition is emptied out of the bag and fully dissolved in the water, especially if the detergent product is used in the detergent dispensing trays on modern HE washing machines. 
     As yet another example, laundry detergent pods have become popular in recent years, In which a single pre-measured unit dose of detergent is encapsulated in a water-soluble pouch, typically ranging from 20 to 40 grams in weight. However, a problem associated with such laundry detergent pods is that they do not dissolve readily because the water-soluble pouch covering the detergent powder must dissolve before the water can access the detergent. Furthermore, the detergent is provided as a large mass of partially-compressed powder, which presents a smaller overall surface area for the water to act on. For these reasons, such pods typically do not dissolve fully when used in the detergent dispensing trays on modern HE washing machines. 
     As yet another example, laundry detergent tablets exhibit similar problems as those described above with respect to laundry detergent pods, due to the large concentrated mass of highly-compressed detergent powder. 
     In general detergent dispensing trays on modern HE washing machines provide too short a time for dissolving the above noted laundry detergent pods and laundry detergent tables, and so they fail to yield optimal results when used in this way. For this reason, laundry detergent pods are better suited for being placed directly in the washing machine drum to be dissolved during the wash cycle. 
     Neither the laundry detergent pod, nor the laundry detergent tablet formats allow for partial doses that may be better suited for laundry loads which are smaller than full loads. 
     As yet another example, U.S. Pat. No. 4,853,142 to Win disclosed a high melting temperature meltblown web, such as a polyester meltblown web, which contains a sufficient amount of condensed liquid detergent to wash a load of laundry and does not exhibit an objectionable sticky feel. Similarly, U.S. Pat. No. 4,938,888 to Kiefer disclosed a cleaning article formed from a detergent composition impregnated into a flexible substrate. The detergent composition includes an alkyl polyglycosides and a detergency builder. The substrates employed are water-insoluble and are solid or substantially solid materials, such as foam, foil, sponge, paper, woven or non-woven cloth. 
     A problem shared by both Win and Kiefer is that they are made with non-dissolvable substrates, which remain in the washing machine drum after completion of the wash cycle. The non-dissolvable substrates also tend to cling to clothing being washed, making it more difficult for the embedded detergent to dissolve completely. Additionally, non-dissolvable substrates are not compatible with detergent dispensing trays on modern HE washing machines, and both of Win&#39;s webs and Kiefer&#39;s cleaning articles, impregnated with detergent composition sufficient for a Full load, would be too large to be used efficiently and reliably in the detergent dispensing trays on modern HE washing machines. Additionally, neither Win&#39;s web nor Kiefer&#39;s cleaning article allow for partial doses that may be better suited for laundry loads which are smaller than full loads. 
     Other prior art attempts include those disclosed in: U.S. Pat. Nos. 4,374,035; 4,806,261; 5,780,418; 6,756,351; 3,062,030; 6,699,826; 6,831,051; 6,995,126; and 8,669,219; and U.S. Patent Application Publication Nos. 2002/0077265; 2008/0242579; 2010/0035789; 2010/0190677; 2014/0024574; and 2002/0169092. 
     However, there remains a need for improvements in active composition delivery systems. 
     SUMMARY OF THE INVENTION 
     What is desired is an improved system and method for delivering an active composition, such as a cleaning or treatment composition, to where it is needed, that overcomes at least some of the problems in the prior art. For example, what may be desired is a system and method for delivering an active composition in the form of a pre-measured unit dose sufficient for a single cleaning or treatment operation. As another example, what may be desired is a system and method for delivering an active composition with a high actives content. As yet another example, what may be desired Is a system and method for delivering an active composition in a form that is easy to handle and store when dry, yet which dissolves completely when contacted by water, such as, for example, in a washing machine during the laundry cycle, without leaving behind any substrate or noticeable residue. 
     By way of example, there Is disclosed an active composition delivery system in the form of a laundry detergent article configured to be added to a washing machine to be contacted by water during the laundry cycle. Preferably, the laundry detergent article contains a premeasured unit dose of a powder cleaning composition comprising a laundry detergent, inside a pouch formed from water-soluble sheets sealed together at the edges, to keep the detergent powder from spilling out from the pouch. Preferably, the water-soluble sheets are made of polyvinyl alcohol (PVA). The water-soluble PVA sheets may be sealed together at the edges by, for example, heating, ultrasonic welding, solvent gluing, or sewing with water-soluble PVA thread. 
     Preferably, the laundry detergent article may include water-soluble stitches through the top and bottom water-soluble sheets, according to an embodiment of the present invention. When included, the water-soluble stitches may be configured to limit the maximum thickness of the laundry detergent article, by contro ling the distribution of the laundry detergent powder inside the pouch. Preferably, the water-soluble stitches may be configured to allow a small gap between the top and bottom water-soluble sheets at each stitch. 
     The water-soluble stitches may preferably be included in the form of two thread-paths that zig-zag and cross one another over the surface areas of the laundry detergent article in a quilted pattern. Preferably, the quilted pattern will maintain a uniform distribution of the powder cleaning composition within the volume defined by the pouch. 
     By limiting the maximum thickness of the pouch and controlling the distribution of the laundry detergent powder within the pouch using the water-soluble stitches, according to preferred embodiments of the present invention, the laundry detergent article may be provided in a form resembling a flat sheet, which is aesthetically pleasing, and easy to handle. However, unlike known dissolvable laundry sheets, laundry detergent articles according to the present invention may contain higher amounts of cleaning composition per square inch, enabling more effective cleaning with substantially the same form factor (or the same level of cleaning in a smaller form factor). 
     By limiting the maximum thickness of the pouch and controlling the distribution of the laundry detergent powder within the pouch using the water-soluble stitches, according to preferred embodiments of the present invention, the laundry detergent article may deliver its cleaning composition contents more rapidly and uniformly in the washing machine, for example. It has been found that by controlling the distribution of the laundry detergent powder, and maintaining an overall flat form of the laundry detergent article with the water-soluble stitches helps to keep the laundry detergent powder spread out over a large surface area, which tends to increase dissolution, and at the same time reduces the type of clumping of the laundry detergent powder, which tends to cause uneven dissolution. 
     Preferably, the laundry detergent article may include a plurality of pouches attached together at the joined edges. It is contemplated that the size and shape of each pouch may be the same, or alternately, the laundry detergent article may include differently sized, and/or shaped pouches. For example, differently sized, and/or shaped pouches may be included to provide different pre-measured unit doses for the user to select. As another example, the pouches may be configured to allow the user to easily select a combination of pre-measured unit doses for a particular application. 
     Most preferably, the laundry detergent article may be provided with a frangible member, or line of weakness along some or all of the joined edges separating the pouches from one another, to make it easier for the user to separate and remove one or more pouches from the laundry detergent article, so they may be used. 
     Although embodiments of the active composition delivery system of the present invention include laundry detergent articles, as mentioned above, the Invention is not limited thereto, but comprehends other applications, depending on the formulations of the active composition, the top and bottom water-soluble sheets, and the water-soluble stitches comprised by the cleaning composition delivery system. 
     For example, other embodiments of the present invention may include active composition delivery systems, wherein the active composition is a cleaning composition, configured for cleaning body parts (i.e. personal care products), for cleaning dishes and utensils, and for cleaning hard surfaces. 
     As another example, other embodiments of the present invention may include active composition delivery systems, wherein the active composition is a treatment composition, configured for treating fabric to provide, for example, scent properties (i.e. scent enhancement), fabric softening properties, anti-microbial properties, anti-bacterial properties, anti-fungal properties, insect repellant properties, scent properties, and combinations thereof. 
     Although embodiments of the active composition delivery system of the present invention include laundry detergent articles, for use in a washing machine, the invention is not limited thereto, but comprehends other manners of use. For example, the active composition delivery system may be configured to enable the user to prepare a volume of a cleaning or treating solution for current use or for later use. For example, the user may dissolve an active composition delivery system in a pail of water and use the solution in the pail together with a mop to clean the floor. As another example, the user may dissolve an active composition delivery system in  8  kitchen sink filled with a volume of water and use the solution to wash dishes. As yet another example, the user may hold an active composition delivery system in his hands under running water to cleanse his hands, and/or other body parts. As yet another example, the user may hold an active composition delivery system in her hands or on her head in the shower to shampoo or condition her hair. As yet another example, the user may dissolve an active composition delivery system in a spray bottle filled with a volume of water and use solution to clean hard surfaces. As yet another example, the user may dissolve an active composition delivery system in a disposable or reusable storage bottle filled with a volume of water and later dispense the solution, on an as needed basis, to use as a liquid fabric softener, a liquid dish detergent, a liquid laundry detergent, or the like. 
     Therefore, in accordance with one aspect of the present invention, there is disclosed an active composition delivery system comprising: 
     at least one water-soluble sheet arranged and joined together to form at least one pouch having a top layer and a bottom layer, and being surrounded by joined edges; 
     an active composition disposed in said at least one pouch; and 
     a plurality of water-soluble joints joining said top layer and said bottom layer, said water-soluble joints being arranged in a region surrounded by said joined edges, to form two or more compartments, with said active composition being disposed substantially evenly across said two or more compartments; 
     wherein said active composition delivery system has a substantially flat, sheet-like shape; and 
     wherein said active composition delivery system releases said active composition after being contacted with a sufficient amount of water to dissolve said at least one water-soluble sheet. 
     According to another aspect of the present invention, there is disclosed a use of said active composition delivery system mentioned above, in a washing machine, wherein said active composition comprises a laundry detergent active or a fabric softener active. 
     According to yet another aspect of the present invention, there is disclosed a use of said active composition delivery system mentioned above, in a dishwasher, wherein said active composition comprises a dishwasher detergent. 
     According to yet another aspect of the present invention, there are disclosed a method of making an active composition delivery system, said method comprising the steps of: 
     a) arranging and joining at least one water-soluble sheet together to form a tube; 
     b) closing one end of said tube with a first transverse joint; 
     c) filling at least a portion of said tube with an amount of active composition through an open end of said tube; 
     d) closing said tube with a downstream transverse joint spaced a predetermined distance from said first transverse joint, with said active composition disposed between said first transverse joint and said downstream transverse joint to form a pouch, said pouch having said active composition disposed therein, and having a top layer and a bottom layer; and
         e) providing a plurality of water-soluble joints joining said top layer and said bottom layer to form two or more compartments, with said active composition being disposed substantially evenly across said two or more compartments;   wherein said active composition delivery system has a substantially flat, sheet-like shape; and wherein said active composition delivery system releases said active composition after being contacted with a sufficient amount of water to dissolve said at least one water-soluble sheet.       

    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made to the preferred embodiments of the present invention with reference, by way of example only, to the following drawings in which: 
         FIG. 1  is a top view of an active composition delivery system according to an embodiment of the present invention; 
         FIG. 2  is a cross-sectional view of the active composition delivery system of  FIG. 1  taken along line A-A; Figure $ is a cross-sectional view of the active composition delivery system of  FIG. 1  taken along line B-B; 
         FIG. 4  is an enlarged view of a top sheet of the active composition delivery system of  FIG. 1 , to illustrate its texture; 
         FIG. 5  is a top view of an active composition delivery system according to another embodiment of the present invention; 
         FIG. 6  is a top view of an active composition delivery system according to another embodiment of the present invention; 
         FIG. 7  is a top view of an active composition delivery system according to another embodiment of the present invention; 
         FIG. 8  is a top view of an active composition delivery system according to another embodiment of the present invention; and 
         FIG. 9  is a top view of an apparatus for making the active composition delivery system of  FIG. 1 , according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention is described in more detail with reference to exemplary embodiments thereof as shown in the appended drawings. While the present invention is described below including preferred embodiments, it should be understood that the present invention is not limited thereto. Those of ordinary skill in the art having access to the teachings herein will recognize additional implementations, modifications, and embodiments which are within the scope of the present invention as disclosed and claimed herein. 
     An active composition delivery system  10  according to an embodiment of the present invention is shown in  FIGS. 1 to 3 . As shown, the active composition delivery system  10  has a top layer  12 , a bottom layer  14 , and an active composition  16  disposed between the top and bottom layers  12 ,  14 . Preferably, the top and bottom layers  12 ,  14  are joined together along their edges  18  to contain the active composition  16 . What is important is that the top and bottom layers  12 ,  14 , together with their joined edges  18 , form a pouch  20 , sized and shaped to hold a pre-measured amount of an active composition  16 , so that the active composition delivery system  10  may be used for its intended use, as will be discussed in more detail below. 
     Preferably, the top and bottom layers  12 ,  14 , are water-soluble sheets made of polyvinyl alcohol (PVA), and the joined edges  18  may be formed by sealing the top and bottom layers  12 ,  14  together at their edges by, for example, heating, ultrasonic welding, or solvent gluing. As another example, the joined edges  18  may be formed by sewing the top and bottom layers  12 ,  14  together at their edges with water-soluble thread, which may also be formed from PVA, as shown in  FIGS. 8 and 9 . It will be appreciated that forming the joined edges  18  by sewing with PVA thread will require using sufficiently tight stitches  22 , arranged in a continuous thread path  24  to ensure that the active composition  16  does not spill or leak out of the pouch  20  through gaps between the top and bottom layers  12 ,  14 . Preferably, the PVA thread will be selected to have similar dissolution properties to those of the top and bottom layers  12 ,  14 . 
     The active composition may also be water-soluble, in which case the active composition delivery system  10  will be completely dissolvable in water. However, according to other embodiments of the present invention, the active composition  16  may be water insoluble, In which case, the active composition delivery system  10  will not be completely dissolvable in water, although only the active composition will remain, for example as a fabric treatment of encapsulated fragrance coating or impregnating portions of the treated fabric. 
     Although the top and bottom layers  12 ,  14  may be provided as separate sheets of PVA material, it is also contemplated that they may be provided as a single sheet of material, which is folded over (not shown). In this embodiment of the present invention, one half of the folded sheet of material forms the top layer  12 , and the other half of the folded sheet of material forms the bottom layer  14 . For the purposes of this description, the fold may be considered one of the joined edges  18 . Additionally, the folded edge may be further processed to match the look of the other joined edges, for example by heating, ultrasonic welding, solvent gluing, or sewing. 
     All such embodiments are comprehended by the present invention. 
     Preferably, the active composition delivery system  10  also includes a plurality of loose stitches  26  joining the top and bottom layers  12 ,  14  in a region  28  surrounded by the joined edges  18 . These loose stitches  26  may be arranged to define one or more thread paths  30  contained in the region  28 . Preferably, the one or more thread paths  28  may form a quilted pattern in the region  28 , which gives the active composition delivery system  10  an aesthetic look, and pleasing feel. In this regard,  FIG. 1  shows, by way of example only, a quilted pattern formed by two zig-zagging thread paths  28  in the region  30  surrounded by the joined edges  18 . Although,  FIG. 1  shows a quilted pattern consisting substantially of triangles and squares (or diamonds), other quilted patterns are comprehended by the present invention, including those, formed from other rectilinear, and non-rectilinear shapes. 
     With reference to  FIG. 2 , it can be seen from this cross-sectional view that the active composition  16  is contained in the pouch  20  formed by the top and bottom layers  12 ,  14 , and their joined edges  18 . Additionally, there is shown that the loose stitches  26  are configured and arranged In the region  30  to limit a maximum thickness  32  of the active composition delivery system  10 , so that it will have a generally flat, quilted profile. Preferably, the maximum thickness  32  may be ⅛ inch to ⅜ Inch, inclusive. In this regard, the loose stitches  26  may be configured to allow a gap  34  to form between the top and bottom layers  12 ,  14  at each loose stitch  26 . Advantageously, the gaps  34  permit slight movement of the active composition  16  within the pouch  20 , which adds flexibility to the active composition delivery system  10 . Thus the term “loose stitch” as used herein does not mean that the stitch may be easily undone, but rather that stitch allows the top and bottom layers  12 ,  14  to be slightly spaced apart to allow a gap  34  to be created, that will help define the maximum thickness  32  of the active composition delivery system  10 . However, it is contemplated that the loose stitches  26  in the region  28  between the joined edges  18  may be replaced with tight stitches  22 , in other embodiments of the present invention, thereby removing the gaps  34 . Accordingly, the loose stitches  26  may preferably be configured to provide a gap  34  with a vertical length of between 0 Inch and 1/16 inch, inclusive. All such embodiments are comprehended by the present invention. 
     As will now be understood, the water-soluble loose stitches  26  create joints between the top and bottom water-soluble sheets to maintain a flat sheet-like shape of the dissolvable active composition delivery system  10 . The joints arranged in the quilted thread-paths  30  limit the maximum thickness  32  of the active composition delivery system  10 , and form compartments to control the distribution of active composition  16  contained within the active composition delivery system  10 . Preferably, the joints are configured to allow the small gap  34  between the top and bottom layers  12 ,  14  at each joint. As the active composition delivery system  10  dissolves in water, the active composition Inside is exposed as much as possible in terms of surface area to the water surrounding the active composition delivery system  10 . The arrangement helps prevent clumps of active composition that could take longer to dissolve as compared to the thinner flat, sheet-like structure, according to the present invention. 
     Another advantage of flat, sheet-like structure of the active composition delivery system  10 , is that it may be configured to be compatible with automatic dispensers in a new generation of washing machine designs. 
     It is contemplated that the water-soluble joints, and resulting gaps  34  may be formed by processes other than sewing with water-soluble thread, known in the art, including heating, ultrasonic welding, solvent gluing, and the like. All such embodiments are comprehended by the present Invention. 
     Good results have been obtained by using Pellon® 541 non-woven water soluble stabilizer fabric for making the top and bottom layers  12 ,  14 . This lightweight embroidery stabilizer (available from Patton Consumer Products, Clearwater, Fla., U.S.A.) is conventionally used to stabilize fabric during stitching, such as machine embroidery, applique, cut work, and monogramming. As can be seen in  FIG. 4 , which shows a preferred embodiment of a top layer  12  (the bottom layer  12  appearing the same), the surface has a perforated fibrous texture, which gives the active composition delivery system  10  a pleasing look and feel, akin to the look and feel of a conventional laundry dryer sheet, rather than the unpleasant plastic-like, often tacky feel of a laundry detergent pod or plastic-encased laundry detergent tablet, It should be noted that the image in  FIG. 4  is enlarged and over-exposed to show its texture, Under normal lighting and without magnification, the top layer  12  shown in  FIG. 4  appears as a soft, white material. 
     A preferred water soluble thread is a Tex-40 weight PVA thread. 
     The water-soluble material used to make the top and bottom layers  12 ,  14 , as well as the water-soluble thread used to make the joined edges  18 , the tight stitches  22 , and the loose stitches  26 , may be white, or coloured, to provide a desired look for the active composition delivery system  10 . 
     The choice of active composition  16  will of course depend on the intended use of the active composition delivery system  10 . 
     For example, the active composition  16  may be a cleaning composition, configured for cleaning things such as, for example, body parts (i.e. personal care products), dishes and utensils, and hard surfaces. 
     As another example, the active composition  16  may be a treatment composition, configured for treating fabric to provide, for example, scent properties (i.e. scent enhancement), fabric softening properties, anti-microbial properties, anti-bacterial properties, anti-fungal properties, insect repellant properties, scent properties, and combinations thereof. 
     Preferably, the active composition  16  will be anhydrous, or have a sufficiently low water content so as not to dissolve the top and bottom layers  12 ,  14 . As such, the active composition may be in the form of a powder, a gel, a hydrophobic liquid, or a sticky composition. All such embodiments are comprehended by the present invention. 
     in view of the above description, it will now be understood that the preferred active composition delivery system  10  is configured so as to dissolve completely and release all of the active composition  16  it contains, when contacted with a sufficient amount of water consistent with its intended use. 
     Preferably, the active composition delivery system  10  may be sized, shaped, and configured for a particular use. By way of example, for use in a household washing machine (not shown), the active composition delivery system  10  may be provided in the form of a laundry detergent article  10  containing a pre-measured unit dose of a cleaning composition  16 , in powder form, comprising a laundry detergent. The laundry detergent article  10  contains the powder cleaning composition  16  inside a pouch  20  formed between the water-soluble top and bottom layers  12 ,  14 , which are sealed together along their edges  18 , to keep the laundry detergent powder  16  from spilling out. By way of example only, the laundry detergent article  10  may be rectangular, appearing substantially as shown in  FIG. 1 , having a length of 13 cm, a width of 5 cm, and a thickness of for example, 118 inch to ⅜ inch. Advantageously, a laundry detergent article  10  having those dimensions may have a ratio of a) laundry detergent powder weight, to b) the weight of the PVA material containing the laundry detergent powder  16  that is fairly high, typically being 15:1 or higher. Therefore, the percent of active composition  16  may be configured to be 90% or higher for a active composition delivery system  10 , according to an embodiment of the present invention. 
     By limiting the maximum thickness  32  of the pouch  20  and controlling the distribution of the laundry detergent powder  16  within the pouch  20  using the water-soluble loose stitches  26 , the laundry detergent article  10  may be provided in a form resembling a flat sheet, which is aesthetically pleasing, and easy to handle. However, unlike known dissolvable laundry sheets, laundry detergent articles  10  according to the present invention may contain higher amounts of active cleaning composition  16  per square inch, enabling more effective cleaning with substantially the same form factor (or the same level of cleaning in a smaller form factor). 
     Additionally, by limiting the maximum thickness  32  of the pouch  20  and controlling the distribution of the laundry detergent powder  16  within the pouch  20  using the water-soluble loose stitches  26 , the laundry detergent article  10  may deliver its active cleaning composition  16  contents more rapidly and uniformly in the washing machine. It has been found that by controlling the distribution of the laundry detergent powder  16 , and maintaining an overall flat form of the laundry detergent article  10  with the water-soluble loose stitches  26  helps to keep the laundry detergent powder  16  spread out over a large surface area, which tends to increase dissolution, and at the same time reduces the type of clumping of the laundry detergent powder  16 , which tends to cause uneven dissolution. 
     Although embodiments of the active composition delivery system  10  of the present invention include laundry detergent articles, as mentioned above, the invention is not limited thereto, but comprehends other applications, depending on the formulations of the active composition  16 , the top and bottom layers  12 ,  14 , and the water-soluble stitches  22 ,  26  comprised by the cleaning composition delivery system  10 . 
     For example, other embodiments of the present invention may include active composition delivery systems  10 , wherein the active composition  16  is a cleaning composition, configured for cleaning body parts (i.e. personal care products), for cleaning dishes and utensils, and for cleaning hard surfaces. All such embodiments are comprehended by the present invention. 
     As another example, other embodiments of the present invention may include active composition delivery systems  10 , wherein the active composition  16  is a treatment composition, configured for treating fabric to provide, for-example, scent properties (i.e. scent enhancement), fabric softening properties, anti-microbial properties, anti-bacterial properties, anti-fungal properties, Insect repellant properties, scent properties, and combinations thereof. All such embodiments are comprehended by the present invention. 
     Referring now to  FIGS. 5 and 6 , the active composition delivery system  10  may include a plurality of pouches  20  joined together at their joined edges  18 . The size and shape of each pouch  20  may be the same, or alternately, the active composition delivery system  10  may include differently sized, and/or shaped pouches  20 . For example, differently sized, and/or shaped pouches  20  may be included to provide different pre-measured unit doses for the user to select. As another example, the pouches  20  may be configured to allow the user to easily select a combination of pre-measured unit doses for a particular application. Most preferably, the active composition delivery system  10  may be provided with a frangible member, or line of weakness  36  along some or all of the joined edges  18  separating the pouches  20  from one another, to make it easier for the user to separate and remove one or more pouches  20  from the article composition delivery system  10 , so they may be used. 
     Preferably, the frangible member/line of weakness  36  may be in the form of a line of perforations, cuts, partial cuts, or thinner material. 
     By way of example, the active composition delivery system  10  shown in  FIG. 5  is in the shape of a square and contains six pouches  20 , that may be separated along the lines of weakness  36  by a user. It will be appreciated that the active composition delivery system  10  may contain more or fewer such pouches  20 . The active composition delivery system  10  shown includes a full load pouch  38 , three half load pouches  40 , and two quarter load pouches  42 , that may be used individually, or in combination. For example, two half load poaches  40  may be good for one application, such as for example washing a full load of laundry. Similarly, two quarter load pouches  42  may be good for a partial application, such as for example washing a half load of laundry. Similarly, a quarter load pouch  42  together with a half load poach  40  may be good for a partial application, such as for example, washing a three-quarter load of laundry. And so on. 
     By way of another example, the active composition delivery system  10  shown in  FIG. 6  is in the shape of a strip containing five pouches  20 , that may be separated along the lines of weakness  36  by a user. It will be appreciated that the active composition delivery system  10  may contain more or fewer such pouches  20 . 
     Furthermore, it Is contemplated that the active composition delivery system  10  may contain many such pouches  10  rolled up to allow for easier dispensing. In this example, the pouches  20  have the same dimensions. For example, the pouches  20  may each be good for a partial application, such as for example washing a quarter load of laundry. Accordingly, a user would be able to sever between one and four pouches  20  from the roll depending on whether the size of the load of laundry that needed washing represented a quarter load, a half load, a three-quarter load, ora full load. 
       FIG. 7  shows an active composition delivery system  10  according to another embodiment of the present invention. In this example, the active composition delivery system  10  has a rectangular shape, and contains a pre-measured unit dose of a powder cleaning composition  16 . The water-soluble PVA top and bottom layers  12 ,  14  are joined together at their edges  18  by sewing with PVA thread using sufficiently tight stitches  22 , arranged in a continuous thread path  24  to ensure that the active composition  16  does not spill or leak out of the pouch  20  through spaces between the top and bottom layers  12 ,  14 . The PVA thread has similar dissolution properties to those of the top and bottom layers  12 ,  14 . 
     Additionally, the active composition delivery system  10  also includes a plurality of loose stiches  26  configured and arranged in the region  30  to limit a maximum thickness  32  of the active composition delivery system  10 , so that it will have a generally flat, quilted profile. The plurality of loose stitches  26  are arranged in a plurality of crossing thread paths  30  to form a quilted pattern of squares. In this example, the water-soluble PVA thread has a different colour than the colour of the top and bottom layers  12 ,  14 , so that It stands out. 
       FIG. 8  shows an active composition delivery system  10  according to another embodiment of the present Invention. In this example, the active composition delivery system  10  has a rectangular shape, and contains a pre-measured unit dose of a powder cleaning composition  16 . The water-soluble PVA top and bottom layers  12 ,  14  are joined together at their edges  18  by sewing with PVA thread using sufficiently tight stitches  22 , arranged in a continuous thread path  24  to ensure that the active composition  16  does not spill or leak out of the pouch  20  through gaps between the top and bottom layers  12 ,  14 . The PVA thread has similar dissolution properties to those of the top and bottom layers  12 ,  14 . 
     Additionally, the active composition delivery system  10  also includes a plurality of loose stiches  26  configured and arranged in the region  30  to limit a maximum thickness  32  of the active composition delivery system  10 , so that it will have a generally flat, quilted profile. The plurality of loose stitches  26  are arranged in a plurality of crossing thread paths  30  to form a quilted pattern of squares. In this example, the water-soluble PVA thread has the same colour as the colour of the top and bottom layers  12 ,  14 , so that it blends in. 
     Having described embodiments of the active composition delivery system  10  of the present invention, a method for making the same is described next. 
     According to one embodiment of the present invention, the active composition delivery system  10  is made by a two-stage process. 
     In a first-stage of the two-stage process, a continuous vertical form-fill-seal method Is used to make a train of pouches, each containing a pre-measured amount of active composition  16 . In this continuous vertical form-fill-seal method, a pair of water-soluble sheets of PVA material (or a single folded over sheet of water-soluble PVA material) are joined together along their edges to form a tube, and the bottom of the tube is closed with a transverse joint to form a first pouch below a hopper. As will be appreciated, the joined edges and the transverse joints may be formed by, for example, heating, ultrasonic welding, solvent gluing, or sewing with water-soluble PVA thread. These joined edges and transverse joints become the joined edges  18  of the active composition delivery system  10 , described above. 
     Active composition  16 , such as laundry detergent powder is then added to the first pouch through the hopper, and the tube is closed with a transverse joint above the first pouch to form a second pouch below the hopper. Active composition  16  is then added to the second pouch, and the tube is again closed with a transverse joint above the second pouch to form a third pouch below the hopper. The process may be repeated several times to form a train of pouches filled with active composition  16 . 
     The second stage of the two-stage process will now be described with reference to  FIG. 9 . Preferably, the train  44  of pouches  20  filled with active composition  16  proceeds from the first stage along a horizontal conveyor. As shown, the train  44  is passed below a roller  46  and proceeds in the direction of arrow  48 . The roller  46  is free to move vertically according to its own weight, and is configured to ensure that the active composition  16  is evenly distributed with the pouches  20 . Although only one roller  46  is shown, a plurality of rollers may be provided next to each other to ensure even distribution of the pouches  20 . Alternately, or in addition to the roller(s)  46 , vibration may be used to ensure the even distribution. As the train  44  continues to be carried by the conveyor in the direction of arrow  46 , it will pass through a pair of synchronized sewing machines  50  which oscillate back and forth transversely across the pouches  20  in the direction of arrows  52 , to form mirrored zig-zag thread paths  30  which result In a quilted pattern. In a final step (not shown), a cutting device may be configured to cleave the train  44  at each transverse joint, to form the active composition delivery system  10  comprising one pouch  20 . Alternately, the final step (not shown), may be configured to a) provide a line of weakness  36 , such as a line of user tearable perforations in every transverse joint, and b) cutting the train  44  at every other predetermined number of transverse joints (i.e. every sixth transverse joint), to form active composition delivery system  10  comprising more than one pouch  20  (i.e. five pouches as shown in  FIG. 6 ), which are severable from each other by the user. 
     Preferably, the sewing machines  50  may be configured to travel back and forth a distance equal to the width between the Joined edges  18 , synchronized to each other, as well as the conveyor moving the train  44  underneath the sewing machines  50 . 
     Advantageously, embodiments of the active composition delivery system  10  comprehends many manners of use. For example, the active composition delivery system  10  may be configured to enable the user to prepare a volume of a cleaning or treating solution for current use or for later use. For example, the user may dissolve an active composition delivery system  10  in a pail of water and use the solution In the pail together with a mop to clean the floor. As another example, the user may dissolve an active composition delivery system  10  in a kitchen sink filled with a volume of water and use the solution to wash dishes. As yet another example, the user may hold an active composition delivery system  10  in his hands under running water to cleanse his hands, and/or other body parts. As yet another example, the user may hold an active composition delivery system  10  in her hands or on her head in the shower to shampoo or condition her hair. As yet another example, the user may dissolve an active composition delivery system  10  in a spray bottle filled with a volume of water and use solution to clean hard surfaces. As yet another example, the user may dissolve an active composition delivery system  10  in a disposable or reusable storage bottle filled with a volume of water and later dispense the solution, on an as needed basis, to use as a liquid fabric softener, a liquid dish detergent, a liquid laundry detergent, or the like. 
     Accordingly, the active composition delivery system  10  lends itself to uses relating to cleaning or treating people, animals, or things. 
     Accordingly, the active composition delivery system  10  of the present invention is not limited to the specific examples described herein to illustrate the invention, but comprehends other uses and applications, depending on the formulations of the active composition, the top and bottom water-soluble layers, and the water-soluble joints comprised by the cleaning composition delivery system, as will be recognized by persons skilled. 
     While reference has been made to various preferred embodiments of the invention other variations, implementations, modifications, alterations and embodiments are comprehended by the broad scope of the appended claims. Some of these have been discussed in detail In this specification and others will be apparent to those skilled in the art. For example, the loose stitches  26  in the region  28  between the joined edges  18  may be replaced with tight stitches  22 , thereby removing the gaps  34 . Those of ordinary skill in the art having access to the teachings herein will recognize these additional variations, implementations, modifications, alterations and embodiments, all of which are within the scope of the present invention, which invention is limited only by the appended claims.