Patent Description:
Water soluble pouches for delivering substrate treatment compositions, such as dishwashing detergents, laundry detergents, surface cleaning compositions, and laundry treatment compositions, are increasing in popularity globally. Typically, the consumer places the pouch in a compartment in the dishwashing machine or in the drum of a clothing washing machine or bucket of water, the pouch is exposed to water, and the pouch dissolves and releases the treatment composition.

The substrate treatment composition can be a solid or liquid. Some pouches have multiple compartments and liquids in each of the compartments. Some pouches have multiple compartments with one compartment containing a solid and another compartment containing a liquid. Individual compartments of multi-compartment pouches can have different dissolution rates, thereby providing for delivery of the substrate treatment compositions within individual compartments at different times during the cycle of the wash.

Water soluble pouches are commonly produced by thermoforming a water soluble film. A water soluble film is positioned on a thermoforming mold, the film is thermoformed to conform with recesses in the mold, a substrate treatment composition is placed in the open pockets of the thermoformed water soluble film, and another water soluble film is joined to the thermoformed water soluble film to close the pockets. In practice, a continuous web comprising a plurality of closed pockets is produced. The continuous web of closed pockets is cut to yield individual closed pockets. Cutting may occur while the web of closed pockets is carried on the thermoforming mold or after the web is removed from the thermoforming mold. At some step of the process of manufacturing water soluble pouches, the individual pouches must be separated from the thermoforming mold.

<CIT> discloses a process for making water soluble unit dose pouches comprising the steps of:providing an apparatus comprising:a thermoforming mold having a forming surface;a plurality of spaced apart recesses in said forming surface, wherein each said recess comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source;a continuous land area surrounding said recesses, positioning a first water soluble film in facing relationship with said land area,heating said first water soluble film;applying vacuum to said first water soluble film through said vacuum orifices to thermoform said first water soluble film to said recesses thereby forming a plurality of open pockets;placing a substrate treatment composition in said plurality of open pockets;positioning a second water soluble film above said first water soluble film;joining said second water soluble film and said first water soluble film thereby forming a web comprising a plurality of closed pouches;cutting said web to separate said closed pouches from one another; andseparating said closed pouches from said forming surface. <CIT> discusses mold cavity surface Roughness (Ra) of a mold for thermoforming a crystalline sheet.

Water soluble films used to manufacture water soluble pouches containing a substrate treatment composition tend to be soft, flexible, elastic, and sometimes tacky to the touch. These characteristics can complicate separation of the water soluble pouch from the thermoforming mold.

High speed manufacturing processes are dependent upon precise control of the movement of the articles produced. Water soluble pouches that do not easily, predictably, and controllably separate from the thermoforming mold can result in processing irregularities downstream of the location in the process at which the water soluble pouches are separated from the thermoforming mold. Such process irregularities can include damaged or torn water soluble pouches and misalignment of water soluble pouches with respect to knives used to separate individual water soluble pouches from one another. With these limitations in mind, there is a continuing unaddressed need for thermoforming molds and process for using thermoforming molds that provide for improved ability to separate water soluble pouches from the thermoforming mold.

The invention is defined by the features of claim <NUM>.

An apparatus comprising: a thermoforming mold having a forming surface; a plurality of spaced apart recesses in said forming surface, wherein each said recess comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; a continuous land area surrounding said recesses, wherein portions of said land area between said recesses have an average roughness Ra from <NUM> to <NUM>.

A process for making water soluble unit dose pouches comprising the steps of: providing a thermoforming mold comprising: a forming surface; a plurality of spaced apart recesses in said forming surface, wherein each recess comprises a vacuum orifice and each vacuum orifice is in fluid communication with a vacuum source; and a continuous land area surrounding said recesses, wherein portions of said land area between said recesses have an average roughness Ra from <NUM> to <NUM>; positioning a first water soluble film in facing relationship with said land area, wherein said first water soluble film comprises: from <NUM>% to <NUM>% by weight of said first water soluble film polyvinylalcohol polymer; from <NUM>% to <NUM>% by weight of said first water soluble film nonaqueous plasticizer; from <NUM>% to <NUM>% by weight of said water soluble film water; and surfactant; wherein said first water soluble film has a thickness from <NUM> to <NUM> before said first water soluble film is positioned in facing relationship with said land area of said thermoforming mold; heating said first water soluble film; applying vacuum to said first water soluble film through said vacuum orifices to thermoform said first water soluble film to said recesses thereby forming a plurality of open pockets; placing a substrate treatment composition in said plurality of open pockets; positioning a second water soluble film above said first water soluble film; joining said second water soluble film and said first water soluble film thereby forming a web (<NUM>) comprising a plurality of closed pouches; cutting said web to separate said closed pouches from one another; and separating said closed pouches from said forming surface.

As used herein, with respect characterizing land area, average roughness Ra is defined and measured according to ISO <NUM>-<NUM>:<NUM>. As used herein, with respect to characterizing recesses, roughness Sa is defined and measured according to ISO <NUM>-<NUM>:<NUM>.

A water soluble unit dose pouch <NUM> is shown in <FIG>. The pouch <NUM> can comprise a water soluble first sheet <NUM> and a water soluble second sheet <NUM>. The water soluble second sheet <NUM> can be joined to the water soluble first sheet <NUM>. Together, the two sheets can at least partially define a chamber <NUM> containing a substrate treatment composition <NUM>.

Each of the first sheet <NUM> and second sheet <NUM> can have an interior surface <NUM> and an opposing exterior surface <NUM>, as shown in <FIG>. The interior surface <NUM> of the first sheet <NUM> and second sheet <NUM> can together form a chamber <NUM>. The edges <NUM> of the first sheet <NUM> and second sheet <NUM> can be joined to one another to form the chamber <NUM>. Within the chamber <NUM>, the substrate treatment composition <NUM> can be disposed. At least one of the first sheet <NUM> and second sheet <NUM> can be a thermoformed sheet <NUM>. The interior surface <NUM> of the first sheet <NUM> and second sheet <NUM> can be oriented towards the chamber <NUM>.

The plan view of the of the water soluble pouch <NUM> can be substantially rectangular, substantially square, substantially circular, substantially elliptical, substantially superelliptical, or any other desired shape that is practical to manufacture. The overall plan area of the water soluble pouch can be less than about <NUM><NUM>, or even less than about <NUM><NUM>. Sized and dimensioned as such, the water soluble pouch <NUM> can fit conveniently within the grasp of an adult human hand. Further, for water soluble pouches <NUM> intended for use in automatic dishwashing machines, such a size can conveniently fit in the detergent receptacle within the machine.

The edges <NUM> of the first sheet <NUM> and second sheet <NUM> can be bonded to one another. For example, the edges <NUM> of the first sheet <NUM> and second sheet <NUM> can be joined to one another by a thermal bond or a solvent weld or combination thereof. A thermal bond can be formed by applying one or more of heat and pressure to the two materials to be bonded to one another. A solvent weld can be formed by applying a solvent to one or both of the first sheet and second sheet and contacting the first sheet <NUM> and second sheet <NUM> in the location at which a bond is desired. For water soluble pouches, the solvent can be water and or steam.

The first sheet <NUM> and the second sheet <NUM> can be sufficiently translucent, or even transparent, such that the substrate treatment composition <NUM> is visible from the exterior of the pouch <NUM>. That is, the consumer using the pouch <NUM> can see the substrate treatment composition <NUM> contained in the pouch <NUM>.

The pouch <NUM> can have a plurality of chambers <NUM>. For example a plurality of pouches <NUM> can be joined to one another to form a multi-compartment pouch. One or more pouches of the kind illustrated in <FIG> can be joined to one another. The pouch <NUM> can be of the type presently marketed as TIDE PODS, CASCADE ACTION PACS,CASCADE PLATINUM, CASCADE COMPLETE, ARIEL <NUM> IN <NUM> PODS, TIDE BOOST ORIGINAL DUO PACs, TIDE BOOST FEBREZE SPORT DUO PACS, TIDE BOOST FEE DUO PACS, TIDE BOOSE VIVID WHITE BRIGHT PACS, DASH, FAIRY (PLATINUM, ALL-IN ONE, YES (PLATINUM ALL-IN ONE, JAR (PLATINUM, ALL-IN ONE, DREFT (PLATINUM, ALL-IN ONE by The Procter & Gamble Company in various geographies globally. The pouch <NUM> can have <NUM> chambers <NUM>. The first sheet <NUM> and second sheet <NUM> can form a first chamber <NUM>. Another first sheet <NUM> and second sheet <NUM> can form a second chamber <NUM> or one or more additional chambers <NUM>. The two pouches <NUM> can be joined together. The chambers <NUM> can be superimposed upon one another. The chambers <NUM> can be a in a side by side relationship.

The substrate treatment composition <NUM> can be a liquid or solid. The substrate treatment composition <NUM> can be selected from the group consisting of laundry detergent, laundry additive, dishwashing detergent, hard surface cleaner, and dishwashing additive.

The pouch <NUM> can be sized and dimensioned to fit in an adult human hand. The pouch <NUM> can have a volume from about <NUM> to about <NUM>. The pouch <NUM> can have a volume from about <NUM> about <NUM>. The pouch <NUM> can have a volume from about <NUM> about <NUM>. The edges <NUM> can have a length of from about <NUM> to about <NUM>. The edges <NUM> can have a length of from about <NUM> to about <NUM>. The edges <NUM> can have a length of from about <NUM> to about <NUM>.

An apparatus <NUM> for forming a water soluble pouch <NUM> is shown in <FIG>. The apparatus <NUM> can comprise a first film unwind roll <NUM> and a thermoforming mold <NUM>. The thermoforming mold <NUM> can be movable in the machine direction MD. The first unwind roll <NUM> can be upstream of the thermoforming molds <NUM>. A heater <NUM> can be positioned downstream of the first film unwind roll <NUM>. The heater <NUM> can be positioned between the first film unwind roll <NUM> and the merging location <NUM>. The heater <NUM> can be positioned between the first film unwind roll <NUM> and the dosing device <NUM>. The heater <NUM> can be a non-contact heater <NUM>. The heater <NUM> can be an infrared heater. Optionally, the heater <NUM> can be a heated roller. A dosing device <NUM> can be positioned above the forming surface <NUM> of the thermoforming mold <NUM> at a location at which vacuum orifices in the thermoforming mold <NUM> are in fluid communication with a vacuum source <NUM>. The thermoforming mold <NUM> can be slidably engaged with a vacuum manifold <NUM>, the vacuum manifold being in fluid communication with each vacuum orifice. The vacuum manifold <NUM> can transmit vacuum from the vacuum source <NUM> to the recess or recesses of the thermoforming mold. A second film unwind roll <NUM> can be operably positioned to supply a continuous web of second water soluble film <NUM> above the forming surface <NUM> downstream of the dosing device <NUM> and at a merging location <NUM> at which the vacuum orifices are in fluid communication with the vacuum source <NUM>.

The apparatus can further comprise a cutting system <NUM> downstream of the merging location <NUM>. The cutting system <NUM> can comprise one or more longitudinal cutting knives <NUM> downstream of the merging location. The longitudinal cutting knives <NUM> can have a longitudinal cutting direction aligned with the machine direction MD. The longitudinal cutting knife <NUM> or knives <NUM> can be configured to cut the joined first water soluble film <NUM> and second water soluble film <NUM> in the machine direction between recesses adjacent to one another in the cross direction orthogonal to the machine direction MD. The longitudinal cutting knife <NUM> or knives <NUM> can be rotary cutting knives <NUM>.

The cutting system <NUM> can comprise a plurality of transverse cutting knives <NUM> downstream of the merging location <NUM>. The transverse cutting knives <NUM> can have a transverse cutting direction in the cross direction which is orthogonal to the machine direction MD. The transverse cutting knife <NUM> or transverse cutting knives <NUM> can be configured to cut the joined first water soluble film <NUM> and second water soluble film <NUM> in the cross direction between recesses adjacent to one another in the machine direction MD.

The cutting system <NUM> can comprise die cutters. Die cutters can provide for continuous cuts around the periphery of individual water soluble unit dose pouches <NUM>. The die cutters can employ a stamping process that provide for cuts between individual water soluble unit dose pouches <NUM> by stamping a die to an anvil to cut around individual water soluble unit dose pouches <NUM> that form a web of water soluble pouches. The die cutters can be rotary die cutters that provide for die cuts between individual water soluble unit dose pouches <NUM> and employ a rotary process to make such cuts as a web of water soluble pouches <NUM> travels between the rotary die and anvil or anvil portion of the mold <NUM>. Optionally, the cutting system <NUM> can be a laser cutting system <NUM>. Optionally, the cutting system <NUM> can be a hot wire cutting system <NUM>.

A continuous web of first water soluble film <NUM> can be positioned on the first film unwind roll <NUM>. The first water soluble film <NUM> can extend downstream of the merging location <NUM> and can be positioned in facing relationship with the land area of the thermoforming mold <NUM> downstream of the first film unwind roll <NUM>. Likewise, a continuous web of second water soluble film <NUM> can be positioned on the second film unwind roll <NUM>. The second water soluble film <NUM> can extend downstream of the merging location <NUM> and be positioned above the first water soluble film <NUM> downstream of the merging location <NUM>.

The thermoforming mold <NUM> can be mounted on a rotatable drum <NUM> or on a flat conveyance. A flat conveyance can be a continuous belt or a series of linear motor vehicles that carry the mold <NUM> in a straight line or horizontal line in the machine direction MD through the process of making water soluble unit dose pouches <NUM>. The flat conveyance can be a series of individual molds <NUM> that can be positioned to abut one another to form the flat conveyance. The individual molds <NUM> can be joined to one another to provide for a continuous belt of molds <NUM>. The forming surfaces <NUM> of the individual molds <NUM> abutting one another can form the flat conveyance. As the molds <NUM> traverse a curve, for example, when the molds <NUM> are recirculated upstream, the forming surfaces <NUM> of the molds <NUM> may become spaced apart from one another. Optionally, the forming surfaces <NUM> of the molds <NUM> may remain abutting to one another as the molds are recirculated upstream if the molds <NUM> are provided with structure that permits adjacent forming surfaces <NUM> to move hingedly relative to one another.

A thermoforming mold <NUM> is shown in <FIG>. The thermoforming mold <NUM> can have a forming surface <NUM>. The forming surface <NUM> is the surface to which the first water soluble film <NUM> is contacted. The forming surface <NUM> can comprise a plurality of spaced apart recesses <NUM>. Each of the recesses <NUM> can comprise a vacuum orifice <NUM> or plurality of vacuum orifices <NUM>. Each vacuum orifice <NUM> can be in fluid communication with a vacuum source <NUM>.

A continuous land area <NUM> can surround the recesses <NUM>. Portions of the land area <NUM> between the recesses <NUM> can have an average roughness Ra from <NUM> to <NUM>, optionally from <NUM> to <NUM>, optionally from <NUM> to <NUM>. Optionally, portions of each of the recesses <NUM> can have a roughness Sa from <NUM> to <NUM>, optionally from <NUM> to <NUM>, optionally from <NUM> to <NUM>. Optionally, from about <NUM>% to about <NUM>% by area of each recess <NUM> can have a roughness Sa from <NUM> to <NUM>, optionally from <NUM> to <NUM>, optionally from <NUM> to <NUM>. Area of the recess includes the vacuum orifices <NUM>. Surprisingly, providing thermoforming mold <NUM> having a rough surface forming at least part or the entirety of the continuous land area <NUM> and or the recesses <NUM> can help improve the ability for the manufacturer to separate the water soluble pouch <NUM> or continuous web of water soluble pouches <NUM> from the thermoforming mold <NUM> after thermoforming. From <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally about <NUM>%, optionally <NUM>%, of the land area <NUM> between the recesses <NUM> can have an average roughness from <NUM> to <NUM>, optionally from <NUM> to <NUM>, optionally from <NUM> to <NUM>.

The forming surface <NUM>, which includes the land area <NUM> and the recesses <NUM> can be fabricated of <NUM> aluminum. The forming surface <NUM> can be treated by sand blasting to impart the desired average roughness Ra and roughness Sa. The forming surface <NUM> can be anodized.

The transition between the land area <NUM> and the recess can be chamfered or filleted. Chamfering or filleting the transition, or in other words the boundary between the land area <NUM> and the recess <NUM>, can reduce stress concentrations in the water soluble film as it is thermoformed. The boundary between the land area <NUM> and recess <NUM> can be chamfered at an angle from about <NUM> degrees to about <NUM> degrees, optionally from about <NUM> degrees to about <NUM> degrees, optionally about <NUM> degrees to about <NUM> degrees relative to the land area. The chamfering can be provided over a chamfer length measured in the direction of the chamfer of from about <NUM> to about <NUM>, optionally about <NUM> to about <NUM>, optionally about <NUM>. The filleting at the boundary between the land area <NUM> and recess <NUM> can be a convex curved surface. The filleting at the boundary between the land area <NUM> and recess <NUM> can have a radius from about <NUM> to about <NUM>, optionally about <NUM> to about <NUM>.

The depth of the recesses <NUM> relative to the land area <NUM> can be from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>. The recesses <NUM> can have a curved shape. The bottom of the recesses <NUM> can be curved. Curved surfaces may tend to reduce stress concentrations in the thermoformed first water soluble film <NUM>.

Water soluble pouches <NUM> containing a substrate treatment composition <NUM> are commonly manufactured by a thermoforming process. During thermoforming, the first water soluble film <NUM> is heated to improve the ability for the first water soluble film <NUM> to be formed into a shape in conformance with the thermoforming mold <NUM>. When heated, water soluble film <NUM> of the type ordinarily used to construct water soluble pouches containing a substrate treatment composition <NUM> tends to become soft, flexible, elastic, and tacky. The tackiness can arise at least partly by the process of heating the first water soluble film <NUM> which can tend to result in the first water soluble film <NUM> expelling water.

Heat is typically applied to the water soluble film <NUM> immediately upstream of or at the location at which thermoforming occurs. Heat can be applied by passing the water soluble film <NUM> beneath one or more heat lamps, for example infrared heat lamps, rolling the water soluble film <NUM> over one or more heated rollers, or passing the water soluble film <NUM> over one or more heated plates.

Heat can be applied via a heat lamp, infrared heat lamp, heat plate, heat roller. Downstream of the location at which thermoforming occurs, heat is typically not added to the first water soluble film <NUM> or incidentally to the thermoforming mold <NUM>. Once the water soluble pouches <NUM> are removed from the thermoforming mold <NUM>, the thermoforming mold <NUM> travels a circuit to be back upstream of the location at which first water soluble film <NUM> is positioned in facing relationship with the land area <NUM> of the thermoforming mold <NUM>. As the thermoforming mold <NUM> recirculates to again be upstream of the location at which first water soluble film <NUM> is placed on the land area <NUM> of the thermoforming mold <NUM>, the thermoforming mold <NUM>, and in particular the land area <NUM> and surfaces of the recesses <NUM>, tends to cool relative to the temperature at which the thermoforming mold <NUM> and components thereof are when thermoforming occurs. As such, the temperature of the first water soluble film <NUM> when heated for thermoforming tends to be greater than the temperature of the land area <NUM> and surfaces of the recess <NUM> when the first water soluble film is placed onto the land area <NUM> of the thermoforming mold <NUM>.

Water expelled by the first water soluble film <NUM> as a result of heating may be retained on the surface of the first water soluble film <NUM> presented to the land area <NUM> and recesses <NUM> of the thermoforming mold <NUM>. Water on the surface of the first water soluble film <NUM> may partially solubilize the surface of the first water soluble film <NUM>. When the first water soluble film <NUM> is positioned in contact with the land area <NUM>, which may be cooler than the first water soluble film <NUM>, the partially solubilized surface of the first water soluble film <NUM> may solidify, thereby adhering the first water soluble film <NUM> to the land area <NUM>.

Furthermore, prior to the first water soluble film <NUM> being thermoformed, there is a gap between the first water soluble film <NUM> and the recesses <NUM>. Water may evaporate from the surface of the first water soluble film <NUM> into the gap between the first water soluble film <NUM> and the surface of the recesses <NUM>. Since the surfaces of the recesses <NUM> may be cooler than the first water soluble film <NUM>, water vapor in the gap may condense onto the surface of the recesses <NUM>. When the first water soluble film <NUM> is thermoformed into conformance with the recesses <NUM>, the combination of a wet surface of the first water soluble film <NUM> that may be partially solubilized and condensation of water onto the surface of the recesses <NUM> can result in the first water soluble film <NUM> becoming adhered to the surface of the recesses <NUM>.

Providing the forming surface <NUM> having a rough surface can help ease separation of the thermoformed pouches <NUM> from the thermoforming mold <NUM>. A rough surface can also make separating the thermoformed pouches <NUM> from the thermoforming mold <NUM> more predictable and controllable. Without being bound by theory, it is thought that a rough surface tends to support the first water soluble film <NUM> at peaks of the rough surface and the first water soluble film <NUM> bridges from peak to peak. Thus for a rough surface, some portions of the surface of the first water soluble film <NUM> oriented towards the forming surface <NUM> between peaks of the rough surface may not be in contact with the forming surface <NUM>. That can reduce the amount of force necessary for separating the pouch <NUM> from the forming surface <NUM> as compared to if the entirety of the surface of the first water soluble film <NUM> oriented towards the forming surface <NUM> was in contact with a smoother, or perfectly smooth, forming surface <NUM>. Reducing the amount of force required to separate a pouch <NUM> from the forming surface <NUM> can provide for more predictable separation of the pouch <NUM> from the forming surface <NUM> and improved control of the pouch <NUM> as it is separated from the forming surface <NUM>. By improving control of separation of the pouch <NUM> from the forming surface <NUM>, the manufacturing line speed may be increased compared to a manufacturing line employing thermoforming molds <NUM> having a smoother forming surface <NUM>.

The forming surface <NUM> can have a forming surface area. The forming surface area is a scalar quantity in units of length squared. The forming surface area is computed based on the peripheral bounds of the forming surface. The forming surface <NUM> is the surface of the thermoforming mold <NUM> that contacts the first water soluble film <NUM>. The forming surface area is computed such that variations in the surface topography of the forming surface <NUM> and the three dimensional shape of the recesses <NUM> are not accounted for. As such, the forming surface area is computed in the plane or curved plane defined by the continuous land area <NUM>. For example, a rectangular forming surface having a length and a width has a forming surface area that is the product of the length and width, notwithstanding that the forming surface may not be perfectly smooth and includes recesses <NUM>. Similarly, the continuous land area <NUM> can have a continuous land area surface area. The continuous land area surface area is computed based on the bounds, peripheral and internal, of the continuous land area <NUM>. The continuous land area surface area does not include the recesses <NUM>. The continuous land area surface area is computed such that variations in the surface topography of the continuous land area <NUM> are not accounted for. The continuous land area surface area can be less than about <NUM>%, optionally less than about <NUM>%, optionally less than about <NUM>%, optionally from about <NUM>% to about <NUM>%, optionally from about <NUM>% to about <NUM>% of the forming surface area.

The recesses <NUM> can be sized and dimensioned to provide for open pockets that can accommodate a desired volume of substrate treatment composition. The recesses can have an individual volume from about <NUM> to about <NUM>. Recesses <NUM> can be spaced apart from one another by from about <NUM> to about <NUM>, optionally about <NUM> to about <NUM>. The recesses <NUM> can have a center to center spacing in the machine direction MD and cross direction from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>.

The recess <NUM> can be provided as shown in <FIG>.

The thermoforming molds <NUM> can be curved so as to be able to fit onto a drum <NUM> and operate in a rotary process, as illustrated in <FIG>. Optionally, the thermoforming molds <NUM> can be flat, as shown in <FIG>, so as to be usable in a process that operates along a flat conveyance <NUM>. An apparatus <NUM> for forming a water soluble pouch <NUM> is shown in <FIG>. The apparatus <NUM> can comprise a first film unwind roll <NUM>, optionally a printing unit <NUM>, a flat conveyance <NUM>, a plurality of thermoforming molds <NUM> movably mounted on the flat conveyance <NUM>, a heater <NUM>, a dosing device <NUM>, and a second film unwind roll <NUM>. Upstream of the dosing device <NUM>, the apparatus <NUM> can comprise a vacuum source <NUM>. The vacuum source <NUM> can provide for two stages of vacuum application via a first vacuum source 150a and a second vacuum source 150b, the second vacuum source 150b being between the first vacuum source 150a and the dosing device <NUM>. The first water soluble film <NUM> can be fed through the optional printing unit <NUM> prior to being placed on the flat conveyance <NUM>. The first water soluble film <NUM> can then be fed onto the flat conveyance <NUM>. The flat conveyance <NUM> can convey the thermoforming molds <NUM> in the machine direction MD. The dosing device <NUM> can be movable in the machine direction MD and in a direction upstream of the machine direction MD, for example a reciprocating dosing device <NUM>.

The flat conveyance <NUM> can convey the thermoforming molds <NUM> and thereby first water soluble film <NUM> at a rate of from about <NUM>/min to about <NUM>/min, inclusive of any ranges of or single values of integers there between.

The flat conveyance <NUM> can carry a plurality of thermoforming molds <NUM>. The films discussed herein can be held on the thermoforming molds <NUM> discussed herein by a web-holding vacuum system in the continuous land areas <NUM> of the thermoforming molds <NUM>. The thermoforming molds <NUM> can be fabricated from aluminum or aluminum alloy. Each thermoforming mold <NUM> can have one or more spaced apart recesses <NUM>. There can be one or more thermoforming molds in the cross machine direction. The flat conveyance <NUM> can convey the thermoforming molds <NUM> in the machine direction MD during formation and filling of the pouches <NUM>.

As the first water soluble film <NUM> is conveyed in the machine direction MD, the first water soluble film <NUM> can pass beneath a heater <NUM>. The heater <NUM> can be an infrared lamp. The heater <NUM> can be an infrared lamp having a temperature of from about <NUM> C to about <NUM> C. As the first water soluble film <NUM> passes beneath the heater <NUM>, the first water soluble film <NUM> can be heated to the desired temperature. The distance between the heater <NUM> and the first water soluble film <NUM> can be adjustable so that the temperature of the first water soluble film <NUM> can be controlled. Similarly, the temperature of the heater <NUM> can be adjustable so that the temperature of the first water soluble film <NUM> can be controlled. Multiple heaters <NUM> can be provided in series. The multiple heaters <NUM> can have the same temperature as one another or be set at different temperatures to vary the rate at which the first water soluble film <NUM> is heated.

As the first water soluble film <NUM> is heated to the desired temperature, the thermoforming mold <NUM> can be conveyed over the vacuum source <NUM>. The vacuum source <NUM> can be used to apply a first negative gage pressure to the vacuum orifice <NUM> or vacuum orifices <NUM> of the recesses <NUM>. When the first negative gage pressure is applied to the vacuum orifice <NUM> or vacuum orifices <NUM> the first water soluble film <NUM> can have a temperature from about <NUM> C to about <NUM> C over the recess <NUM>. When the first water soluble film <NUM> is heated, it is possible that the temperature of the first water soluble film <NUM> is non-uniform in the machine direction MD and the cross direction. This can occur because part of the first water soluble film <NUM> is resting on the land area <NUM> of the thermoforming mold <NUM> and part of the first water soluble film <NUM> is overlying a recess <NUM>. The difference in boundary conditions for the first water soluble film <NUM> in the direction of the thickness of the first water soluble film <NUM> can result in non-uniform heating of the first water soluble film <NUM>. For instance, the portion of the first water soluble film <NUM> overlying the center of a recess <NUM> may be at a temperature of <NUM> C and the portion of the first water soluble film <NUM> out on the land area <NUM> may have a temperature of about <NUM> C. The portion of the first water soluble film <NUM> overlying the center of a recess <NUM> may be at a temperature of <NUM> C and the portion of the first water soluble film <NUM> out on the continuous land area <NUM> may have a temperature of about <NUM> C. The portion of the first water soluble film <NUM> overlying the center of a recess <NUM> may be at a temperature of <NUM> C and the portion of the first water soluble film <NUM> out on the land area <NUM> may have a temperature of about <NUM> C. A higher temperature of the portion of the first water soluble film <NUM> overlying the center of a recess <NUM> can promote improved thermoforming resulting in fewer and or less structurally significant microscopic cracks. Further, higher temperatures during thermoforming can promote plastic deformation which can result in less internal pressure of the finished pouch <NUM> as compared to if the first water soluble film <NUM> is elastically deformed. If the temperature is too high, the first water soluble film <NUM> may become so pliable that the web may be drawn into the vacuum orifice <NUM> or vacuum orifices <NUM> in the recess <NUM>, which can be detrimental to the structural integrity of the finished pouch <NUM>.

Each of the vacuum orifices <NUM> can have an area from about <NUM><NUM> to about <NUM><NUM>, optionally from about <NUM><NUM> to about <NUM><NUM>. The vacuum orifices <NUM> can be circular. There can be from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, vacuum orifices <NUM> in each recess <NUM>. The vacuum orifices <NUM> can be sized such that at the temperature of thermoforming, the first water soluble film <NUM> is not drawn into the vacuum orifices <NUM> to a degree such that the structural integrity of the finished pouch <NUM> is compromised.

Each recess <NUM> in the thermoforming mold <NUM> can have a volume from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>.

The first water soluble film <NUM> can be thermoformed in two stages. A first negative gage pressure can be applied to provide for initial thermoforming of the first water soluble film <NUM>. A second negative gage pressure can be subsequently applied to complete thermoforming to conform the first water soluble film <NUM> to the recess <NUM>. The first negative gage pressure can be from about <NUM> mbar to about <NUM> mbar below atmospheric pressure. The first water soluble film <NUM> can be subjected to the first negative gage pressure for from about <NUM> to about <NUM>. The first water soluble film <NUM> can be subjected to the first negative pressure for from about <NUM> to about <NUM>. The first water soluble film <NUM> can be subjected to the first negative pressure for from about <NUM> to about <NUM>. The first negative gage pressure can be from about <NUM> mbar to about <NUM> mbar below atmospheric pressure. The first negative gage pressure can be from about <NUM> mbar to about <NUM> mbar below atmospheric pressure. The first water soluble film <NUM> can have a temperature from about <NUM> C to about <NUM> C over the recess <NUM> when vacuum is first applied to the first water soluble film <NUM>. The lower the first negative gage pressure the faster the first water soluble film <NUM> will be deformed. Slower deformation can reduce the amount of micro-cracking in the deformed first water soluble film <NUM>. For a lower temperature of deformation, the first negative gage pressure may be greater, i.e. less vacuum, so that deformation of the first water soluble film <NUM> is slow, which can reduce micro-cracking in the first water soluble film <NUM>.

As the first water soluble film <NUM> is conveyed further in the machine direction MD, a second negative gage pressure can be applied to vacuum orifice <NUM> or vacuum orifices <NUM> of the recess <NUM>. The second negative gage pressure can be applied with a second vacuum source 150b. The second negative gage pressure can be applied when the first water soluble film <NUM> above the recess <NUM> is at a temperature that is greater than the temperature at which vacuum is first applied.

For clarity, gage pressure is zero referenced at atmospheric pressure. So if the first negative gage pressure is <NUM> mbar below atmospheric pressure and the second negative gage pressure is <NUM> mbar below atmospheric pressure, it can be said that the second negative gage pressure is less than the first negative gage pressure. And, it can be said a gage pressure of <NUM> mbar below atmospheric pressure is a negative gage pressure since it is pressure below atmospheric pressure. Since a negative gage pressure of <NUM> mbar below atmospheric pressure is below atmospheric pressure, it is a vacuum. So, in the circumstances in which the second negative gage pressure is less than or equal to the first negative gage pressure, it can be thought of as the first negative gage pressure being a first level of vacuum and the second negative gage pressure being a second level of vacuum, and the second level of vacuum is more forceful than the first level of vacuum.

The temperature of the first water soluble film <NUM> above the recess <NUM> when a second negative gate pressure is applied can be from about <NUM> C to about <NUM> C, optionally from about <NUM> C to about <NUM> C. The second negative gage pressure can be from about <NUM> mbar to about <NUM> mbar, optionally from about <NUM> mbar to about <NUM> mbar below atmospheric pressure. The second negative gage pressure can be from about <NUM> mbar to about <NUM> mbar below atmospheric pressure. The second negative gage pressure can be from about <NUM> mbar to about <NUM> mbar below atmospheric pressure. The second negative gage pressure can be from about <NUM> mbar to about <NUM> mbar below atmospheric pressure. That is, the second negative gage pressure pulls harder on the first water soluble film <NUM> than the first negative gage pressure.

As the thermoforming mold <NUM> is conveyed downstream in the machine direction MD, the thermoforming mold <NUM> can be brought into position such that the second vacuum source 150b can apply a second negative gage pressure to the vacuum orifice <NUM> or vacuum orifices <NUM> of the thermoforming mold <NUM>.

Formation of the pocket <NUM> in the first water soluble film <NUM> can be a multi-stage process. In the first stage of the process, the thermoforming mold <NUM> is positioned to be operatively engaged with the first vacuum source 150a to apply a first negative gage pressure to the vacuum orifice <NUM> or vacuum orifices <NUM> in the recess <NUM> to draw the first water soluble film <NUM> partially into the recess <NUM>. In the second stage of the process, the thermoforming mold <NUM> is positioned to be operatively engaged with the second vacuum source 150b to apply a second negative gage pressure to the vacuum orifice <NUM> or vacuum orifices <NUM> in the recess <NUM> to draw the first water soluble film <NUM> further into the recess <NUM>. The temperature of the first water soluble film <NUM> above the recess <NUM> can be greater than or equal to when the second vacuum source 150b is applied than when the first vacuum source 150a is applied.

After the vacuum has been applied to the first water soluble film <NUM> through the vacuum orifice <NUM> or vacuum orifices <NUM> to conform the first water soluble film <NUM> to the recesses <NUM> to form a plurality of open pockets <NUM>, a substrate treatment composition <NUM> can be placed into the plurality of open pockets <NUM> via the dosing device <NUM>. The second water soluble film <NUM> can then be brought into facing relationship with the thermoformed first water soluble film <NUM> and sealed to the first water soluble film <NUM> to form a pouch <NUM>. The second water soluble film <NUM> can be at a temperature of from about ambient temperature to about <NUM> C. The second water soluble film <NUM> can be at a temperature of from about <NUM> C to about <NUM> C. The second water soluble film <NUM> can be at a temperature of from about <NUM> C to about <NUM> C.

Any suitable process of joining the first water soluble film <NUM> and the second water soluble film <NUM> may be used. The sealing may occur in the continuous land areas <NUM> between individual recesses <NUM> of the thermoforming mold <NUM>. Non-limiting examples of such means include heat sealing, solvent welding, solvent or wet sealing, and combinations thereof. Heat and or solvent can be applied to the entire surface of the film or films or only the area which is to form the seal can be treated with heat or solvent. The heat or solvent can be applied by any process, typically on the closing material, and optionally only on the areas which are to form the seal. If solvent or wet sealing or welding is used, heat can also be applied. Wet or solvent sealing/welding processes include selectively applying solvent onto the area between the molds, or on the closing material, by for example, spraying or printing this onto these areas or applying water or other solvent by way of felt rollers that rotate through a bath of water or solvent, and then applying pressure onto these areas, to form the seal. Sealing rolls and belts as described above that optionally also provide heat can be used, for example.

A cutting operation can be integral with or located down-stream of the apparatus shown in <FIG> and <FIG> to separate the pouches <NUM> into individual pouches <NUM>. The formed pouches <NUM> may then be cut by a cutting device. Cutting can be accomplished using any known process. A rotary knife <NUM> can be used to cut in the machine direction. A variable speed rotary transverse cutting knife <NUM> can be used to cut in the cross direction CD. The cutting can be done in continuous manner, optionally with constant speed and in a horizontal position. The cutting device can be a laser. The cutting device can, for example, be a sharp item or a hot item, whereby in the latter case, the hot item 'burns' through the sheet/sealing area. The cutting device or devices can be a rotary die cutter or flexible knife to make cuts in the cross direction and a cutting wheel to make cuts in the machine direction MD. Cuts in the machine direction MD, and optionally cross direction CD, can be made while the continuous web of water soluble pouches <NUM> is carried on the molds <NUM>. Optionally, cuts in the machine direction MD can be made after lifting the continuous web or strips of water soluble pouches <NUM> off of the molds <NUM> and transferring the continuous web or strips of water soluble pouches <NUM> to an anvil upon which the pouches <NUM> are separated from one another in the cross direction CD.

From the viewpoint of an individual water soluble unit dose pouch <NUM>, the process for making the water soluble unit dose pouch <NUM> is a multi-step process. A thermoforming mold <NUM> is provided. The thermoforming mold <NUM> can comprise a forming surface <NUM>, a plurality of spaced apart recesses <NUM> in the forming surface <NUM>, a vacuum source <NUM>, and a continuous land area <NUM> surrounding the recesses <NUM>. Each recess <NUM> can comprise a vacuum orifice <NUM> or vacuum orifices <NUM>, each vacuum orifice <NUM> being in fluid communication with the vacuum source <NUM>. Portions of the continuous land area <NUM> between the recesses <NUM> can have an average roughness from <NUM> to <NUM>. The first water soluble film <NUM> can be positioned in facing relationship with the continuous land area <NUM>. The first water soluble film <NUM> can be heated. Vacuum can be applied to the first water soluble film <NUM> through the vacuum orifices <NUM> to thermoform the first water soluble film <NUM> to the recesses <NUM> thereby forming a plurality of open pockets <NUM>. The substrate treatment composition <NUM> can be placed in the plurality of open pockets <NUM>. A second water soluble film <NUM> can be positioned above the first water soluble film <NUM>. The second water soluble film <NUM> and the first water soluble film <NUM> can be joined to one another to form a web <NUM> comprising a plurality of closed pouches <NUM>. The web <NUM> can be cut to separate the closed pouches <NUM> from one another. The closed pouches <NUM> can be separated from the forming surface <NUM>, before or after the web <NUM> of closed pouches <NUM> is cut to separate closed pouches <NUM> from one another.

The first water soluble film <NUM> can have a temperature above the recess <NUM> from about <NUM> C to about <NUM> C upon thermoforming the first water soluble film <NUM>. Without being bound by theory, it is thought that the amount of time that it takes to heat the first water soluble film <NUM> to such temperature from being at ambient temperature may permit an appreciable amount of water to be expelled by the first water soluble film <NUM> and such water may tend to condense onto the surface of the recess <NUM> and or partially solubilize the surface of the first water soluble film <NUM> facing the recess <NUM>. Optionally, heat can be applied to the first water soluble film <NUM> for more than one second to heat the first water soluble film <NUM> from an ambient temperature to a temperature above the recess <NUM> that is from <NUM> C to <NUM> C before initiating thermoforming of the first water soluble film <NUM>. Ambient temperature can be <NUM> C plus or minus <NUM> C (i.e. from <NUM> C to <NUM> C). The first water soluble film <NUM> can have a residence time while in facing relationship with the land area <NUM> of the thermoforming mold <NUM> at a temperature from <NUM> C to <NUM> C above the recess <NUM> before vacuum is first applied to the first water soluble film <NUM> that is greater than <NUM> second.

The apparatus <NUM> and process for making water soluble unit dose pouches <NUM> may be conducted in an environment under conditions of <NUM> C +/- <NUM> C and <NUM>% +/- <NUM>% relative humidity. The water soluble films employed herein may be conditioned to such environment. Water soluble films conditioned in such environment used herein can have a residual moisture content of at least <NUM>%, optionally in a range of from <NUM>% to <NUM>%, optionally at least <NUM>%, optionally from <NUM>% to <NUM>%, by weight of the water-soluble film as measured by Karl Fischer titration.

The first water soluble film <NUM> can have a temperature above the recess <NUM> from about <NUM> C to about <NUM> C after having been heated for more than one second before initiating thermoforming of the first water soluble film <NUM>. The first water soluble film <NUM> can be in facing relationship with the land area <NUM> and the temperature of the water soluble film <NUM> above the recess <NUM> can be from about <NUM> C to about <NUM> C after having been heated for more than one second before initiating thermoforming of the first water soluble film <NUM>. The first water soluble film <NUM> can have a residence time before thermoforming during which the first water soluble film <NUM> is in facing relationship with the land area <NUM> and the temperature of the water soluble film <NUM> above the recess <NUM> is heated from ambient temperature to <NUM> C to <NUM> C. The residence time can be greater than one second. After the first water soluble film is positioned in facing relationship with the land area <NUM>, the first water soluble film <NUM> can be heated above ambient temperature for more than one second to a temperature above the recess <NUM> from about <NUM> C to about <NUM> C before initiating thermoforming of the first water soluble film <NUM>. After the first water soluble film <NUM> is positioned in facing relationship with the land area <NUM>, the first water soluble film <NUM> can have a temperature above the recess <NUM> from about <NUM> C to about <NUM> C when thermoforming is initiated.

The first water soluble film <NUM> can be held at a tension in the machine direction MD from about <NUM> N/m of width to about <NUM> N/m of width, optionally from about <NUM> N/m of width to about <NUM> N/m of width. Tension in the machine direction MD can be controlled by provided by including a dancer engaged with the first water soluble film <NUM> between the first film unwind roll <NUM> and the location at which the first water soluble film <NUM> is positioned on the thermoforming molds <NUM>.

Depending on the properties of the water soluble films forming the pouch <NUM>, the first water soluble film <NUM> that is thermoformed to form the pocket <NUM> into which the substrate treatment composition <NUM> is placed may partially rebound after the first water soluble film <NUM> is joined to the second water soluble film <NUM>. Depending on the properties of the first water soluble film <NUM> and the second water soluble film <NUM>, the pouch <NUM> can be designed to have more or less curved surfaces.

If more than one pouch <NUM> are to be joined to one another, the apparatus <NUM> can be provided with a top pouch forming device <NUM>, as shown in <FIG>. In such an arrangement the bottom pouch <NUM> can be formed as described above with respect to forming pouches <NUM>. The top pouch forming device <NUM> can comprise a third unwind roll <NUM>. A third water soluble film <NUM> can be provided from the third unwind roll <NUM>. The third water soluble film <NUM> can be heated with a heater <NUM> or heated roller. The heater <NUM> can heat the third water soluble film <NUM> to a temperature of from about <NUM> C to about <NUM> C. The heater <NUM> can heat the third water soluble film <NUM> to a temperature of from about <NUM> C to about <NUM> C. The higher the temperature of the third water soluble film <NUM>, the greater the propensity for the deformation to be by thermoforming.

The third water soluble film <NUM> can be carried on a thermoforming mold <NUM>. The thermoforming mold <NUM> that carries the third water soluble film <NUM> can be mounted on a rotatable drum <NUM>, as shown in <FIG>, or a flat conveyance <NUM> in substantially the same manner as thermoforming mold <NUM> that carries first water soluble film <NUM> shown in <FIG>.

The thermoforming molds <NUM> for the top pouch forming device <NUM> are fundamentally structured in the same manner as the thermoforming molds <NUM> used to thermoform the first water soluble film <NUM>. The recesses <NUM> in the top pouch forming device <NUM> can have a shape that differs from those used to shape the first water soluble film <NUM>. The top pouch forming device <NUM> can comprise a vacuum source <NUM> operable on the thermoforming molds <NUM>.

The third web <NUM> can be formed into an open pocket <NUM> by applying a pressure difference across the third water soluble film <NUM>. Once the open pocket <NUM> is formed in the third water soluble film <NUM>, a substrate treatment composition <NUM> can be placed in the open pocket <NUM>. The open pocket <NUM> can be filled or partially filled with a substrate treatment composition <NUM>. Filling or partial filling can be provided by a dosing device <NUM>. Filling can occur when the open pocket <NUM> is proximal the apex of its travel path if a drum <NUM> is employed in thermoforming the first water soluble film <NUM> or third water soluble film <NUM>. The dosing device <NUM> associated with the top pouch forming device <NUM> can travel with the thermoforming mold <NUM> and then reciprocate back upstream. For instance, the dosing device <NUM> that fills the open pocket <NUM> formed in the third water soluble film <NUM> can travel back and forth over a limited range of motion as shown in <FIG>. After open pocket <NUM> in the third web <NUM> is filled, the second water soluble film <NUM> can then be sealed to the thermoformed third water soluble film <NUM> to form an enclosed pouch <NUM>.

Any suitable process of sealing the second water soluble film <NUM> and the third water soluble film <NUM> may be used, as described previously for sealing the first water soluble film <NUM> and the second water soluble film <NUM>.

The pouch <NUM> formed between the third water soluble film <NUM> and the second water soluble film <NUM> can then be joined with the first water soluble film <NUM> to form the pouch <NUM> between the second water soluble film <NUM> and the first water soluble film <NUM>. The second water soluble film <NUM> and the first water soluble film <NUM> can be joined to one another as described previously. Such an arrangement can provide for a superposed pouch <NUM> in which two pouches overlie one another.

The substrate treatment composition <NUM> can be a liquid, but may be a solid or tablet. By the term 'liquid' it is meant to include liquid, paste, waxy or gel compositions. A liquid substrate treatment composition <NUM> may comprise a solid. Solids may include powder or agglomerates, such as micro-capsules, beads, noodles or one or more pearlized balls or mixtures thereof. Such a solid element may provide a technical benefit, through the wash or as a pre-treat, delayed or sequential release component. Alternatively it may provide an aesthetic effect. The substrate treatment compositions <NUM> may comprise one or more of the ingredients discussed below.

The substrate treatment composition <NUM> of the present invention can comprise a surfactant. The total surfactant level may be in the range of from about <NUM>% to about <NUM>% by weight of the substrate treatment composition <NUM>. The substrate treatment composition <NUM> can comprise linear alkylbenzene sulfonates and or alcoholethoxy sulfate and or C12-<NUM> Pareth-<NUM> and or fatty acid salts and or enzyme and or sodium carbonate and or sodium percarbonate and or methyl glycine diacetic acid, trisodium salt and or alcohol alkoxylate.

The substrate treatment composition <NUM> can be selected from the group consisting of liquid laundry detergent, a powdered laundry detergent, a liquid dishwashing detergent, a powder dishwashing detergent, a liquid bleaching agent, a powdered bleaching agent, a liquid fabric softener, a powdered fabric softener, a liquid laundry scent additive, a powder laundry scent additive, a liquid fabric care benefit agent, and a solid fabric care benefit agent. The substrate treatment composition <NUM> can be a fabric softener comprising a quaternary ammonium salt and or a dehydrogenated tallow dimethyl ammonium chloride and or a diethyl ester dimethyl ammonium chloride. A substrate treatment composition <NUM> can be formulated to treat a substrate selected from the group consisting of glassware, dishware, flooring, textiles, tires, automobile bodies, teeth, dentures, skin, fingernails, toenails, hair, appliance surfaces, appliance interiors, toilets, bathtubs, showers, mirrors, deck materials, windows, and the like.

The first water soluble film <NUM>, second water soluble film <NUM>, and optional third water soluble film <NUM> can be the water soluble film described as follows. The water soluble film of the present invention is soluble or dispersible in water. The water soluble film optionally has a thickness of from <NUM> to <NUM> micron, optionally <NUM> to <NUM> micron, optionally <NUM> to <NUM> micron, optionally about <NUM> micron.

The first water soluble film <NUM>, second water soluble film <NUM>, and optional third water soluble film <NUM> can comprise from about <NUM>% to about <NUM>% by weight of the respective water soluble film polyvinylalcohol polymer, from about <NUM>% to about <NUM>% by weight of the respective water soluble film nonaqueous plasticizer, from about <NUM>% to about <NUM>% by weight of the respective water soluble film water, and surfactant. The first water soluble film <NUM>, second water soluble film <NUM>, and optional third water soluble film <NUM> can have a thickness from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally about <NUM>. The first water soluble film <NUM> can have a thickness from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally from about <NUM> to about <NUM>, optionally about <NUM>, before being placed in facing relationship with the land area <NUM> of the thermoforming mold <NUM>.

Optionally, the film has a water solubility of at least <NUM>%, optionally at least <NUM>% or even at least <NUM>%, as measured by the method set out here after using a glass-filter with a maximum pore size of <NUM> microns: <NUM> grams ± <NUM> gram of film material is added in a pre-weighed <NUM> beaker and <NUM> ± <NUM> of distilled water is added. This is stirred vigorously on a magnetic stirrer, Labline model No. <NUM> or equivalent and <NUM> magnetic stirrer, set at <NUM> rpm, for <NUM> minutes at <NUM>. Then, the mixture is filtered through a folded qualitative sintered-glass filter with a pore size as defined above (max. <NUM> micron). The water is dried off from the collected filtrate by any conventional method, and the weight of the remaining material is determined (which is the dissolved or dispersed fraction). Then, the percentage solubility or dispersibility can be calculated.

The water soluble film material may be obtained by casting, blow-molding, extrusion or blown extrusion of the polymeric material, as known in the art.

The water soluble film can comprise polyvinylalcohol. The polyvinylalcohol may be present between <NUM>% and <NUM>%, optionally between <NUM>% and <NUM>%, optionally between <NUM>% and <NUM>% by weight of the water soluble film. The polyvinylalcohol optionally comprises polyvinylalcohol homopolymer, polyvinylalcohol copolymer, or a mixture thereof. Optionally, the water soluble film can comprise a blend of polyvinylalcohol homopolymers and/or anionic polyvinylalcohol copolymers, optionally wherein the polyvinylalcohol copolymers are selected from sulphonated and carboxylated anionic polyvinylalcohol copolymers especially carboxylated anionic polyvinylalcohol copolymers, optionally the water soluble film comprises a blend of a polyvinylalcohol homopolymer and a carboxylated anionic polyvinylalcohol copolymer, or a blend of polyvinylalcohol homopolymers. Alternatively, the polyvinylalcohol can comprise an anionic polyvinyl alcohol copolymer, optionally a carboxylated anionic polyvinylalcohol copolymer. When the polyvinylalcohol in the water soluble film is a blend of a polyvinylalcohol homopolymer and a carboxylated anionic polyvinylalcohol copolymer, the homopolymer and the anionic copolymer can be present in a relative weight ratio of <NUM>/<NUM> to <NUM>/<NUM>, optionally <NUM>/<NUM> to <NUM>/<NUM>, optionally <NUM>/<NUM> to <NUM>/<NUM>. Without wishing to be bound by theory, the term "homopolymer" generally includes polymers having a single type of monomeric repeating unit (e.g., a polymeric chain comprising or consisting of a single monomeric repeating unit). For the particular case of polyvinylalcohol, the term "homopolymer" further includes copolymers having a distribution of vinyl alcohol monomer units and optionally vinyl acetate monomer units, depending on the degree of hydrolysis (e.g., a polymeric chain comprising or consisting of vinyl alcohol and vinyl acetate monomer units). In the case of <NUM>% hydrolysis, a polyvinylalcohol homopolymer can include only vinyl alcohol units. Without wishing to be bound by theory, the term "copolymer" generally includes polymers having two or more types of monomeric repeating units (e.g., a polymeric chain comprising or consisting of two or more different monomeric repeating units, whether as random copolymers, block copolymers, etc.). For the particular case of polyvinylalcohol, the term "copolymer" (or "polyvinyl alcohol copolymer") further includes copolymers having a distribution of vinyl alcohol monomer units and vinyl acetate monomer units, depending on the degree of hydrolysis, as well as at least one other type of monomeric repeating unit (e.g., a ter- (or higher) polymeric chain comprising or consisting of vinyl alcohol monomer units, vinyl acetate monomer units, and one or more other monomer units, for example anionic monomer units). In the case of <NUM>% hydrolysis, a polyvinylalcohol copolymer can include a copolymer having vinyl alcohol units and one or more other monomer units, but no vinyl acetate units. Without wishing to be bound by theory, the term "anionic copolymer" includes copolymers having an anionic monomer unit comprising an anionic moiety. General classes of anionic monomer units which can be used for the anionic polyvinyl alcohol co-polymer include the vinyl polymerization units corresponding to monocarboxylic acid vinyl monomers, their esters and anhydrides, dicarboxylic monomers having a polymerizable double bond, their esters and anhydrides, vinyl sulfonic acid monomers, and alkali metal salts of any of the foregoing. Examples of suitable anionic monomer units include the vinyl polymerization units corresponding to vinyl anionic monomers including vinyl acetic acid, maleic acid, monoalkyl maleate, dialkyl maleate, monomethyl maleate, dimethyl maleate, maleic anyhydride, fumaric acid, monoalkyl fumarate, dialkyl fumarate, monomethyl fumarate, dimethyl fumarate, fumaric anyhydride, itaconic acid, monomethyl itaconate, dimethyl itaconate, itaconic anhydride, vinyl sulfonic acid, allyl sulfonic acid, ethylene sulfonic acid, <NUM>-acrylamido-<NUM>-methylpropanesulfonic acid, <NUM>-acrylamido-<NUM>-methylpropanesulfonic acid, <NUM>-methylacrylamido-<NUM>-methylpropanesulfonic acid, <NUM>-sufoethyl acrylate, alkali metal salts of the foregoing (e.g., sodium, potassium, or other alkali metal salts), esters of the foregoing (e.g., methyl, ethyl, or other C1-C4 or C6 alkyl esters), and combinations thereof (e.g., multiple types of anionic monomers or equivalent forms of the same anionic monomer). The anionic monomer may be one or more acrylamido methylpropanesulfonic acids (e.g., <NUM>-acrylamido-<NUM>-methylpropanesulfonic acid, <NUM>-acrylamido-<NUM>-methylpropanesulfonic acid, <NUM>-methylacrylamido-<NUM>-methylpropanesulfonic acid), alkali metal salts thereof (e.g., sodium salts), and combinations thereof. Optionally, the anionic moiety of the first anionic monomer unit can be selected from a sulphonate, a carboxylate, or a mixture thereof, optionally a carboxylate, optionally an acrylate, a methacrylate, a maleate, or a mixture thereof. Optionally, the anionic monomer unit can be present in the anionic polyvinyl alcohol copolymer in an average amount in a range of between <NUM> mol. % and <NUM> mol. %, optionally between <NUM> mol. % and <NUM> mol. Optionally, the polyvinyl alcohol, and/or in case of polyvinylalcohol blends the individual polyvinylalcohol polymers, can have an average viscosity (µ1) in a range of between <NUM> mPa. s and <NUM> mPa. s, optionally between 10mPa. s and <NUM> mPa. s, measured as a <NUM>% polyvinyl alcohol copolymer solution in demineralized water at <NUM> degrees C. The viscosity of a polyvinyl alcohol polymer is determined by measuring a freshly made solution using a Brookfield LV type viscometer with UL adapter as described in British Standard EN ISO <NUM>-<NUM>:<NUM> Annex E Brookfield Test method. It is international practice to state the viscosity of <NUM>% aqueous polyvinyl alcohol solutions at <NUM>. It is well known in the art that the viscosity of an aqueous water soluble polymer solution (polyvinylalcohol or otherwise) is correlated with the weight-average molecular weight of the same polymer, and often the viscosity is used as a proxy for weight-average molecular weight. Thus, the weight-average molecular weight of the polyvinylalcohol can be in a range of <NUM>,<NUM> to <NUM>,<NUM>, or <NUM>,<NUM> to <NUM>,<NUM>, or <NUM>,<NUM> to <NUM>,<NUM>. Optionally, the polyvinyl alcohol, and/or in case of polyvinylalcohol blends the individual polyvinylalcohol polymers, can have an average degree of hydrolysis in a range of between <NUM>% and <NUM>%, optionally between <NUM>% and <NUM>%, optionally between <NUM>% and <NUM>%. A suitable test method to measure the degree of hydrolysis is as according to standard method JIS K6726.

Optionally, the water soluble film can comprise a non-aqueous plasticizer. Optionally, the non-aqueous plasticizer can be selected from polyols, sugar alcohols, and mixtures thereof. Suitable polyols include polyols selected from the group consisting of glycerol, diglycerin, ethylene glycol, diethylene glycol, triethyleneglycol, tetraethylene glycol, polyethylene glycols up to <NUM> molecular weight, neopentyl glycol, <NUM>,<NUM>-propylene glycol, <NUM>,<NUM>-propanediol, dipropylene glycol, polypropylene glycol, <NUM>-methyl-<NUM>,<NUM>-propanediol, trimethylolpropane and polyether polyols, or a mixture thereof. Suitable sugar alcohols include sugar alcohols selected from the group consisting of isomalt, maltitol, sorbitol, xylitol, erythritol, adonitol, dulcitol, pentaerythritol and mannitol, or a mixture thereof. More preferably the non-aqueous plasticizer is selected from glycerol, <NUM>,<NUM>-propanediol, dipropylene glycol, <NUM>-methyl-<NUM>,<NUM>-propanediol, trimethylolpropane, triethyleneglycol, polyethyleneglycol, sorbitol, or a mixture thereof, most preferably selected from glycerol, sorbitol, trimethylolpropane, dipropylene glycol, and mixtures thereof. One particularly suitable plasticizer system includes a blend of glycerol, sorbitol and trimethylol propane. Another particularly suitable plasticizer system includes a blend of glycerin, dipropylene glycol, and sorbitol. Optionally, the film comprises between <NUM>% and <NUM>%, preferably between <NUM>% and <NUM>%, optionally between <NUM>% and <NUM>% by weight of the film of the non-aqueous plasticizer.

Optionally, the water soluble film can comprise a surfactant. Optionally, the water soluble film can comprise a surfactant in an amount between <NUM>% and <NUM>%, optionally between <NUM>% and <NUM>% by weight of the water soluble film. Suitable surfactants can include the nonionic, cationic, anionic and zwitterionic classes. Suitable surfactants include, but are not limited to, polyoxyethylenated polyoxypropylene glycols, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionics), polyoxyethylenated amines, quaternary ammonium salts and quaternized polyoxyethylenated amines (cationics), and amine oxides, N-alkylbetaines and sulfobetaines (zwitterionics). Other suitable surfactants include dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerol and propylene glycol, lactylic esters of fatty acids, sodium alkyl sulfates, polysorbate <NUM>, polysorbate <NUM>, polysorbate <NUM>, polysorbate <NUM>, lecithin, acetylated fatty acid esters of glycerol and propylene glycol, and acetylated esters of fatty acids, and combinations thereof.

Optionally the water soluble film according to the invention can comprise lubricants / release agents. Suitable lubricants/release agents can include, but are not limited to, fatty acids and their salts, fatty alcohols, fatty esters, fatty amines, fatty amine acetates and fatty amides. Optional lubricants/release agents are fatty acids, fatty acid salts, and fatty amine acetates. The amount of lubricant/release agent in the water soluble film can be in a range of from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>% by weight of the water soluble film.

Optionally, the water soluble film comprises fillers, extenders, antiblocking agents, detackifying agents or a mixture thereof. Suitable fillers, extenders, antiblocking agents, detackifying agents or a mixture thereof include, but are not limited to, starches, modified starches, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metallic oxides, calcium carbonate, talc and mica. Optional materials are starches, modified starches and silica. Optionally, the amount of filler, extender, antiblocking agent, detackifying agent or mixture thereof in the water soluble film is in a range of from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>% by weight of the water soluble film. In the absence of starch, one optional range for a suitable filler, extender, antiblocking agent, detackifying agent or mixture thereof is from <NUM>% to <NUM>%, preferably <NUM>%, optionally <NUM>%, optionally from <NUM>% to <NUM>%, optionally from <NUM>% to <NUM>%, by weight of the water soluble film.

Optionally, films exhibit good dissolution in cold water, meaning unheated distilled water. Optionally, such films exhibit good dissolution at temperatures of <NUM>, optionally at <NUM>. By good dissolution it is meant that the film exhibits water-solubility of at least <NUM>%, optionally at least <NUM>% or even at least <NUM>%, as measured by the method set out here after using a glass-filter with a maximum pore size of <NUM> microns, described above.

Optional water soluble films include those films used in ARIEL <NUM>-IN <NUM> PODS sold by The Procter & Gamble Company in the United Kingdom, and TIDE PODS in the United States as of March <NUM>.

The water soluble film may be opaque, transparent or translucent. The water soluble film may comprise a printed area. The area of print may be achieved using standard techniques, such as flexographic printing or inkjet printing. Optionally, the ink used in the printed area comprises between Oppm and 20ppm, optionally between Oppm and 15ppm, optionally between Oppm and 10ppm, optionally between Oppm and 5ppm, optionally between Oppm and 1ppm, optionally between Oppb and 100ppb, optionally Oppb dioxane. Those skilled in the art will be aware of known methods and techniques to determine the dioxane level within the ink formulations.

The water soluble film may comprise an aversive agent, for example a bittering agent. Suitable bittering agents include, but are not limited to, naringin, sucrose octaacetate, quinine hydrochloride, denatonium benzoate, or mixtures thereof. Any suitable level of aversive agent may be used in the film. Suitable levels include, but are not limited to, <NUM> to 5000ppm, or even <NUM> to 2500ppm, or even <NUM> to 2000rpm.

Optionally, the water soluble film or water soluble unit dose article or both are coated in a lubricating agent, preferably, wherein the lubricating agent is selected from talc, zinc oxide, silicas, siloxanes, zeolites, silicic acid, alumina, sodium sulphate, potassium sulphate, calcium carbonate, magnesium carbonate, sodium citrate, sodium tripolyphosphate, potassium citrate, potassium tripolyphosphate, calcium stearate, zinc stearate, magnesium stearate, starch, modified starches, clay, kaolin, gypsum, cyclodextrins or mixtures thereof.

Optionally, the water soluble film, and each individual component thereof, independently comprises between Oppm and 20ppm, optionally between Oppm and 15ppm, optionally between Oppm and 10ppm, optionally between Oppm and 5ppm, optionally between Oppm and 1ppm, optionally between Oppb and 100ppb, optionally Oppb dioxane. Those skilled in the art will be aware of known methods and techniques to determine the dioxane level within water soluble films and ingredients thereof.

Claim 1:
A process for making water soluble unit dose pouches comprising the steps of:
providing an apparatus (<NUM>) comprising:
a thermoforming mold (<NUM>) having a forming surface (<NUM>);
a plurality of spaced apart recesses (<NUM>) in said forming surface, wherein each said recess comprises a vacuum orifice (<NUM>) and each vacuum orifice is in fluid communication with a vacuum source (<NUM>);
a continuous land area (<NUM>) surrounding said recesses, wherein portions of said land area between said recesses have an average roughness Ra from <NUM> to <NUM>;
positioning a first water soluble film in facing relationship with said land area, wherein said first water soluble film comprises:
from <NUM>% to <NUM>% by weight of said first water soluble film polyvinylalcohol polymer;
from <NUM>% to <NUM>% by weight of said first water soluble film nonaqueous plasticizer;
from <NUM>% to <NUM>% by weight of said first water soluble film water; and
surfactant;
wherein said first water soluble film has a thickness from <NUM> to <NUM> before said first water soluble film is positioned in facing relationship with said land area of said thermoforming mold;
heating said first water soluble film;
applying vacuum to said first water soluble film through said vacuum orifices to thermoform said first water soluble film to said recesses thereby forming a plurality of open pockets;
placing a substrate treatment composition in said plurality of open pockets;
positioning a second water soluble film above said first water soluble film;
joining said second water soluble film and said first water soluble film thereby forming a web (<NUM>) comprising a plurality of closed pouches;
cutting said web to separate said closed pouches from one another; and
separating said closed pouches from said forming surface.