Production of unit dose constructs
Dissolvable unit dose constructs and their method of manufacture are disclosed in which the unit dose constructs are formed of a composition including a polymer matrix that includes a water soluble polymer, active ingredient, and a liquid carrier. The composition is deposited directly, such as by stenciling, to form individual unit doses without the need to cut and convert long, continuous rolls of film.
1. A method of forming a dissolvable unit dose construct comprising:
providing a first composition comprising a water soluble polymer and a liquid carrier;
depositing the first composition onto a substrate;
providing a second composition comprising a water soluble polymer and a liquid carrier;
stenciling the second composition at a plurality of discrete locations overlying the first composition; and
removing at least a portion of the liquid carrier from the first and second compositions to form a multi-layer unit dose construct.
2. The method of claim 1 , further comprising removing a portion of the liquid carrier from the first composition intermediate the steps of depositing and stenciling.
3. The method of claim 1 , comprising forming a first multi-layer unit dose construct by the steps of providing, depositing, providing, stenciling, and removing and forming an adjacent second multi-layer unit dose construct by the steps of providing, depositing, providing, stenciling, and removing, wherein a volume of the second composition stenciled overlying the first composition of the first multi-layer unit dose construct is greater than a volume of the second composition stenciled overlying the first composition of the second multi-layer unit dose construct.
4. The method of claim 3 , wherein the first and second multi-layer units contain a same volume of the first composition.
5. The method of claim 3 , wherein the first and second compositions are formed as films.
6. The method of claim 1 , comprising depositing the first composition on the substrate as individual units.
7. The method of claim 1 , wherein the second composition further comprises an active ingredient.
8. The method of claim 1 , wherein the first composition further comprises an active ingredient.
9. The method of claim 1 , wherein the step of removing comprises vacuum drying, application of heat, vibration, ultrasound, or a combination thereof.
10. The method of claim 1 , further comprising
providing a third composition comprising a water soluble polymer and a liquid carrier;
depositing the third composition overlying a portion of the first composition,
wherein a first multi-layer unit dose construct comprises the first and second compositions and a second multi-layer unit dose construct comprises the first and third compositions.
11. The method of claim 10 , wherein the first individual unit dose construct consists of the first and second compositions and the second individual unit dose construct consists of the first and third compositions.
12. A method of forming a dissolvable unit dose construct comprising:
providing a first composition comprising a water soluble polymer and a liquid carrier;
depositing the first composition onto a substrate to form a plurality of individual units;
providing a second composition comprising a water soluble polymer, an active ingredient and a liquid carrier;
depositing the second composition overlying a portion of an individual unit of the first composition;
providing a third composition comprising a water soluble polymer, an active ingredient of an identity different from the active ingredient of the second composition, and a liquid carrier;
depositing the third composition overlying a portion of the individual unit of the first composition different from the portion overlain by the second composition; and
removing at least a portion of the liquid carrier from the compositions to form a multi-layer unit dose construct.
13. The method of claim 12 , wherein the second and third compositions are differentiable by color.
14. The method of claim 12 , wherein the step of removing comprises vacuum drying, application of heat, vibration, ultrasound, or a combination thereof.
15. The method of claim 12 , wherein at least one of the depositing steps is accomplished by stenciling.
16. The method of claim 12 , wherein the area of the second composition overlying the first composition is greater than the area of the third composition overlying the first composition.