Web of cleaning products having a modified internal atmosphere and method of manufacture
A web ( 8 ) of cleaning products ( 10 ) and a method of manufacturing the same is disclosed. The web includes first ( 20 ) and second carrier ( 30 ) sheets and a plurality of pouches ( 50 ) containing a cleaning composition. Each of the pouches is disposed in a respective depression ( 26 ) formed in an upper surface ( 28 ) of the first carrier sheet. A first internal atmosphere ( 80 ) is enclosed within each of the pouches. The first carrier sheet is sealed to the second carrier sheet such that a second internal atmosphere ( 82 ) exists between the second carrier sheet and the plurality of pouches. The second internal atmosphere has a greater absolute pressure (P) than the first internal atmosphere so that the plurality of pouches and at least a portion of the cleaning composition in the plurality of pouches are compressed into the plurality of depressions in the first carrier sheet by the second internal atmosphere.
1. A web of cleaning products comprising:
a first carrier sheet having a plurality of depressions formed in its upper surface;
a plurality of pouches disposed in the plurality of depressions and containing a cleaning composition;
a first internal atmosphere enclosed within each of the plurality of pouches;
a second carrier sheet sealed to the upper surface of the first carrier sheet and enclosing the plurality of pouches within their corresponding depressions;
above each pouch of the plurality of pouches, a second internal atmosphere confined to a region above the pouch and below the second carrier sheet, the second internal atmosphere having a greater absolute pressure than the first internal atmosphere, the second internal atmosphere pushing the pouch in a downward direction into a respective depression of the plurality of depressions in the first carrier sheet; and
each pouch of the plurality of pouches including an outwardly extending peripheral flange sealed to the upper surface of the first carrier sheet.
2. The web of claim 1 , the plurality of pouches being made of a water-soluble material.
3. The web of claim 1 , the first and second carrier sheets being made of a water-resistant material.
4. The web of claim 1 , the first internal atmosphere being a vacuum and having an absolute pressure substantially equal to zero.
5. The web of claim 1 , the second internal atmosphere having an absolute pressure greater than or equal to atmospheric pressure.
6. The web of claim 1 , the first internal atmosphere including a gaseous mixture different from air.
7. The web of claim 1 , each of the plurality of pouches comprising:
an internal holder thermoformed to the first carrier sheet and filled with the cleaning composition; and
an internal lid sealed to and covering an open end of the internal holder.
8. The web of claim 1 , the second carrier sheet being sealed to the first carrier sheet about a rim of each of the plurality of depressions so that each of the plurality of depressions defines a separate sealed interior cavity containing the second internal atmosphere.
9. The web of claim 1 , comprising a first plurality of weakened tear lines formed in the first carrier sheet about the rim of each of the plurality of depressions, and a second plurality of weakened tear lines formed in the second carrier sheet to define a plurality of external lids corresponding with the plurality of depressions, each of the second plurality of weakened tear lines being aligned with a corresponding one of the first plurality of weakened tear lines.
10. A cleaning product comprising:
a first water-resistant carrier sheet having a depression formed in its upper surface;
a water-soluble pouch disposed in the depression and containing a cleaning composition;
a first internal atmosphere enclosed within the water-soluble pouch;
a second water-resistant carrier sheet sealed to the upper surface of the first water-resistant carrier sheet about a rim of the depression;
a second internal atmosphere confined to a region above the water-soluble pouch and below the second water-resistant carrier sheet, the second internal atmosphere having a greater absolute pressure than the first internal atmosphere, the second internal atmosphere pushing the water-soluble pouch in a downward direction into the depression in the first water-resistant carrier sheet; and
the water-soluble pouch including an outwardly extending peripheral flange sealed to the upper surface of the first water-resistant carrier sheet about the depression in the first water-resistant carrier sheet.
11. The cleaning product of claim 10 , the first internal atmosphere being a vacuum and having an absolute pressure substantially equal to zero.
12. The cleaning product of claim 10 , the second internal atmosphere having an absolute pressure greater than or equal to atmospheric pressure.
13. The cleaning product of claim 10 , the pouch including an internal holder thermoformed to the first water-resistant carrier sheet and an internal lid sealed to and covering an open end of the internal holder.
14. The cleaning product of claim 10 , the cleaning composition being at least one of a dishwashing detergent, a laundry detergent, a water softener, or a rinse aid.
15. The cleaning product of claim 10 , wherein exterior walls of the water-soluble pouch are flush with interior walls of the depression in the first water-resistant carrier sheet such that the second internal atmosphere does not exist between the exterior walls of the water-soluble pouch and the interior walls of the depression.