US-12624320-B2 - Dissolvable cleaning products free of plastics and/or polyvinyl alcohol

Abstract

Methods, systems, and apparatuses for forming dissolvable cleaning products. The dissolvable cleaning products may be formed by forming a first component solution by mixing ingredients in a first mixer. The mixing may be suspended and the first component solution may be allowed to rest for a first holding period. A second component solution may be formed by mixing ingredients in a second mixer. The mixing may be suspended and the second component solution may be allowed to rest for a second holding period. The first and second component solutions may be mixed together and one or more of enzymes and preservatives and a water-soluble polymer may be added to form a final solution. Optionally one or more fragrances may be added. The final solution may be transferred to a mold and dried to a predetermined moisture content. The dried final solution may be cut into one or more shapes.

Inventors

• Malcolm Bond Burbank
• JAMES RODNEY DICKERSON
• Darren Gross
• Laura Hinojosa

Assignees

• TRU EARTH ENVIRONMENTAL PRODUCTS INC.

Dates

Publication Date

20260512

Application Date

20250725

Claims (16)

1. 1 . A dissolvable cleaning product in a form of a sheet consisting of: approximately 6.1 wt % to approximately 6.7 wt % of water-soluble cellulose ethers; approximately 38.4 wt % to approximately 41.9 wt % of a surfactant; approximately 9.2 wt % to approximately 10.1 wt % of sodium citrate; approximately 1.5 wt % to approximately 1.7 wt % of a preservative; approximately 30.7 wt % to approximately 33.6 wt % of glycerin; approximately 6 wt % to approximately 12 wt % of water; approximately 2.0 wt % to approximately 2.1 wt % of a fragrance selected from the group consisting of an essential oil extract, fragrance oil, and mixtures thereof; and optionally: approximately 1 wt % to approximately 2 wt % of an enzyme; and at least one additional component selected from the group consisting of an optical brightener, a fabric softener, a bleach, a water softening agent, a chelating agent, a soil anti-redeposition agent, a color-protecting agent, a dye-transfer agent, and mixtures thereof.
2. 2 . The dissolvable cleaning product of claim 1 , wherein the fragrance is an essential oil extract.
3. 3 . The dissolvable cleaning product of claim 1 , wherein the preservative is sodium benzoate.
4. 4 . The dissolvable cleaning product of claim 1 , wherein the preservative is calcium benzoate.
5. 5 . The dissolvable cleaning product of claim 1 , wherein the preservative is potassium benzoate.
6. 6 . The dissolvable cleaning product of claim 1 , wherein the preservative is a weak acid.
7. 7 . The dissolvable cleaning product of claim 1 , wherein the surfactant is methyl ester sulfonate (“MES”).
8. 8 . The dissolvable cleaning product of claim 1 , wherein the sheet has a length of approximately 4 inches and a width of approximately 4 inches.
9. 9 . The dissolvable cleaning product of claim 8 , wherein the sheet has two strips separated down a middle of the sheet by a feature that allows the two strips to be separated.
10. 10 . The dissolvable cleaning product of claim 9 , wherein each strip of the two strips has a length of approximately 4 inches and a width of approximately 2 inches.
11. 11 . The dissolvable cleaning product of claim 9 , wherein the feature is a perforation.
12. 12 . The dissolvable cleaning product of claim 9 , wherein the feature is an indentation.
13. 13 . The dissolvable cleaning product of claim 1 , wherein the dissolvable cleaning product a weight of approximately 3.8 g.
14. 14 . The dissolvable cleaning product of claim 1 , wherein the enzyme is present in the dissolvable cleaning product.
15. 15 . The dissolvable cleaning product of claim 14 , wherein the enzyme is selected from the group consisting of amylase, protease, lipase, cellulase, and mixtures thereof.
16. 16 . The dissolvable cleaning product of claim 1 , wherein the at least one additional component is present in the dissolvable cleaning product.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a divisional of U.S. application Ser. No. 19/050,545, filed Feb. 11, 2025, now U.S. Pat. No. 12,404,481, which claims benefit of U.S. Provisional Patent Application No. 63/561,075, filed Mar. 4, 2024 and U.S. Provisional Patent Application No. 63/706,869, filed Oct. 14, 2024. The entireties of these applications are hereby incorporated herein by reference. TECHNICAL FIELD The present disclosure generally relates to the field of cleaning products, and more particularly to dissolvable cleaning products that are free of plastics and/or polyvinyl alcohol (“PVA”) and methods, processes, and apparatuses for making the same. BACKGROUND The majority of conventional cleaning products come in as a liquid in a vessel with a dispenser or in packs/pods that are wrapped in one or more types of plastic. These vessels are mostly made up of plastic, glass, and/or cardboard lined with plastic to serve as a water barrier. However, single use plastic is wreaking havoc on the environment and plastic residues have been found to have determinantal effects on health. Only a small percentage of all plastic is actually recycled, and packaging generates the largest portion of municipal waste. Packaged products are inefficient for businesses and the people who buy them. Due to changes in customer buying behavior, and a focus on sustainability, cleaning products having a reduced package size and that do not contain plastics are becoming more popular. Thus, a need exists for new stable formulations of cleaning products that meet the needs of consumers, while also reducing the amount of waste, such as plastics, generated in their production and shipping. SUMMARY Methods, systems, and apparatuses for forming dissolvable cleaning products. The dissolvable cleaning products may be formed by forming a first component solution in a first mixer by: adding a first portion of water to the first mixer, the first portion of water having a first temperature, adding water-soluble cellulose ethers to the first portion of water and mixing for a first mixing time to form a first mixture, and adding a second portion of water to the first mixture and mixing for a second mixing time, the second portion of water having a second temperature. A second component solution may be formed in a second mixer by: adding a third portion of water to the second mixer, the third portion of water having a third temperature, adding a surfactant to the third portion of water and mixing for a third mixing time to form a second mixture, and adding sodium citrate to the second mixture and mixing for a fourth mixing time. The first component solution to rest for a first holding period. The second component solution to rest for a second holding period. A final solution may be formed in a third mixer by: adding the second component solution to the third mixer, adding a water-soluble polymer to the third mixer and mixing for a fifth mixing time, ceasing mixing after the fifth mixing time, adding the first component solution to the third mixer after the fifth mixing time and mixing for a sixth mixing time, and adding one or more of enzymes and preservatives the third mixer and mixing for a seventh mixing time. The final solution may be transferred to a mold. The final solution may be dried within the mold to a predetermined moisture content. The dried final solution may be removed from the mold and cut into one or more shapes. In another example, the dissolvable cleaning products may be formed by forming a first component solution in a first mixer by: adding a first portion of water to the first mixer, the first portion of water having a first temperature, adding water-soluble cellulose ethers to the first portion of water and mixing for a first mixing time to form a first mixture, and adding a second portion of water to the first mixture and mixing for a second mixing time, the second portion of water having a second temperature. A second component solution may be formed in a second mixer by: adding a third portion of water to the second mixer, the third portion of water having a third temperature, adding a surfactant to the third portion of water and mixing for a third mixing time to form a second mixture, and adding sodium citrate to the second mixture and mixing for a fourth mixing time. The first component solution may be allowed to rest for a first holding period. The second component solution may be allowed to rest for a second holding period. A final solution may be formed in a third mixer by: mixing the first component solution and the second component solution in the third mixer for a fifth mixing time to form an intermediate solution, and adding one or more of dry ingredients and liquid ingredients to the intermediary solution and mixing for a sixth mixing time. The final solution may be transferred to a mold. The final solution may be dried within the mold to a predetermined moisture content. The dried final s