AUTOMATIC DISHWASHING COMPOSITION DISPENSING CARTRIDGES

Description

TECHNICAL FIELD

The present disclosure is directed to automatic dishwashing composition dispensing cartridges.

BACKGROUND

Automatic dishwashing systems often rely on mechanisms to deliver cleaning compositions during the wash cycle. These mechanisms efficiently store and dispense various forms of dishwashing compositions, such as liquids, powders, and gels. Existing solutions frequently encounter issues related to the uniformity of dispensing, the integrity of the storage unit during use, and the ability to handle different types of compositions within a single unit. EP 4339268 A1 discloses methods and apparatuses for automatic dishwashing chemical distribution. US 2013206772 A1 discloses a refill cartridge for a cylindrical type multi-dosing detergent delivery device. WO 2005061685 A1 discloses an automatic machine laundering of fabrics. AU 2021103708 A4 discloses a unit dose capsule. US 2016251131 A1 discloses a web of cleaning products and methods of manufacture.

SUMMARY OF INVENTION

The present invention provides an automatic dishwashing composition dispensing cartridge comprising: a thermoformed sachet comprising a first flexible sheet and a second flexible sheet sealed together to form a seal along an edge of the first flexible sheet and the second flexible sheet; wherein the thermoformed sachet comprises a plurality of internal, discrete pockets filled with the dishwashing composition; wherein one or more of the plurality of internal, discrete pockets is formed to include at least one curvature, whereby an angle of the at least one curvature in relation to a main plane is between about 45 and about 90 degrees, whereby the main plane is defined by a portion of the seal adjacent to the curvature; and wherein each of the plurality of internal, discrete pockets includes a height in relation to the main plane, whereby the height of all of the plurality of internal, discrete pockets is the same. 

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1D are each a side view of an example automatic dishwashing composition dispensing cartridge according to the present invention.

FIG. 2 is a plan view of an example automatic dishwashing composition dispensing cartridge according to some embodiments of the present invention.

FIG. 3 is a section of an example multi-layer laminate for a first or second flexible sheet according to some embodiments of the present invention.

FIG. 4 is a schematic view of an example insert which may be received between the first and second flexible sheets according to some embodiments of the present invention.

FIG. 5 is a schematic view of an example edge seal of an automatic dishwashing composition dispensing cartridge according to some embodiments of the present invention.

FIG. 6 is a plan view of an example automatic dishwashing composition dispensing cartridge according to some embodiments of the present invention.

FIG. 7 is a side view and plan view of an example automatic dishwashing composition dispensing cartridge kit according to some embodiments of the present invention.

DETAILED DESCRIPTION

Conventional dishwashing dispensing mechanisms are employed in automatic dishwashing machines to supply dishwashing compositions during the wash cycle. In some instances, a consumer fills a permanent reservoir inside of the dishwashing machine with such compositions. Designs which require consumers to directly fill product into the dishwashing machine may restrict the compositions which can be directly handled by the consumer due to safety concerns and regulations. This can lead to reduced cleaning performance. Direct filling can also lead to cross contamination or chemical reactions when different products or brands are mixed inside these permanent reservoirs.

In other instances, a single chemical-containing sachet, such as a pod, simultaneously administers various forms of dishwashing compositions. In other instances, various enclosures are filled with separate compositions to dispense compositions at different times during the cleaning cycle. A cartridge should be understood as a self-standing unit permitting refilling and dispensing of an automatic dishwasher with an automatic dishwashing composition. More recently, multi-use automatic dispensing cartridges have been utilized which can administer a number of compositions during multiple wash cycles. Providing chemicals to the dishwashing machine separately from each other allows the dishwashing machine to administer the chemicals at different times of the cleaning cycle and allows for chemicals that may not otherwise be stable in the presence of each other to be provided in one container.

A sachet should be understood as a structure obtained from two flat substrates, or from a single flat substrate folded onto itself, which may be sealed on all edges or partially sealed on one or more edges. As will be explained below, a sachet according to this disclosure is a thermoformed sachet, such that one or more of the flat substrates will eventually not maintain a flat structure. A sachet may be used to contain and dispense products such as powders, liquids, or gels.

Thermoformed should be understood to refer to a manufacturing process wherein a plastic sheet is heated to a pliable forming temperature, shaped into a specific form using a mold, and then cooled to create a finished product. In some examples, a cutting tool may be used to define a perimeter of the product. In the context of this disclosure, it describes the process used to create a sachet by forming two flexible sheets into discrete pockets that hold the dishwashing composition.

As mentioned above, sachets according to this disclosure are structures comprising two flexible sheets, at least one being thermoformed, the sheets being sealed together, forming discrete pockets to hold dishwashing compositions.

The structural design of these mechanisms can impact their performance, particularly in terms of how well they collapse and dispense the contents with reduced or no venting. Additionally, the structural design of these mechanisms can impact space utilization due to irregular shapes failing to conform to the shape of the storage unit. Furthermore, such systems often employ single use dispensing and are not intended to be used in multiple cycles, recycled, or refilled. There remains a need for improved mechanisms that address these challenges and provide a more reliable and versatile solution for automatic dishwashing systems.

Such multi-use automatic dispensing cartridges are generally formed of rigid or semi-rigid materials forming a self-sustainable cavity or volume, at least in part to withstand the harsh conditions within a dishwasher including: varying temperature conditions up to 70^oC, high humidity, sustained contact with heated water containing chemical compositions, and contact with compositions within the cartridge. Multi-use cartridges also should be designed to prevent or reduce human contact (skin or eye) with the contained compositions under normal usage conditions.

Semi-rigid refers to a material or structure that exhibits both flexibility and rigidity. It is not completely flexible like a soft material which would collapse under its own weight, nor is it entirely rigid like a hard material. Rigid refers to a material or structure that is inflexible and does not easily bend or deform under stress. In the context of the patent application, it describes materials used in dishwashing composition dispensing cartridges that maintain their shape and structural integrity, requiring venting structures to dispense contents effectively.

Rigid or semi-rigid cartridges also require complex venting structures and may not evacuate all contents during the lifetime of their use. Closed rigid cartridges generally require a degassing valve to compensate for pressure build-up due to expanding gas in the cartridge headspace at increased temperatures. These valves also generally require mechanisms to prevent water within the dishwasher from entering into the cartridge, prevent leakage of the cartridges’ contents from said valves, and prevent blockage which may be caused by dry-out on the valve surface.

Such valves also need to compensate for the volume loss when dispensing or pumping out contents by letting air into the cartridge. For some dishwashing composition formulations which are sensitive to oxidation or degradation due to being reactive with gasses or air, there is a need for reduced or airless systems which collapse without venting or air intake.

There is thus a need for improved mechanisms that address these challenges and provide a more reliable and versatile solution for automatic dishwashing systems. The need includes providing efficient timed, automatic distribution of various dishwashing chemicals during the wash cycle with the ability to be refilled and reused.

The present disclosure addresses the need by providing a multi-use automatic dishwashing composition dispensing cartridge which effectively dispenses various compositions during the wash cycle with the ability to collapse and dispense substantially all contents with reduced or no need for venting.

FIG. 1A represents a side view of an automatic dishwashing composition dispensing cartridge of one or more embodiments of the present invention. FIG. 1A shows a first flexible sheet (FS) and second flexible sheet (SS), at least one of which is thermoformed, sealed together along an edge thereof to form the cartridge and comprises a plurality of internal, discrete pockets. A sheet should be understood to refer to a flat, flexible layer of material used to form part of the automatic dishwashing composition dispensing cartridge. Internal should be understood to refer to something located within or inside the cartridge indicating that the internal pockets are contained inside the overall structure of the cartridge. Discrete should be understood to refer to individual, separate, and distinct pockets within the cartridge which can be independently formed, filled, and evacuated allowing for the separation and containment of different components or compositions within the same cartridge. Each of the plurality of discrete pockets is filled with dishwashing composition.

Flexible refers to a material's characteristic of being able to bend, stretch, or deform without breaking. A flexible sheet according to this disclosure should also be understood as a sheet which would collapse under its own weight (i.e. not be self-sustainable). In the context of the patent application, it describes the property of the first and second sheets used in the automatic dishwashing composition dispensing cartridge, which allows them to form a seal along the edge and create discrete pockets that can expand, and contract as needed without compromising the structural integrity of the cartridge.

The automatic dishwashing composition dispensing cartridge comprising a first and a second flexible sheet sealed together along an edge can provide a robust and leak-proof enclosure for the dishwashing composition, ensuring that the contents are securely contained during storage and use. This sealing method enhances the structural integrity of the automatic dishwashing composition dispensing cartridge, reducing the risk of spillage or contamination.

The inclusion of a plurality of internal, discrete pockets filled with the dishwashing composition allows for the separation of different components within the same automatic dishwashing composition dispensing cartridge. This design enables the dispensing of various forms of dishwashing compositions, such as liquids, powders, and gels, at different times during the wash cycle, improving the efficiency and effectiveness of the cleaning process. This design also enables dispensing of non-compatible or sensitive compositions to improve cleaning efficiency. Maintaining separated compositions also enables delivery of specific compositions at different points in the wash cycle to enable to use of concentrated compositions which may reduce the overall size of the cartridge. This reduces the amount of raw materials needed to form the cartridge making the final product more sustainable. Using concentrated compositions can also shorten the wash-cycle or improve wash efficiency at lower temperatures leading to less water and/or energy use per cycle.

As seen in FIG. 1A, one or more pockets include at least one curvature having an angle, α in relation to a plane defined by a portion of the seal adjacent to the curvature. As a pocket is filled, the respective angle α may be between 45 and 90 degrees. This plane is represented by element P in FIG. 1A. This specific angle range can provide for a more compact and stable structure, which may better withstand internal pressure during filling and handling. This defined curvature may allow the automatic dishwashing composition dispensing cartridge to achieve a more efficient use of space when installed within the dishwasher enclosure by reducing potential dead space and can reduce or prevent deformation during filling, thereby reducing the risk of deformation and leakage. The specific angle range ensures that the pockets can expand and contract without deforming the overall structure of the cartridge. This can make the cartridge more durable and reliable. In some examples, α is between 50 and 90 degrees in relation to the plane defined by a portion of the seal adjacent to the curvature. In some examples, α is between 60 and 90 degrees in relation to the plane defined by a portion of the seal adjacent to the curvature. The angle α of a curvature of a pocket should be understood to correspond to a maximum angle between a plane defined by a portion of the seal adjacent to the curvature and a plane tangent to a surface of the curvature. In some embodiments, one or more of the pockets comprises a flat top or flat bottom pocket, see for example FIGS. 1B -D, such angle α should correspond to the angle between a plane P parallel to the flat top or flat bottom, and a plane P2 tangent to a point of the curvature corresponding to an inflexion point IP of the curvature between the plane P defined by a portion of the seal adjacent to the curvature and the plane corresponding to the flat top or flat bottom. In some examples, seals surround, or at least partially surround, the pockets, the seals substantially pertaining to a same plane, i.e. the main plane, such plane being parallel to a flat bottom or flat top of the pockets. In FIG. 1A, the pocket having the height h2, while thermoformed, does not have a planar top or bottom. In such FIG. 1A the other pocket having the height h1 is not necessarily thermoformed. In some embodiments, both the first and second sheets are thermoformed. While not illustrated here, in other examples, a single one of the first and second sheets is thermoformed.

Each of the plurality of discrete pockets may have a height, h (h1 for pocket 1, h2 for pocket 2), in relation to plane P, plane P comprising in this example seals between the first and the second sheet, such seals pertaining to a same plane or main plane. In some embodiments, one or more of the plurality of discrete pockets extend in both directions away from the plane P. In some embodiments, each of the first and second flexible sheets may contribute half of the depth of each pocket.

The height of all of the plurality of pockets – when filled – may be the same. In some examples, a same height should be understood as a same height within a 5% deviation. When the height varies across a pocket, the height of the pocket should be understood to correspond to the maximum height of the pocket. By ensuring that the height of all the plurality of discrete pockets is the same, the automatic dishwashing composition dispensing cartridge can achieve a substantially uniform shape, which can enhance the overall structural integrity and stability of the cartridge. This uniformity can reduce or prevent deformation during refilling and handling, increasing the likelihood that the automatic dishwashing composition dispensing cartridge will maintain its intended shape and volume. This can ensure that each pocket can contain the desired amount of dishwashing composition with reduced risk of overfilling or underfilling.

The uniform height of the discrete pockets can also improve space efficiency of the automatic dishwashing composition dispensing cartridge when installed within the dishwasher enclosure. This can reduce the amount of dead space within the enclosure which can maximize or increase the number of cycles each automatic dishwashing composition dispensing cartridge can sustain before refilling or disposal. This can lead to cost savings and reduced environmental impact. Further, as dishwashers are designed to increase space for dishes, glasses, pots, pans, and cutlery, free space within the dishwasher is limited and available height for automatic dishwashing composition dispensing cartridges is restricted as to not reduce loading capacity. When the dishwasher enclosure includes space for the cartridge in the door, the available height is restricted to the thickness of the door and the position of the racks inside the machine. This may lead to an available height of 25-45mm. Controlling the depth of the pockets within the automatic dishwashing composition dispensing cartridge can ensure compliance with the available door thickness height thereby improving design efficiency.

Additionally, the uniform height can facilitate a more controlled and predictable filling and refilling process. This can ensure that each pocket can hold a precise amount of dishwashing composition, enhancing dosing accuracy and reducing waste.

The uniform height of the pockets can also contribute to a more aesthetically pleasing appearance and reduce or prevent text and/or image distortion, which can enhance brand perception and consumer appeal. The uniform shape and planar top and bottom surface provide a professional appearance that can significantly influence purchasing decisions, particularly for products displayed on retail shelves.

The fact that the sachet is thermoformed permits obtaining uniform height even if the internal, discrete pockets of a given sachet have different dimensions. In some examples, as illustrated in FIG. 1B, the sachet comprises two internal, discrete pockets, whereby the first pocket is thermoformed to include a curvature in relation to the main plane between 45 and 90 degrees, whereas the second pocket is not formed but simply filled such that the first and second sheet get separated at filling such that a same height is obtained. As illustrated, the thermoforming and the forming of a curvature as hereby described permit obtaining an increased fill amount for a given sachet footprint in a plane parallel to the main plane, and permits obtaining a desired height level. In some examples, more than one pocket is formed to comprise a curvature in relation to the main plane between 45 and 90 degrees. In some examples, all pockets of the sachet are formed to comprise a curvature in relation to the main plane between 45 and 90 degrees.

In some embodiments, as illustrated in FIG. 1B, the pockets are symmetrical about the plane P. Symmetrical should be understood to refer to the pockets being balanced and proportionate, such that one side is a mirror image of the other. It describes the arrangement of pockets within the dishwashing composition dispensing cartridge that are mirror images of each other about the plane P within a 5% deviation, ensuring uniformity and balance in the structure.

In other embodiments, as illustrated in FIG. 1C, the pockets may be asymmetrical about the plane P. Asymmetrical should be understood to refer to the pockets not mirroring each other about the plane resulting in different shapes or configurations in each of the first and second flexible sheets which formed the cartridge.

In some embodiments, when the automatic dishwashing composition dispensing cartridge is filled with material, the filled pockets have a planar top surface and/or a planar bottom surface (see FIG. 1D). Planar should be understood to mean a surface that is flat and lies substantially entirely within a single plane. A surface lying substantially entirely within a single plane may for example comprise a surface representing at least 20% of a footprint of a pocket lying substantially within a distance DP of such single plane, the distance DP corresponding to 5% of the height h of the pocket in relation to the main plane P. In some examples, such single plane is parallel to plane P. In some examples, a surface lying substantially entirely within a single plane may for example comprise a surface representing at least 40% of a footprint of a pocket lying substantially within a distance DP of such single plane. In some examples, such single plane is parallel to plane P. In some examples, a surface lying substantially entirely within a single plane may for example comprise a surface representing at least 60% of a footprint of a pocket lying substantially within a distance DP of such single plane. In the context of this disclosure, such planar surfaces describe top and bottom surfaces of the pockets that are aligned with the main plane P ensuring uniformity and stability in the structure. This feature may increase the use of available space within the dishwasher enclosure. This design may also reduce or minimize deformation of the automatic dishwashing composition dispensing cartridge during filling, which can prevent or reduce uneven surfaces. The planar surfaces can provide a shape that may be easier to handle, stack, and store, and can thereby improve overall space efficiency and reduce the risk of damage during transportation and storage.

The planar top and bottom surfaces can also improve the filling process by reducing or preventing the likelihood of overfilling or underfilling, thereby increasing the precision in the filling amount. This precision in filling not only can increase the reliability of the automatic dishwashing composition dispensing cartridge but also may reduce or prevent waste, which can contribute to cost savings and environmental benefits. In some examples, the planar top and bottom surfaces are parallel to each other, and parallel to a plane comprising the sealed edge. This can assist in minimizing headspace during and after filling to help reduce the overall size of the cartridge while also prolonging shelf life. Pressure build up which can result from expanding gas in the headspace can also be reduced even when the cartridge is exposed to elevated temperatures within the dishwasher.

Additionally, the planar surfaces can improve the aesthetic appeal of the automatic dishwashing composition dispensing cartridge, making it more attractive to consumers and preventing or reducing any readability issues of any text and/or images printed on the automatic dishwashing composition dispensing cartridge. The planar shape and smooth surface can provide a professional appearance that can enhance brand perception and consumer trust. This is relevant for automatic dishwashing composition dispensing cartridges as such products may be displayed on retail shelves, where visual appeal can significantly influence purchasing decisions.

In other embodiments (see FIG. 1A-1C) one or more of the pockets may have at least one top or one bottom surface which is not planar.

FIG. 2 represents a plan view the main plane of an automatic dishwashing composition dispensing cartridge according to some embodiments of the present invention. As can be seen in FIG. 2, the automatic dishwashing composition dispensing cartridge comprises the plurality of discrete pockets (p1, p2, p3 and p4) such that each discrete pocket has a footprint in the main plane. Although four discrete pockets are illustrated in FIG. 2, the automatic dishwashing composition dispensing cartridge is not limited to four pockets and in some embodiments may include less than four or more than four pockets based on consumer need. In some embodiments, at least some of the pockets have footprints that are different shapes or sizes. In some examples, two of the pockets of a same cartridge have footprints which differ by at least 10% in footprint surface. In some examples, two of the pockets of a same cartridge have footprints which differ by at least 20% in footprint surface. In other embodiments, all of the pockets have substantially the same footprint.

Substantially is a term used to indicate that a certain condition or characteristic is largely, but not necessarily completely, met. It implies that the described feature or condition is present to a significant degree, though minor deviations or exceptions may exist. In some example, a substantially same footprint should be understood as a same footprint within a 5% deviation.

By allowing each pocket of the plurality of pockets to have a footprint in the main plane with at least some of the footprints having different shapes or sizes, the automatic dishwashing composition dispensing cartridge can accommodate various types and quantities of dishwashing compositions. This flexibility in design can allow customizing the use of space within the automatic dishwashing composition dispensing cartridge, ensuring that different compositions can be stored and dispensed efficiently. For example, larger pockets can be used for compositions that are required in greater quantities, while smaller pockets can be used for those needed in lesser amounts. In some examples, as illustrated in FIG. 2, each and every pocket of a same sachet comprise at least a portion of their respective perimeter on a same side of the sachet, in this example side S, such that each and every pocket of this same sachet may be accessed for use from the same side S. In some examples, such as example sachet 600 of FIG. 6, all inserts are provided on a same side to easy dispensing from such sachet.

This variation in pocket shapes and sizes can also enhance the structural integrity of the automatic dishwashing composition dispensing cartridge by distributing the internal pressure more evenly across the different pockets. This can reduce the risk of deformation or rupture during filling, handling, and use. Additionally, the ability to have different shapes and sizes of pockets can improve the overall stability of the automatic dishwashing composition dispensing cartridge when installed within the dishwasher, as it can better conform to the available space and reduce dead space.

As seen in FIG. 2, in some embodiments, the cartridge may have a curved perimeter and each pocket may have curved contours such that no hinged points are included the cartridge. This may improve structural integrity of each pocket within the cartridge. In other embodiments (not shown), the perimeter of the cartridge and contours of each pocket may have a different shape based on space limitations of the enclosure.

Due at least in part to the thermoformed design of the automatic dishwashing composition dispensing cartridge, the shape of each discrete pocket is not deformed or distorted by the shape, size, or fill volume of other pockets within the cartridge when the other pockets are filled with composition.

Text and/or images may be printed on one or more of the first or second flexible sheets forming the automatic dishwashing composition dispensing cartridge. In some embodiments, as seen in FIG. 3, one or each of the first and second flexible sheets can be formed of a multi-layer sheet (300a, 300b). In some examples, the one or more of text and images (301) is between two layers of the multi-layer sheet. In such embodiments, the text and/or images are protected via being sandwiched between the multiple layers of the one or more of the first and second flexible sheets. Such protection is of relevance due to the humid environment within a dishwashing machine during use. In other embodiments, the text and/or images may be printed directly on an interior surface of an exterior layer of the multi-layer sheet and may be protected with a water or product-resistant varnish or coating to protect the ink from reacting with the dishwashing composition or be washed off during the wash cycle. In other embodiments, the text and/or images may be printed on an intermediate layer disposed between exterior most layers of the multi-layer sheet. In some embodiments, one or both of the first and second sheets are formed of a single layer. In some embodiments, one or both of the first and second sheets are printless.

By incorporating text and/or images on one or more of the first and second flexible sheets, the automatic dishwashing composition dispensing cartridge can provide information directly on the cartridge itself without the need for additional labels that could be washed off in the dishwasher. This can include usage instructions, safety warnings, legal information, ingredient listing, branding, or other relevant details, enhancing user convenience, safety, and traceability. The presence of text and images can also improve the overall user experience by making the product more informative and easier to use.

Additionally, the ability to print text and images on the flexible sheets can enhance the aesthetic appeal of the automatic dishwashing composition dispensing cartridge, making it more attractive to consumers. This can be particularly beneficial for cartridges placed on retail shelves, where visual appeal can significantly influence purchasing decisions. The printed information can also serve as a marketing tool, reinforcing brand identity and increasing consumer trust.

By printing text and/or images directly on an interior surface of an exterior layer of the multi-layer sheet, the printed information may be well-protected from external environmental factors such as moisture, abrasion, and chemical exposure. This encapsulation between layers can improve legibility and aesthetic quality of the printed content, which can enhance the durability and longevity of the artwork and text. This approach also allows for reverse printing techniques, where the ink is applied to the underside of the top layer, improving the likelihood that the printed content remains intact and visually appealing throughout the lifecycle of the automatic dishwashing composition dispensing cartridge. Reverse printing on the top layer also enables use of reel-to-reel printing processes in flexo or offset print presses.

Flexo printing, or flexographic printing, is a printing technique that uses flexible relief plates to transfer ink onto a variety of substrates, including paper, plastic, and metallic films. It is commonly used for packaging and labels due to its ability to print on diverse materials and its high-speed production capabilities. Flexo printing is known for its efficiency and versatility, making it suitable for large-scale production runs.

Offset printing is a widely used printing technique where an inked image is transferred (or "offset") from a plate to a rubber blanket, and then to the printing surface. This method is commonly used for producing high-quality prints on paper, cardboard, and other materials, and is known for its ability to produce consistent and sharp images with a wide range of colors.

In cases where the text and/or images are printed on an intermediate layer disposed between the exterior most layers of the multi-layer sheet, the method can provide an additional layer of protection for the printed content. This intermediate layer may shield printing fluid from direct contact with the external environment and the dishwashing composition, which may reduce or prevent potential degradation or contamination of the printed information. The respective layers of the multi-layer sheets, or the sheets of flexible material, may be appropriately transparent, at least in part, to enable a user to see the text/images.

Transparent refers to a material's characteristic of allowing light to pass through it such that objects behind the material can be clearly seen. In the context of the patent application, it describes the property of the flexible sheets used in the cartridge which may enable visibility of the contents or any printed text and images on the cartridge. This transparency can be relevant for consumer products where visual inspection of the dishwashing composition is desired. By allowing consumers to visually inspect the compositions contained within the cartridge, consumers can obtain information about the perceived function of each composition, for example pre-wash, main-wash, booster, bleach, or rinse aid.

Both printing methods (printing on an internal layer, or on an intermediate layer) can contribute to a more professional and visually appealing product, which can enhance brand perception and consumer trust. The protected printed content can reduce or prevent distortion of any legal text, branding, and other important information. This is relevant for regulatory compliance and effective communication with consumers. Additionally, this approach can reduce the need for additional labelling steps post-formation and can simplify the manufacturing process and reducing production costs.

The pre-printed flexible sheet can then be laminated or glued to a second layer. In some embodiments, such adhesion results in a mono-material configuration which maintains desired mechanical strength and resistance while simplifying recycling.

The thickness of each of the first and second flexible sheets may be between 30 400 microns. In some examples, the thickness of each of the first and second flexible sheets may of less than 350 microns, of less than 300 microns, of less than 250 microns, or of less than 200 microns. A lower thickness may be related to an increased film flexibility which would facilitate collapsing with reduced or no venting and provide a more efficient and reliable cartridge. In some examples, the thickness of each of the first and second flexible sheets may be between 50 and 350 microns. In some examples, thickness of each of the first and second flexible sheets may be between 70 and 300 microns. In some examples, thickness of each of the first and second flexible sheets may be between 90 and 250 microns. In some examples, thickness of each of the first and second flexible sheets may be between 100 and 200 microns. In some embodiments the first and second flexible sheets may have the same thickness. In other embodiments the thickness of each of the first and second flexible sheets can vary in thickness within the above range. Increasing the thickness of each of the first and second flexible sheets above 400 microns may result in sheets having too rigid a structure to maintain necessary flexibility for the present cartridge whereas sheets having a thickness below 30 microns may not provide sufficient structural support in forming the cartridge and may be more likely to rupture or tear.

In some examples, at least one of the first and second flexible sheets comprise multi-layer laminates and the overall thickness of the multi-layer laminate is within 30-400 microns as laid out above. In some embodiments, the printed layer may have a thickness less than any additional layers within the laminate. In other embodiments, all layers within the multi-layer laminate may be the same thickness.

FIG. 4 shows an embodiment of the automatic dishwashing composition dispensing cartridge including an insert, 400, placed between the first and second flexible sheets. The insert may be disposed between the first and second flexible sheets about the edge and sealed therebetween. Such sealing may be accomplished via heat sealing the first and second flexible sheets together and around the insert therebetween. The insert may comprise a conduit to allow the automatic dishwashing composition dispensing cartridge to be filled with the dishwashing composition and may allow for dispensing of such composition so as to evacuate substantially all composition with reduced or absent need for venting.

The insert may provide a reliable and user-friendly mechanism for dispensing the dishwashing composition, which may enhance the overall functionality of the automatic dishwashing composition dispensing cartridge. The insert may initiate the timed and controlled distribution of dishwashing composition during various stages of the wash cycle according to need. This can ensure precise dosing during the proper stage of the wash cycle. The ability to dispense the composition with reduced or absent venting requirements may also simplify the design and manufacturing process, reducing the need for additional components, such as an air-intake valve or pressure relief valve, and potential failure points.

The insert may allow for more controlled filling of dishwashing composition within the cartridge and more controlled dispensing during use. It also allows for refilling of the cartridge by the consumer. This contributes to the reduced or absent venting requirement as the cartridge collapses during dispensing at least in part because of the flexibility of the first and second flexible sheets. This feature can reduce or eliminate complexities associated with venting systems, such as potential leakage or blockage.

The ability of the cartridge to collapse with reduced or absent venting during dispensing can also improve space efficiency and reduce waste. As the cartridge collapses, the residual volume of the material left inside is reduced, increasing usage of the contents by promoting substantially all contents to be dispensed. The 3D structure of the cartridge may control the collapsing resulting in predictable composition dispensing and prevention of voids or pockets which could trap residual product within the cartridge. This can improve consumer satisfaction and reduce residue in the cartridge at the end of life.

Additionally, the sealed insert can provide a robust and reliable connection point for dispensing mechanisms, which can be designed within the dishwasher enclosure to interface the cartridge. This can enhance the user experience by providing a way to dispense the product with reduced risk of spills, contamination, or safety issues (skin or eye contact).

In some embodiments, the insert may be formed of the same material as the first and second flexible sheets. In other embodiments, at least one of the insert, first flexible sheet, or second flexible sheet may be made of different materials.

By forming the insert and the first and second flexible sheets from the same material, the automatic dishwashing composition dispensing cartridge can achieve a more uniform and cohesive structure. This material uniformity can enhance the overall compatibility and bonding between the insert and the flexible sheets, reducing the risk of separation or leakage at the seams. The consistent material properties can also improve the mechanical strength and durability of the automatic dishwashing composition dispensing cartridge, ensuring reliable performance during use.

Using the same material for the insert and the flexible sheets can simplify the manufacturing process, as it eliminates the need for different processing techniques or adhesives for different materials. This can lead to cost savings and increased production efficiency. Additionally, the uniform material composition can facilitate recycling and disposal of the automatic dishwashing composition dispensing cartridge, as it can be processed as a single material type, reducing environmental impact and environmental regulatory fees to be paid.

The material uniformity can also contribute to a more aesthetically pleasing appearance, as the insert and the flexible sheets will have a consistent look and feel. This can enhance the overall visual appeal of the automatic dishwashing composition dispensing cartridge, making it more attractive to consumers and improving brand perception.

In some embodiments, the dishwashing composition contained within the cartridge may comprise a plurality of products selected from the group consisting of liquid, powder, gel, and a combination thereof.

By allowing the dishwashing composition to comprise a plurality of products selected from a group consisting of liquid, powder, gel, and a combination thereof, the automatic dishwashing composition dispensing cartridge can accommodate various types of cleaning agents within a single unit. This flexibility enhances the versatility of the automatic dishwashing composition dispensing cartridge, enabling it to deliver different forms of dishwashing compositions as required during different stages of the wash cycle. This can improve the overall cleaning performance by ensuring that the most appropriate form of the composition is used at the right time.

The ability to include multiple types of products within the same automatic dishwashing composition dispensing cartridge can also reduce the need for multiple separate cartridges, simplifying the user experience and reducing storage requirements. This can lead to cost savings for the user and reduce the environmental impact by minimizing packaging waste. Additionally, the combination of different forms of compositions can provide a more comprehensive cleaning solution, addressing various types of stains and residues more effectively. It can also enable shorter wash cycles, require less water, and lower required operating temperatures thereby reducing the environmental impact of the dishwashing process while increasing process speed and reducing consumption cost to the consumer.

For example, an automatic dishwashing composition dispensing cartridge could contain a liquid detergent for the initial wash cycle, a powder for scrubbing action, and a gel for a final rinse, all within the same unit. This multi-product capability ensures that the dishwasher can deliver a tailored cleaning process, enhancing the efficiency and effectiveness of the dishwashing operation.

Due to the design of the present automatic dishwashing composition dispensing cartridge, dishwashing composition may fill 60-99% of the volume of each pocket. In some examples, the material may fill 70-99% of the volume of each pocket. In some examples, the material may fill 80-99% of the volume of each pocket. In some examples, the material may fill 90-99% of the volume of each pocket. This fill volume may reduce or minimize wasted space within the pocket and may reduce the amount of headspace. Reduced head space is of relevance in maintaining the structural integrity and stability of the automatic dishwashing composition dispensing cartridge during handling and transportation. Reduced headspace can also reduce or prevent the risk of dishwashing composition movement within the pocket, which can lead to leakage or deformation. In some examples, the volume of each pocket which is not filled by the dishwashing composition is filled by air.

This high fill percentage contributes to improved storage capacity efficiency of the automatic dishwashing composition dispensing cartridge, such that a substantial amount of material relative to its overall size may be introduced. This may be beneficial for increasing the number of dishwashing cycles the automatic dishwashing composition dispensing cartridge may complete before requiring refilling or disposal. This improved use of space within the pockets also may contribute to cost savings in terms of material usage and transportation, as more product can be packed into a given volume.

Additionally, the controlled fill volume can contribute to forming automatic dishwashing composition dispensing cartridge with consistent shapes and appearance, which is relevant for branding and consumer appeal. Uniformity in shape and volume can enhance the visual appeal of the automatic dishwashing composition dispensing cartridge, which may make it more attractive to consumers and improve the overall user experience. This uniformity can also facilitate better stacking and storage, as the sachets can be arranged more efficiently with reduced risk of deformation or instability.

The volume capacity of the automatic dishwashing composition dispensing cartridge may be between 200ml and 3000ml. Each individual pocket may have a volume capacity of between 10mL and 2000mL. Overall capacity may be adjusted based on consumer need, available enclosure space, and desired number of operating cycles. In some examples, the cartridge may contain 630 -700mL of dishwashing composition which can dispense composition for approximately 20 wash cycles before requiring refilling or disposal.

FIG. 5 shows the sealing edge of an automatic dishwashing composition dispensing cartridge according to some embodiments of the present disclosure. Each of the first and second flexible sheets may have a first thickness, T1, in a region beyond the sealing edge and deformed interior space and a second thickness, T2, in a region of the deformed interior space. The first thickness, T1, may be greater than the second thickness, T2. The thickness of the deformed interior space of each of the first and second flexible sheets, T2, may be 30-95% of the thickness beyond the sealing edge and deformed interior space , T1, due to a stretching effect in this region as a consequence of a manufacturing process in forming the automatic dishwashing composition dispensing cartridge. In other words, the first flexible sheet and the second flexible sheet each have a thickness T1 at the edge and a thickness T2 in a region of the at least one curvature, wherein for both the first and second flexible sheets, the thickness at the edge is greater than the thickness in the region of the at least one curvature. In some examples, T2 may be 40-95% of the thickness of the edge region T1. In some examples, T2 may be 60-95% of the thickness of the edge region T1. While illustrated in a case of sheets having a same thickness, such stretching would also take place, for each sheet, even if their thicknesses were different at the edge.

Due at least in part to the thermoformed design of the cartridges, each of the first and second flexible sheets is only required to supply half of the depth of each pocket, as shown in FIG. 1A-1D. As such, each of the first and second flexible sheets may be subjected to reduced stretching as compared to a sheet being stretched to accommodate the entire depth of a pocket in previous designs. This enables the present cartridge to maintain impact resistance and reduces the risk of leakage. This also allows the first and second flexible sheets to be made with less starting material as less stretch is required to achieve the desired pocket volume capacity which may reduce manufacturing costs and environmental impacts.

By ensuring the first and second flexible sheets maintain thickness T2 in relation to T1 as laid out above may prevent damage to the automatic dishwashing composition dispensing cartridge when filled. If the thickness T2 is reduced below the disclosed range, there may be an increased risk of tearing or rupture due to decreased structure integrity of the first and second flexible sheets forming the automatic dishwashing composition dispensing cartridge. Conversely, If thickness T2 is greater in relation to T1 than the disclosed range, this may indicate the first and second flexible sheets were not sufficiently deformed to a desired shape in the manufacturing process.

As seen in FIG. 5, each of the first and second flexible sheets may further comprise a third thickness, T3, corresponding to a region of the first or second flexible sheet including a planar front surface or a planar back surface substantially aligned with the main plane. The thickness in the region of the at least one curvature, T2, is less than the thickness in the region of the planar front or planar back surface, T3. The thickness of the deformed interior space of each of the first and second flexible sheets, T2, may be 30-95% of the thickness of the top or bottom planar surface, T3, due to a stretching effect in this region as a consequence of a manufacturing process in forming the automatic dishwashing composition dispensing cartridge. In other words, the first flexible sheet and the second flexible sheet each have a thickness T2 in a region of the at least one curvature and a thickness T3 in a region of the top or bottom planar surface, wherein for both the first and second flexible sheets, the thickness at the top or bottom planar surface is greater than the thickness in the region of the at least one curvature. In some examples, T2 may be 40-95% of the thickness of the edge region T3. In some examples, T2 may be 60-95% of the thickness of the edge region T3. While illustrated in a case of sheets having a same thickness, such stretching would also take place, for each sheet, even if their thicknesses were different at the top or bottom planar surface. Such third thickness T3 is an example of a thickness beyond the region of the at least one curvature and beyond the seal.

By ensuring that the flexible sheet forming the curvature has a thinner thickness in the region of the curvature, T2, compared to the thickness of the top or bottom planar surface, T3, the cartridge can achieve enhanced flexibility and adaptability. This design allows the pockets to expand and contract more easily, accommodating the dishwashing composition without compromising the structural integrity of the cartridge.

By maintaining increased thickness of the top or bottom planar surface, the structural integrity of the cartridge can be maintained to reduce or prevent the risk of leakage, puncture, or rupture along the top or bottom planar surface.

The reduced thickness in the curvature region may be obtained during the thermoforming process. This resulting flexibility ensures a more reliable and durable cartridge that can withstand repeated use and handling.

Additionally, the variation in thickness may improve material usage, potentially reducing manufacturing costs while maintaining the necessary strength and functionality of the cartridge. This design choice supports efficient production and contributes to the overall cost-effectiveness of the product.

In some embodiments, one or more of the first and second flexible sheets comprise a non-water soluble film. Non-water soluble refers to a material's characteristic of not dissolving or breaking down when exposed to water such that a non-water soluble polymer should be understood to describe a polymer that does not readily dissolve or disperse in solvents or water. In the context of the patent application, it describes the property of the flexible sheets used in the cartridge, ensuring that the cartridge maintains its structural integrity and does not degrade or dissolve when in contact with water, dishwashing compositions, or aqueous solutions.

In some embodiments, the first and second flexible sheet are formed of the same polymeric, non-water soluble flexible films. Examples of polymeric, non-water soluble flexible films include polyethylene, polypropylene, bi-oriented polypropylene, polyvinyl chloride, polyethylene terephthalate, polyamide, or polystyrene. In some examples, a mono-material is used for the automatic dishwashing composition dispensing cartridge to facilitate recycling. In some examples, the mono-material is a polyethylene. In other embodiments, the first and second flexible sheet are formed of different non-water soluble flexible films. The film construction can be tailored to have specific barrier properties against moisture, oxygen, perfume, oil, solvents to prolong shelf life and in-use life of the dishwashing compositions. The film construction can also have higher temperature resistant external or internal polymer layers to protect the cartridge from deformation when exposed to high temperatures inside the dishwasher over multiple cycles.

In utilizing non-water-soluble films for the first and second flexible sheets, the automatic dishwashing composition dispensing cartridge can maintain its structural integrity and prevent dissolution or degradation when exposed to water and/or dishwashing compositions during the dishwashing cycle. This ensures that the dishwashing composition remains securely contained within the pockets until it is dispensed at the appropriate time, enhancing the reliability and effectiveness of the cleaning process.

The use of non-water-soluble films can also improve the durability and longevity of the automatic dishwashing composition dispensing cartridge, allowing it to withstand multiple dishwashing cycles without compromising its performance. This can lead to cost savings for the user, as the cartridge is reused multiple times before needing refilling or replacement, and it can reduce environmental impact by minimizing waste.

By designing the automatic dishwashing composition dispensing cartridge for multiple uses and enabling it to be refilled, the invention can reduce the carbon footprint associated with the cartridge. This approach may reduce the amount of plastic waste generated, as the same cartridge can be reused multiple times, thereby contributing to an extended lifecycle and reducing the need for frequent replacements. This contributes to environmental sustainability by lowering the overall consumption of raw materials and reducing the volume of waste that ends up in landfills.

The ability to refill the automatic dishwashing composition dispensing cartridge also offers practical benefits for consumers, as it provides a cost-effective and convenient solution for managing household products. Users can purchase refills instead of entirely new cartridges, which can be more economical and reduce the frequency of waste disposal. This feature can enhance the user experience by providing a more sustainable and user-friendly packaging option.

By offering a reusable and refillable option, the invention may also support efforts to reduce the environmental impact of packaging and promotes a circular economy where materials are kept in use for as long as possible. This may benefit the environment and also may enhance the marketability of the product by appealing to environmentally conscious consumers.

FIG. 6 represents a plan view of the automatic dishwashing composition dispensing cartridge (600) in the main plane. In FIG. 6, the cartridge (600) is sealed about its edge along the edge seal (ES) forming the plurality of pockets (P5, P6, P7, […] PN). Although there are four discrete pockets represented in FIG. 6, the present disclosure is not limited thereto and may have any number of discrete pockets within the automatic dishwashing composition dispensing cartridge based on consumer need. The cartridge further includes a plurality of inserts (I1, I2, I3, […] IN) wherein each insert of the plurality of inserts corresponds to one or more pockets of the plurality of pockets. In some embodiments, a single insert of the plurality of inserts corresponds to a single pocket of the plurality of pockets (as shown). In other embodiments (not shown), a single insert of the plurality of inserts may correspond to two or more pockets of the plurality of pockets.

By incorporating a plurality of inserts, each corresponding to one or more pockets of the plurality of pockets, the automatic dishwashing composition dispensing cartridge can achieve more precise and controlled dispensing of the dishwashing composition. This design can allow for each pocket to be individually accessed and dispensed, which can improve the accuracy of the dosing and ensure that the correct amount of composition is delivered during each wash cycle.

The use of multiple inserts can also enhance the flexibility of the automatic dishwashing composition dispensing cartridge, enabling it to accommodate different types of dishwashing compositions within the same unit. For example, one insert could be used for liquid detergent, another for powder, and another for gel, allowing for a more tailored and effective cleaning process. This can improve the overall performance of the dishwasher by ensuring that the most appropriate form of the composition is used at the right time. Embodiments wherein there is a single insert for each pocket can ensure that there is no mixing or contamination between compositions during the wash cycle. This is of relevance for compositions which are not compatible for use together.

Additionally, the presence of multiple inserts can improve the structural integrity of the automatic dishwashing composition dispensing cartridge by distributing the internal pressure more evenly across the different pockets. This can reduce the risk of deformation or rupture during filling, handling, and use. The inserts can also provide a more robust and reliable connection point for dispensing mechanisms, reducing the risk of spills or contamination during use.

Furthermore, the ability to have multiple inserts can facilitate the refilling process, as each pocket can be individually accessed and refilled as needed. This can extend the lifespan of the automatic dishwashing composition dispensing cartridge and reduce waste, contributing to cost savings and environmental benefits. The design can also simplify the manufacturing process by allowing for standardized inserts to be used across different types of cartridges, improving production efficiency and reducing costs.

Including a plurality of inserts also facilitates dispensing and collapsing of each pocket with reduced or absent need for venting. By incorporating a plurality of inserts within the automatic dishwashing composition dispensing cartridge, each pocket may more fully evacuate its contents, leading to cost savings and improved consumer satisfaction and less residue for simplified recycling of the empty cartridge.

FIG. 7 shows a kit comprising a first automatic dishwashing composition dispensing cartridge (700a) and a second automatic dishwashing composition dispending cartridge (700b) wherein the first automatic dishwashing composition dispensing cartridge is full and the second automatic dishwashing composition dispensing cartridge (700a) has dispensed substantially all composition therein. Full should be understood to refer to the automatic dishwashing composition dispensing cartridge having all pockets therein filled with dishwashing composition to an intended capacity, for example, between 60-99% by volume as previously described. As can be seen in FIG. 7A, from a side view of the first and second automatic dishwashing composition dispensing cartridges, each has a length (L1 and L2, respectively) wherein the length of the first automatic dishwashing composition dispensing cartridge is substantially the same as the second automatic dishwashing composition dispensing cartridge. In some examples, a same length is intended to mean those within a 5% deviation. As can be seen in FIG. 7B, from a plan view of the first and second automatic dishwashing composition dispensing cartridges, each further has a width (W1 and W2, respectively) wherein the width of the first automatic dishwashing composition dispensing cartridge is substantially the same as the second automatic dishwashing composition dispensing cartridge. In some examples, a same width is intended to mean those within a 5% deviation. The result is that a footprint of the first cartridge and a footprint of the second cartridge are substantially the same. In some examples, a same footprint is intended to mean those within a 5% deviation. It should be noted that in some examples, the footprint is not necessarily rectangular.

By ensuring that filled cartridges have a footprint substantially the same as emptied cartridges, the structural integrity of the cartridges can be improved. When filled, the cartridges do not deform and maintain their shape such that there is less internal pressure on the first and second flexible sheets. This can reduce the risk of product leaking from puncture or from degradation of the sealed edge. Furthermore, the maintained footprint ensures the cartridges fit snuggly within the dishwasher enclosure, which reduces the risk of movement or dislodgment of the automatic dishwashing composition dispensing cartridge once installed during operation.

In some embodiments, the automatic dishwashing composition dispensing cartridge may be refilled in order to reuse the cartridge after dispensing all or substantially all of the dishwashing composition contained therein. The method of refilling comprises refilling the automatic dishwashing composition dispensing cartridge through the insert. In some embodiments, the insert may comprise a single insert or a plurality of inserts for refilling one or more compositions within the cartridge.

The method of refilling an automatic dishwashing composition dispensing cartridge through the insert allows for the cartridge to be reused multiple times, which can significantly reduce waste and environmental impact. This refilling capability ensures that the cartridge can be efficiently replenished with dishwashing composition without the need for complete replacement, promoting sustainability and cost-effectiveness.

Refilling through the insert simplifies the process for the user, as it provides a straightforward and accessible means to replenish the dishwashing composition. This can enhance user convenience and reduce the likelihood of improper handling or spillage during the refilling process. The insert's design ensures that the automatic dishwashing composition dispensing cartridge can be refilled without compromising its structural integrity or performance.

By enabling the automatic dishwashing composition dispensing cartridge to collapse without venting during dispensing, the refilling method ensures that the cartridge maintains its shape and functionality over multiple uses. This can improve the overall durability and reliability of the cartridge, ensuring consistent performance throughout its lifecycle. The ability to refill the cartridge through the insert also supports a more controlled and precise dispensing of the dishwashing composition, enhancing the efficiency and effectiveness of the cleaning process.

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

For the purposes of defining the present technology, the transitional phrase “consisting of” may be introduced in the claims as a closed preamble term limiting the scope of the claims to the recited components or steps and any naturally occurring impurities. For the purposes of defining the present technology, the transitional phrase “consisting essentially of” may be introduced in the claims to limit the scope of one or more claims to the recited elements, components, materials, or method steps as well as any non-recited elements, components, materials, or method steps that do not materially affect the novel characteristics of the claimed subject matter. The transitional phrases “consisting of” and “consisting essentially of” may be interpreted to be subsets of the open-ended transitional phrases, such as “comprising” and “including,” such that any use of an open ended phrase to introduce a recitation of a series of elements, components, materials, or steps should be interpreted to also disclose recitation of the series of elements, components, materials, or steps using the closed terms “consisting of” and “consisting essentially of.” For example, the recitation of a composition “comprising” components A, B, and C should be interpreted as also disclosing a composition “consisting of” components A, B, and C as well as a composition “consisting essentially of” components A, B, and C. Any quantitative value expressed in the present application may be considered to include open-ended embodiments consistent with the transitional phrases “comprising” or “including” as well as closed or partially closed embodiments consistent with the transitional phrases “consisting of” and “consisting essentially of.”

As used in the Specification and appended Claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly indicates otherwise. The verb “comprises” and its conjugated forms should be interpreted as referring to elements, components or steps in a non-exclusive manner. The referenced elements, components or steps may be present, utilized or combined with other elements, components or steps not expressly referenced.

It should be understood that any two quantitative values assigned to a property may constitute a range of that property, and all combinations of ranges formed from all stated quantitative values of a given property are contemplated in this disclosure. The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

The subject matter of the present disclosure has been described in detail and by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to the particular embodiment or to any other embodiment.

It should be apparent to those skilled in the art that various modifications and variations may be made to the embodiments described within without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described within provided such modifications and variations come within the scope of the appended claims and their equivalents. Unless otherwise stated within the application, all tests, properties, and experiments are conducted at room temperature and atmospheric pressure.

Having described the subject matter of the present disclosure in detail and by reference to specific embodiments thereof, it is noted that the various details disclosed within should not be taken to imply that these details relate to elements that are essential components of the various embodiments described within, even in cases where a particular element is illustrated in each of the drawings that accompany the present description. Further, it should be apparent that modifications and variations are possible without departing from the scope of the present disclosure, including, but not limited to, embodiments defined in the appended claims. More specifically, although some aspects of the present disclosure are identified as particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

As used in this specification and the claims that follow, the articles "a", "an", and "the" include singular and plural references unless the context clearly dictates otherwise. As such, the terms "a" or "an", "one or more" and "at least one" can be used interchangeably herein. Thus, for example, "a component" may include one or more components unless the reference is specifically indicated as being singular.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.