Porous die roller for poultry, pork, meat substitutes and vegetarian

Abstract

The invention relates to a rotating cylindrical mould member for moulding a product from a foodstuff raw material comprising poultry meat, pork, a meat substitute and vegetarian foodstuff, the mould member having a longitudinal axis and an outer circumference, comprising at least one mould body having a curved outer surface forming at least a part of the outer circumference of the mould member and an opposite inner surface, wherein the mould body is made of a porous material having a porous structure with interconnected pores, wherein the outer circumference is at least partially hermetically sealed, wherein each mould body comprises at least one cavity in which the foodstuff raw material is moulded, the cavity being formed in the curved outer surface, being delimited by a boundary comprising a wall and a bottom, the cavity comprising at a porous bottom wall and / or at a porous side wall thereof and / or at a curved / contoured boundary thereof a deformation layer formed by plastic deformation, the mould body comprising an inner volume of the mould body arranged between the deformation layer and the inner surface, the mould member further comprising a gas supply forcing gas through the inner volume and the deformation layer into the cavity to aid removal of the moulded product from the mould cavity. The invention further relates to a method of providing a cavity in a porous mould body.

Description

Technical Field

[0001] This invention relates to a rotary cylindrical mold component for molding products from food ingredients including poultry, pork, and / or meat substitutes. The mold component has a longitudinal axis and an outer circumference, and includes at least one mold body having a curved outer surface forming at least a portion of the outer circumference of the mold component and opposing inner surfaces. The mold bodies are made of a porous material with an interconnected porous structure. The outer circumference is at least partially hermetically sealed. Each mold body includes at least one cavity in which the food ingredient is molded. The cavity is formed in the curved outer surface and defined by a boundary including a wall and a bottom. The cavity includes a deformable layer formed by plastic deformation at its porous bottom wall and / or its porous sidewalls and / or its curved / contour-like boundary. The mold body includes an internal volume disposed between the deformable layer and the inner surface. The mold component further includes a gas supply device that forces gas through the internal volume and the deformable layer into the cavity to aid in removing the molded product from the mold cavity. The invention also relates to a method of providing cavities in a porous mold body. Background Technology

[0002] For example, a mold component is known from WO 2018 / 034568. However, based on what a person skilled in the art can certainly understand to any extent, the disclosed mold roller has limited applicability, is unsuitable for poultry, pork, meat substitutes and vegetarians, and the operating principle of the disclosed roller has limitations in terms of repeatability.

[0003] Therefore, the problem to be solved by the present invention is to provide a mold roller that is straightforward in operation and does not include the defects of rollers in the prior art. Summary of the Invention

[0004] This problem is overcome by a rotary cylindrical mold component for molding products from food ingredients including poultry, pork, meat substitutes, and vegetarian ingredients. The mold component has a longitudinal axis and an outer circumference, and includes at least one mold body having a curved outer surface forming at least a portion of the outer circumference of the mold component and opposing inner surfaces. The mold body is made of a porous material with a porous structure having interconnected pores. The outer circumference of the mold component is at least partially hermetically sealed. Each mold body includes at least one cavity in which the food ingredient is molded. The cavity is formed in the curved outer surface of the mold body, preferably milled. Each cavity is defined by a boundary including one or more sidewalls and a bottom wall. Each cavity includes a deformation layer at its porous bottom wall and / or its porous sidewalls and / or its boundary, formed by, for example, plastic deformation due to a milling process. The mold body includes an internal volume disposed between the deformation layer and the inner surface. The deformation layer can extend from exposed surfaces of the sidewalls, bottom wall, and / or boundaries into the internal volume.

[0005] The mold component may further include a gas supply section that forces gas through the internal volume and deformation layer into the cavity to help remove the molded product from the mold cavity.

[0006] The average flow resistance of the deformable layer is conceived to be different from the average flow resistance of the internal volume. For example, the average flow resistance of the deformable layer is conceived to be different from (higher or lower than) the average flow resistance of the internal volume. The difference between the average flow resistance of the deformable layer and the average flow resistance of the internal volume can exceed 30%, more preferably 40%, and more preferably 50%. Therefore, for example, if the internal volume has an average flow resistance of X, the average flow resistance of the deformable layer can be less than the product of 0.7 (X), more preferably 0.5 (X), or more preferably 0.3 (X). The ratio of the average flow resistance of the internal volume to the average flow resistance of the deformable layer can be higher than 3:1, more preferably higher than 5:1, even more preferably higher than 8:1, and even more preferably higher than 10:1. The ratio of the average flow resistance of the internal volume to the average flow resistance of the deformable layer can be less than 100:1, or more preferably less than 50:1. The average flow resistance of the deformable layer can be, for example, 1-30% of the flow resistance of the internal volume, preferably 3-20%, more preferably 4-15%, and even more preferably 5-12%.

[0007] Unless otherwise specified (e.g., in a comparison of flow resistance between the sidewall and bottom wall), the flow resistance is averaged over a cavity, meaning there is no difference between the flow resistance of the sidewall and the bottom wall.

[0008] For all the material properties or characteristics measured in this article, the “average value” is determined by adding the measurements together (N is an integer greater than 1) from at least N samples taken at different representative locations, and dividing the sum by the number of samples N (e.g., for sampling N of 2, 3 or 5 samples respectively, the sum of the measurements is divided by 2, 3 or 5).

[0009] The disclosure made in connection with this embodiment of the invention is also applicable to other embodiments, and vice versa. The subject matter disclosed in the context of this embodiment of the invention may also be included in other embodiments, and vice versa.

[0010] This invention relates to a rotating cylindrical mold component, preferably to a roller for molding products from food ingredients, and more preferably to a roller for molding products from food ingredients generally considered to have a low fat content. For example, the invention contemplates a rotating cylindrical mold component, preferably a roller for molding products from food ingredients with a fat content of 15 grams, 12 grams, 10 grams, or 8 grams per 100 grams (g) of uncooked food. The food ingredients may include foods selected from poultry, pork, fish, meat substitutes, and vegetarian foods.

[0011] The mold component has a longitudinal axis and an outer circumference. During the production process, the mold component rotates around the longitudinal axis.

[0012] The mold component includes at least one mold body having a curved outer surface and opposing inner surfaces forming at least a portion of the outer circumference of the mold component. The mold body can be a single piece, such as a roller, or it can be divided into multiple pieces. The mold body can be made of a porous material with a porous structure having interconnected pores, such as sintered metal, ceramic, or plastic materials. It can preferably be stainless steel. A portion of the outer circumference of the mold body can be at least partially, and preferably completely, hermetically sealed. For example, the outer circumference of the mold body can be selectively sealed at predetermined locations around the outer circumference of the mold body (e.g., in areas adjacent to one or more cavities where food ingredients are introduced and molded).

[0013] Each mold body includes at least one cavity, preferably multiple cavities, in which food ingredients are molded. The cavities are formed in the curved outer surface of the mold body, for example, by material removal (e.g., by milling) (e.g., material removal before or after the outer circumference of the mold body is sealed). Each cavity includes preferably porous sidewalls and / or preferably porous bottom walls. The sidewalls and bottom walls define the boundaries of the cavity. The boundaries are typically curved and / or contoured. However, the boundaries may include one or more planar portions (e.g., the bottom wall of the cavity, such as a 2D cavity).

[0014] The mold body may include an internal volume of porous material with or without a structure defining multiple channels. The porous material within the internal volume may include a network of adjacent and interconnected open pores that allow gas to pass through. The porous material within the internal volume may include pores that are generally uniformly distributed.

[0015] The internal volume of the pores can have the following dimensions (i.e., at their maximum size, such as diameter), through which the size variation of the pores is such that at least 50% of the pores or at least 75% of the pores differ from each other by less than 30%, less than 20%, or less than 10% at their maximum size.

[0016] The sidewalls can have any shape, such as circular or elliptical. The bottom can be curved / profiled, or include any other 2D or 3D shape. Each cavity includes a deformable layer formed by plastic deformation at its porous bottom wall and / or its porous sidewalls and / or its boundaries. The deformable layer is typically formed during the milling of the cavity into a porous material. For example, the deformable layer can appear within a sub-surface portion of a die roller (during its manufacture) extending from the cavity wall surface exposed by material removal operations (e.g., milling, such as conventional milling, zigzag milling, and / or co-rotation milling). The sub-surface deformation at this location may be due to the combined effects of cutting forces (e.g., frictional and / or shearing forces), temperature rise, or both occurring during the machining operation.

[0017] The deformable layer can manifest as a sub-surface region extending from the exposed cavity wall surface into a portion of the internal volume (e.g., radially and / or longitudinally). However, its microstructure may differ from the typical microstructure that appears within the internal volume.

[0018] The deformed layer can exhibit an average material density exceeding that of the internal volume (e.g., at least 10%, 20%, 30%, or 40%). The average porosity within the deformed layer can be at least 10%, 20%, 30%, or 40% lower than the average porosity within the internal volume. Therefore, the linear intercept method can be used to detect the deformed layer.

[0019] Depending on the material removal technology used, the average chemical composition and / or metallurgical phase (or number of phases) within the deformed layer may differ from the chemical composition and / or metallurgical phase (or number of phases) in the internal volume.

[0020] Deformation layers can exhibit phase differences of a kind and / or degree that are not detected in chronological phases (e.g., by using scanning electron microscopy (SEM)), such as twins, slip lines, and / or internal volumes.

[0021] The deformable layer can exhibit a microstructure as shown in the following (e.g., as determined by linear intercept analysis): the microstructure has a lower void density per unit volume relative to the adjacent region, and / or a gradient in the number or volume of voids compared to regions further away from the material removal location.

[0022] The deformable layer can exhibit the following microstructure (as determined by linear intercept analysis): the microstructure has a lower pore density per unit volume relative to the adjacent region, and / or a gradient in the number or volume of pores compared to regions further away from the material removal location.

[0023] The deformable layer may exhibit an average pore size that differs from the average pore size of the internal volume as measured by the linear intercept method (e.g., a lower average pore size). The average pore size (over the thickness of the deformable layer perpendicular to the exposed cavity wall surface) may differ from (e.g., be lower than) the average pore size within the internal volume by at least 10%, 15%, 20%, 40%, or 60%. For example, the average pore size obtained at N distinct representative locations (as previously defined) throughout the thickness of the deformable layer may differ from (e.g., be lower than) the average pore size obtained at N distinct representative locations across the cross-section within the internal volume by at least 10%, 15%, 20%, 40%, or 60%.

[0024] The deformable layer can have an average thickness greater than 30 micrometers, 50 micrometers, 70 micrometers, 85 micrometers, 100 micrometers, or 200 micrometers. The deformable layer can have an average thickness less than 500 micrometers, 425 micrometers, 350 micrometers, or 275 micrometers.

[0025] Therefore, the mold body may include an internal volume of porous material disposed between the deformable layer and the inner surface. The thickness of the deformable layer is measured from the exposed outer cavity surface inward (e.g., toward the internal volume).

[0026] On the circumference of a cylindrical mold component, more than one cavity is arranged in a row, preferably extending parallel to the axis of rotation of the cylindrical mold component. However, the row may also be arranged at an angle relative to the axis of rotation. The cylindrical mold component preferably includes more than one row, for example, 2 to 12 rows, wherein during production, each row is simultaneously filled with food raw material, and the cavities in a row are simultaneously emptied. The shape of the cavities in a row can vary. The shape and number of cavities between two rows can also vary.

[0027] The mold component further includes a gas supply section or is fluidly connected to a gas supply section, which forces gas through an internal volume (e.g., through a porous structure and / or channels configured within the internal volume) and a deformation layer into the cavity to aid in the removal of the molded product from the mold cavity. The gas is typically air or nitrogen.

[0028] At least through the porous structure of the mold components, the cavity can be emptied during filling.

[0029] The mold component is preferably a mold roller in which the food material is molded and rotates about the longitudinal axis of the mold roller. After molding, the molded product is removed from the cavity, and the cavity can be refilled. The cavity can be defined within a fully or partially porous material (e.g., sintered material or pressed (e.g., hot-pressed or isostatically pressed) material), such as plastic, ceramic, or metal, preferably an ferrocontaining material containing molybdenum, nickel, chromium, or both, such as ferritic stainless steel, austenitic stainless steel, and / or martensitic stainless steel. Through such a porous material, the molded product can be jetted with gas (or other fluid), and / or during filling, the cavity can be emptied through the porous material, for example, by allowing fluid to flow through the pores in the porous material.

[0030] During production, the rollers rotate continuously or intermittently. At one position, the product cavities in a row are filled with food material, while at a downstream position, the molded food material is discharged from the product cavities in the same row. If the row is angled, the cavities in the row are subsequently partially or completely filled. The product cavities in the row can then be filled again, and so on. To empty the product cavities before and / or during and / or after filling, and / or to support the discharge of the product, the product cavities are at least partially, preferably entirely, made of a porous material, such as sintered metal, sintered ceramic, or plastic, which is permeable to allow the product cavities to be emptied or to allow the release of gases, such as air, to loosen the molded product from the surface of the product cavities. Preferably, the porous material includes interconnected pores (and optional channels). The food molding roller further preferably includes fluid channels that preferably extend in the longitudinal direction of the roller (in a straight, spiral, or other manner), i.e., parallel to or at an angle to the central axis of the roller, and preferably extend from one end of the roller to the other. Through each fluid channel, ventilation fluid (e.g., a gas such as air, nitrogen, or other gases) can be discharged into, for example, the surrounding environment during cavity filling, and / or compressed gas can be forced into the cavity to expel the molded product. Additionally, cleaning fluid can be forced through channels and / or pores (and optional channels) in the porous material of the product cavity.

[0031] Before, during, and / or after filling the cavity with food material, the cavity is sealed with a sealing member, such as a sealing plate, to prevent unwanted food block leakage. This sealing member seals against the surface of the mold component, for example, against the outer circumference of the mold roller. The sealing member is preferably a sealing plate whose length preferably extends along the entire axial length of the roller. In the circumferential direction, the sealing plate preferably covers the circumferential length of one cavity. However, more preferably, the sealing plate is longer than the circumferential length of the cavities in a row. Preferably, the sealing plate includes an opening, preferably a groove, which preferably extends along the entire axial length of the roller. Food material is filled into the mold cavity through this opening. Preferably, the sealing member is flexible (in terms of material properties and / or as a structure), such that the sealing member can elastically deform under load (and subsequently return to its shape before the load is applied) and compensate for irregularities at the roller surface, and / or preferably allows a gap to form between the sealing member and the surface of the mold component due to the pressure of the gas to be discharged. More preferably, the sealing member presses at least partially against the surface of the mold component.

[0032] Typically, cavities are formed by removing material from a porous mold body. The cavity can be machined into the porous mold body, for example by milling, preferably by co-rotating milling, conventional milling, and / or zigzag milling (alternating co-rotating and conventional milling). In the case of a 2D cavity, the final surface milling step of the cavity bottom wall will preferably be zigzag milling, and the cavity sidewalls will preferably be material removed by co-rotating milling and / or conventional milling. In the case of a 3D cavity, the sidewalls can be material removed in the final surface milling step, preferably by conventional milling. The cavity sidewalls may have one or more inclined surfaces relative to the wall defining the bottom of the cavity. The angle of the cavity sidewalls relative to the plane intersecting the bottommost position of the cavity may be 10 to 90°. Although less preferred, material removal can be achieved by other techniques, such as spark erosion.

[0033] The bottom wall can be planar, curved, or contoured. In the case of a 2D cavity, the bottom wall is preferably curved and has a radius that is preferably the radius of the outer circumference of the roller minus the depth of the cavity. This gives the product at least substantially a constant thickness. In the case of a 3D cavity, the bottom wall is contoured and the bottom wall and side walls are fused together. This gives the product thickness that varies along its length and / or width.

[0034] During machining, a deformable layer is preferably formed, wherein the machining tool deforms a portion of the porous structure of the mold component. The internal volume has the porous structure of the mold body prior to machining. Because the porous structure is compressed / deformed during machining, the flow resistance of the deformable layer (e.g., per unit length extending outward from the inner surface of the mold component toward the bottom wall of the cavity, per unit length extending longitudinally toward the sidewalls of the cavity within the internal volume, or both) is preferably higher than the flow resistance of the internal volume.

[0035] After machining, it may be necessary to remove all or part of the deformed layer to alter its flow resistance. This can be achieved through etching, electropolishing, and / or spark erosion.

[0036] The flow resistance can also be altered after complete or partial removal of the deformed layer. For example, a material addition step can be employed after the step of removing the deformed layer. Material addition can be used to add a certain amount of material to the outer surface of one or more walls defining the cavity. The added material can include polymers, ceramics, and / or metals. The added material can include materials having the same chemical composition as the porous structure of the mold component. The added material can also include materials having a different chemical composition than the porous structure of the mold component, but such materials are selected to prevent the formation of brittle corrosion byproducts at the food-contact portions of the formed cavity surface. The added material can be added by coating, impregnation, spraying, wiping, brushing, electroplating, chemical and / or physical vapor deposition, additive manufacturing (e.g., 3D printing), or other methods. The material can be added in a manner that defines a porous layer. The porous layer can have a flow resistance that is the same as or different from (e.g., less than or greater than) the flow resistance of the internal volume.

[0037] As the airflow passes through the internal volume and the deformed layer, it encounters flow resistance. The average flow resistance of the deformed layer is assumed to be different from the average flow resistance of the internal volume. Therefore, the thickness of the deformed layer can be confirmed by measuring the flow resistance (as described herein) at each step of a series of surface material removal steps on the cavity wall up to a predetermined depth, after which no further change in flow resistance is observed.

[0038] The average flow resistance of the deformable layer can vary by an amount greater than 25%, 35%, or 45% of the average flow resistance of the internal volume. The average flow resistance of the deformable layer can be less than half or one-third of the flow resistance of the internal volume. According to the invention, the average flow resistance of the deformable layer can be up to 15%, 20%, or 30% of the flow resistance of the internal volume. It can be at least 1%, at least 3%, or at least 5% of the flow resistance of the internal volume. For example, it can be 1-30%, preferably 3-20%, more preferably 4-15%, and even more preferably 5-12% of the flow resistance of the internal volume.

[0039] The advantage of this inventive feature is that the total average flow resistance, i.e., the sum of the flow resistance of the deformable layer and the flow resistance of the internal volume, is relatively low, allowing the product to be discharged quickly and with relatively low energy consumption. Compared with the prior art, the filling pressure of the product is relatively low, and the mold components are easier to clean. The contribution of the deformable layer is low, but not too low, thus preventing, for example, fat or juice from entering the pores of the internal volume.

[0040] The total average flow resistance of each cavity (FR) Total Calculate according to the following formula:

[0041] FR Total = P / Q

[0042] in, P is the pressure drop [mbar] of the internal volume and the deformable layer, and Q is the corresponding gas flow rate [ln / min]. The pressure drop is provided, for example, in [mbar]. Q is the gas flow rate under steady-state conditions, in [ln / min]. "ln" is the volume of the gas, preferably N2 under standard conditions (e.g., 0°C and 1 bar).

[0043] For all flow resistance measurements, the cavity was empty and not filled with food blocks.

[0044] The total average flow resistance is preferably determined for each cavity at a given gas flow rate [ln / min], for example by directly measuring the pressure upstream of the internal volume and downstream of the cavity, such as within the cavity. The cavities are preferably isolated to prevent gas leakage and thus inaccurate measurements. The total average flow resistance is measured under steady-state conditions, particularly at a constant gas flow rate. The total average flow resistance is preferably the flow resistance of the internal volume and deformable layers of a cavity. The pressure drop is preferably averaged over a cavity. In most cases, measuring the pressure upstream of the internal volume is sufficient, as the pressure downstream of the cavity is at least substantially ambient pressure. The pressure drop is preferably an average value for each cavity, i.e., an average value taken over the sidewalls and bottom wall of a cavity. The pressure drop is determined, for example, according to NEN-EN-ISO 4022-2006. The pressure drop is measured with no product within the cavity.

[0045] Total flow resistance FR of deformable layer and internal volume Total Calculate using the following formula:

[0046] FR Total =FR1 + FR2

[0047] Wherein, FR1 is the flow resistance of the deformed layer, and FR2 is the flow resistance of the internal volume under the same gas flow rate.

[0048] To determine the individual flow resistances FR1 and FR2, in the first step, the total flow resistance FR is measured at a specific gas flow rate [ln / min] or several gas flow rates [ln / min]. Total Subsequently, the deformable layer was completely removed, leaving only the internal volume, and then compared with the volume used to determine FR. Total The flow resistance of the internal volume FR2 was measured at the same gas flow rate (s) [ln / min]. Based on these measurements, FR1 can be calculated using the following formula:

[0049] FR1 = FR Total - FR2

[0050] The measurement range for flow resistance is preferably 2-100 ln / min, and more preferably 5-50 ln / min. The gas selected is preferably air or nitrogen.

[0051] For example, before processing the cavity into a porous material, the complete removal of the deformed layer can be confirmed by comparing the porosity of the test specimen with that of the original material. This can be done quantitatively, for example, preferably by using confocal microscopy and / or topographic images obtained by scanning electron microscopy (SEM). For example, if the porosity of the opening surface of two samples is at least substantially the same as and / or comparable to the porosity of the cross-section, the deformed layer is removed. The deformed layer can be removed stepwise, for example, removing a few nanometers per step, and comparisons can be made after each removal step. A method for determining the porosity of the opening surface is explained below.

[0052] Additionally or optionally, the deformed layer can be removed in subsequent steps, for example, a few nanometers per step, and after each step, the total voltage drop is measured and compared with a previous total voltage drop measurement. As long as the deformed layer is not completely removed, the total voltage drop between two subsequent removal steps will decrease.

[0053] Once the deformed layer is completely removed, the pressure drop remains constant. Therefore, in addition to other distinguishing features discussed herein (e.g., pore size, porosity, etc.), another measurement can be used to reasonably and confidently determine the boundary between the internal volume and the deformed layer. That is, a sample with both a deformed layer and an internal volume can be provided. The deformed layer can be gradually removed (e.g., by controlled spark erosion and / or electropolishing operations for a series of incremental material removal steps) while monitoring the pressure drop of the gas passing through the internal volume. The internal volume is reached when the pressure drop measurement no longer shows any effect caused by the deformed layer (e.g., the pressure drop remains constant).

[0054] FR2, which represents the pressure difference between the upstream and downstream sides of the cavity and the adjacent internal volume, can then be measured. Based on these measurements, FR1 can be calculated using the formula provided above.

[0055] As described above, the deformed layer will be removed for measurement purposes. The thickness of the layer depends primarily on the nature of the porous structure and the manner in which the cavities are generated (milling tool, milling parameters, forces during the milling process), and can vary from 0.05 mm to 1 mm, preferably from 0.1 mm to 0.2 mm.

[0056] The removal of the deformed layer is preferably performed by electropolishing and / or electrical discharge machining (EDM) and / or by etching. To ensure that the deformed layer is completely removed during measurement, sufficient material should be removed. For the determination of FR1, the accompanying reduction in the thickness of the internal volume is preferably ignored.

[0057] This problem is also solved by the present invention or a preferred rotary cylindrical mold component, wherein the average open surface porosity (preferably expressed as a percentage of total area) of the outer surface of the deformable layer is greater than 10% to 40%, and more preferably 15% to 35%. Therefore, the average open surface porosity of the deformable layer can be higher than 10%, 12% or higher, 15% or higher, or 20% or higher. The average open surface porosity of the deformable layer can be 40% or lower, 35% or lower, or 30% or lower.

[0058] The disclosure made in connection with this embodiment of the invention is also applicable to other embodiments, and vice versa. The subject matter disclosed in the context of this embodiment of the invention may also be included in other embodiments, and vice versa.

[0059] As shown, many features involve determining porosity or size using the linear intercept method. More specifically, those skilled in the art will recognize that using ASTM-E112-13 and treating “porosity” (or any other measurement target) in the same way that those skilled in the art treat “grains” in this method will provide measurements according to the teachings of the present invention.

[0060] For example, using techniques from ASTM-E112-13 (e.g., on a cross-sectional SEM image or on a SEM surface image), the average open porosity can be determined. By way of general instruction (not intended to replace standard inspection), when applying the linear intercept method, a line is plotted on the image of the porous structure, and the length of the pores intercepted by that line is determined. The linear porosity is calculated using the following formula:

[0061] Linear porosity = Total length of the pores cut from the line / Total length of the line

[0062] The linear porosity of the deformed layer is preferably determined at the bottom wall and sidewalls, preferably at one or more cross-sections of the bottom wall and sidewalls, and preferably at one or more locations on the cross-sections of the sidewalls. To determine the porosity in the cross-sections, the cavity is preferably cut open.

[0063] Preferably, the average porosity (e.g., measured by the linear intercept method) in a planar cross-section obtained by taking a cross-section perpendicular to the longitudinal axis of the mold roller can be 15-50%, preferably 20-45%. Therefore, the average porosity of the internal volume can be higher than 15% or higher than 20%. The average porosity of the internal volume can be 50% or lower, 45% or lower, or 40% or lower.

[0064] According to another preferred or inventive embodiment of the invention, the average aperture of the internal volume is determined by the linear intercept method to be 30-110µm (e.g., as measured in a planar cross-section obtained by taking a cross-section perpendicular to the longitudinal axis of the mold roller).

[0065] For example, as in this application, according to Figure 3 As explained, according to the linear intercept method, the average hole size can be measured by dividing the total intercept length (using an image derived from the cross-section of the internal volume) by the number of holes.

[0066] The disclosure made in connection with this embodiment of the invention is also applicable to other embodiments, and vice versa. The subject matter disclosed in the context of this embodiment of the invention may also be included in other embodiments, and vice versa.

[0067] Preferably, the cavity is a 2D cavity having a porous bottom wall and porous side walls that are at least substantially curved. A 2D cavity is a cavity that forms a product with a constant thickness over its entire width and length. Examples of 2D products are discs, hamburger patties, etc.

[0068] According to one embodiment of the invention, the plastic deformation caused by forming a porous sidewall can be different from (e.g., higher than) the plastic deformation caused by forming a porous bottom wall. This may result in different properties or other characteristics of the sidewall compared to the bottom wall (e.g., higher flow resistance). The difference in plastic deformation of the sidewall compared to the bottom wall can be intentional and can be achieved through different processing techniques.

[0069] Differences in plastic deformation caused by the formation of these walls can lead to differences in the thickness of the deformed layer, the amount of average surface porosity in the wall, the average pore size in the deformed layer, or any combination thereof, such as the difference between the deformed layer associated with the sidewalls of the cavity and the deformed layer associated with the bottom wall. The value of any such parameter of the sidewall deformed layer can be 0.1 to 3 times, or preferably 0.5 to 1.5 times, the value of the bottom wall deformed layer.

[0070] According to another inventive embodiment or preferred embodiment of the present invention, the cavity is a 3D cavity, which includes at least a contoured bottom wall.

[0071] The disclosure made in connection with this embodiment of the invention is also applicable to other embodiments, and vice versa. The subject matter disclosed in the context of this embodiment of the invention may also be included in other embodiments, and vice versa.

[0072] 3D cavities allow for the production of molded products with varying thicknesses across their width and / or length. A contoured bottom wall will give one side of the product a 3D shape, such as a half-egg, a hemisphere, or a cylinder cut along a central axis. Another example of a 3D product is the Chicken Premier. When the sealing plate is also contoured, 3D products such as sausages or products with pentagonal, hexagonal, heptagonal, or more cross-sections can be achieved. The cross-sections are perpendicular to the longitudinal extension of the product.

[0073] In a preferred embodiment of the 3D cavity (preferably, also including the 2D cavities discussed above), the average open surface porosity of the deformable layer is 11-40%, preferably 15-35%. (The average open surface porosity of the deformable layer is also the open surface porosity of the cavity walls (bottom wall and / or sidewalls). The average open surface porosity of the deformable layer can be 11% or higher, 15% or higher, or 20% or higher. The average open surface porosity of the deformable layer can be 40% or lower, 35% or lower, or 30% or lower.

[0074] Alternatively, the aperture size of the internal volume is preferably 10-100µm. The average aperture size can be at least 40µm, more preferably at least 50µm. The average aperture size can be less than 90µm, more preferably less than 80µm.

[0075] As with other material characteristics described herein, the following applies explicitly to both 2D and 3D cavities, and particularly to all embodiments of the invention.

[0076] Preferably, the thickness of the deformable layer is 0.05-1 mm, and more preferably 0.1-0.2 mm.

[0077] Preferably, at a gas flow rate (e.g., air or N2 flow rate) of 50 ln / min, the average total pressure drop per cavity is 300-400 mbar. Preferably, at a gas flow rate (e.g., air or N2 flow rate) of 20 ln / min, the average total pressure drop per cavity is 120-160 mbar.

[0078] It can be seen that a mold roller with a porous structure can be obtained, which is defined as including a continuous fluid flow path from the inner volume outward through the wall of the defined cavity, so that the fluid passing through the deformation layer from the inner volume exhibits an increased velocity in the deformation layer relative to the velocity of the fluid in the inner volume.

[0079] It can also be seen that a mold roller with an internal volume and a cavity for food can exist, the mold roller including a deformable layer formed by plastic deformation, preferably formed by milling operations, and wherein the average flow resistance (FR1) of the deformable layer is different from the average flow resistance (FR2) of the internal volume, and / or (i) the average flow resistance (FR1) of the deformable layer is, as described elsewhere herein, for example, preferably 1-30% of the average flow resistance (FR2) of the internal volume, more preferably 3-20%, even more preferably 4-15%, and still more preferably 5-12%. The deformable layer may have an average surface porosity as described elsewhere herein; for example, an average surface porosity greater than 11%, more preferably in the range of 20% to 40%. The internal volume and the deformable layer may each have any one or other characteristics described elsewhere herein with respect to their thickness, porosity, pore size. Attached Figure Description

[0080] The invention will now be explained with reference to the accompanying drawings. These explanations also apply to all embodiments of the invention. These explanations do not limit the scope of protection of the invention.

[0081] Figure 1 The mold components of the present invention are described.

[0082] Figure 2 The cross-section of the cavity is depicted.

[0083] Figure 3 The determination of linear porosity and linear pore intercept length is described.

[0084] Figure 4 The cavity of the test sample was depicted.

[0085] Figure 5 This is a photomicrograph of an exemplary cross-section of a mold roller.

[0086] Figure 6 This is another micrograph showing the presence of slip lines, which are characteristic of the deformed layer.

[0087] Figure 7 These are low-magnification (30x) microscopic images of the cavity bottom surface and high-magnification (200x) images of the cavity bottom surface. Detailed Implementation

[0088] Figure 1A cylindrical mold component 1 of the present invention, a roller, is shown, comprising a porous mold body 6, in this example a cylindrical mold body 6 made from a single piece. The porous mold body 6 is made of a sintered metal material, such as stainless steel, preferably 1.4404 stainless steel. The mold body includes a plurality of cavities 2 at its outer circumference 5, which are machined, preferably milled, within the porous mold body. The cavities may have, but do not necessarily have, different shapes. The roller 1 rotates during production, and at one rotational position, such as the 12 o'clock position, a feed member (not shown) is provided to fill the cavities, and at a downstream position, such as the 6 o'clock position, a discharge device (not shown) may be provided to empty the cavities. After the cavities are emptied, they can be refilled. The cavities are arranged in rows 9, here ten rows, each row having a plurality of cavities 2, here sixteen cavities. The cavities in a row are simultaneously filled and emptied. The cavitation of the cavity is supported by air (or another gas, such as nitrogen), which is forced through the porous body at the venting position and / or from its upstream to expel the molded product. Therefore, the cylindrical mold component is provided with channels 7, one channel per row, extending below the porous body, the so-called internal volume, beneath one cavity. In the venting position, the channels are connected to a fluid source (e.g., an air source), which forces fluid (e.g., air or nitrogen) through the channels and the internal volume into the cavity, thereby removing the molded product from the cavity. Each cavity includes a porous bottom wall 3 and porous side walls 4. At the outer circumference 5 of the roller, the holes in the porous mold body are closed, for example, by deep rolling with a rolling element.

[0089] Figure 2 A schematic representation of half a cross-section of cavity 2 is shown, having sidewalls 4 and a bottom wall 3 that together form the boundary of the cavity, and an internal volume 10 below the cavity. Cavity 2 has been milled within a porous mold body 6. The inner surface 11 of the porous mold body 6 contacts a channel 7 that supplies fluid (e.g., air, nitrogen, another gas, or a cleaning fluid) to cavity 2. As indicated by reference numeral 8, during milling, a deformed layer is formed at the boundary of the cavity, and at both the sidewalls 4 and the bottom wall 3. The deformed layer at the sidewalls preferably differs from the deformed layer at the bottom wall in terms of thickness and / or linear porosity. To remove the product from cavity 2, gas, preferably air or nitrogen, is supplied through channel 7 (indicated by 7) to the inner surface of the mold body, then through the internal volume 10, and then through the deformed layer 8 at the sidewalls 4 and the bottom wall 3 into cavity 2. The same applies to cleaning fluid.

[0090] Figure 4The test sample cavity 12 used to obtain experimental data is shown. All dimensions are in mm. The porous mold body 6 is made of sintered stainless steel 1.4404 and, as can be seen in the right-hand view, is slightly curved. The porous mold body 6 is hermetically sealed at its outer circumference 5 and its four sidewalls 14, here by compressing the porous material at the surface. No seal is applied at the inner surface 11 of the porous mold body. The area of ​​the inner surface here is 2348.69 mm². 2 Subsequently, cavity 2 is machined into the porous mold body, here by milling starting from the outer circumference 5. The cavity includes a bottom wall 3 and side walls 4, the bottom wall 3 being a curved bottom wall. The surface area of ​​the bottom wall is 1472.18 mm. 2 The surface area of ​​the sidewall is 1040.92 mm. 2 Although described as relatively precise dimensional values, the teachings herein also include relatively proportional dimensional values. Therefore, to describe this embodiment in another way, the ratio of the relative surface areas of the bottom wall to the side walls could be 1.4:1. For example, this value could deviate to a range of 1:1 to 2:1.

[0091] The cavity here has a depth of 7.5 mm. After insertion into the cavity, an internal volume with a depth of 14.5 mm is left between the cavity and the inner surface 11 of the porous mold body. Due to the machining of the cavity, a deformable layer that contacts the product (not shown) is formed at the boundary of the cavity.

[0092] To determine the flow resistances FR1 and FR2 of the deformable layer 8 and the internal volume 10, respectively, firstly, the pressure drop of the steady-state airflow Q passing through the porous mold body from the inner surface 11 to the cavity 2, as shown by arrow 13, is measured. P, preferably the pressure drop of air or nitrogen. P is used to determine the total flow resistance FR of both the deformable layer 8 and the internal volume 10. Total The total pressure drop includes the pressure drop of the constant airflow through the internal volume and deformable layer 8. The pressure drop is averaged over the entire cavity, specifically the average of the pressure at the bottom and sidewalls over the entire test cavity. In this example, only the gas pressure below the inner surface 11 is measured, and it is assumed that the gas pressure downstream of the compression layer is ambient pressure; this ambient pressure is subtracted from the measured pressure at the inner surface 11 to calculate the pressure drop. P. Then calculate the total flow resistance using the following formula:

[0093] FR Total = P / Q

[0094] in, P represents the internal volume and the pressure drop across the deformable layer, while Q represents the corresponding gas flow. The pressure drop is set in units such as [mbar]. Q is the gas flow rate under steady-state, constant conditions, in units of [ln / min]. "ln" represents the volume under standard conditions, i.e., 0°C and 1 bar.

[0095] Subsequently, the compression layer is removed, for example, by electropolishing and / or EDM, and the flow resistance is then determined again at the same gas flow rate Q in [ln / min] used to measure the total pressure drop, in order to determine the pressure drop across the entire internal volume. P2. This data is used to calculate the flow resistance FR2 of the internal volume using the following formula:

[0096] FR2= P2 / Q

[0097] in, P2 is the pressure drop across the internal volume, and Q is the pressure used for measurement. The same gas flow rate of P, in units of [ln / min].

[0098] The flow resistance FR1 can then be calculated as follows:

[0099] FR1 = FR Total - FR2

[0100] The measurement range for flow resistance is preferably 2-100 [ln / min], more preferably 5-50 [ln / min]. The gas selected is preferably air or nitrogen. Preferably, measurements are performed over different volumetric flow rate ranges, for example, in increments of 10 [ln / min], from 10 to 50 [ln / min]. All data are obtained under constant gas flow rates; that is, the gas flow rate does not change during the measurement (static flow conditions).

[0101] according to Figure 3This diagram illustrates the determination of linear porosity using a linear intercept length (to briefly illustrate the linear intercept method described in ASTM-E112-13). The schematic depicts a porous cross-section along which an artificial line is drawn, representing the total measured length [mm]. The diagram depicts what a technician might see when inspecting the sample using a micrograph prepared using conventional metallographic techniques. The described technique can be implemented using a micrograph of a metallographic test sample prepared using conventional techniques for analyzing dense powdery metal parts. In this example, the line intersects eight holes. Lengths L1–L8 are measured individually for each hole, the sum ∑L1–L8 is calculated, and then divided by the total measured length to obtain the linear porosity. This process can be repeated several times, and the average value of the compressed layer and the average value of the internal volume can be determined. In the deformed layer and / or internal volume, the linear intercept length can be applied to an image of the surface of the deformed layer and / or a cross-section of the porous die body.

[0102] This method can be used to determine the average linear intercept length, which is equal to the average aperture size, and therefore the above disclosure also applies. Figure 3 The document also provides a formula for calculating the average intercept length.

[0103] Figure 5 These are annotated photomicrographs showing a cross-sectional portion of a mold roller with a cavity and internal volume. The exposed bottom surface of the cavity is depicted. A deformable layer extends from the bottom surface of the cavity, beneath which lies the internal volume. It can be seen that the deformable layer in this photomicrograph is characterized by a significantly lower porosity than the internal volume.

[0104] Figure 6 This is another annotated photomicrograph depicting the presence of slip lines (the sample was appropriately etched and then examined by scanning electron microscopy). The presence of slip lines is a feature that, according to this teaching, can be expected to exist within the deformation layer but not within the internal volume of the mold roller. Figure 6 As shown, as one moves inward from the surface of the cavity wall, the presence of slip lines decreases and eventually disappears.

[0105] Figure 7 Scanning electron microscope images at low magnification (30x) and high magnification (200x) are shown to illustrate the openings and pores in the cavity wall surface (e.g., the cavity bottom wall). A network of interconnected pores can be seen penetrating into the mold body towards the internal volume.

[0106] List of reference numerals in the attached diagram:

[0107] 1. Cylindrical mold component, roller

[0108] 2. Cavity of porous products

[0109] 3 Porous bottom wall

[0110] 4 Porous sidewalls

[0111] 5. Outer circumference

[0112] 6. Mold body

[0113] 7 channels

[0114] 8 Deformation layer

[0115] 9. Cavity drain

[0116] 10 Internal volume

[0117] 11 Inner Surface

[0118] 12 Test sample cavity

[0119] 13 Gas Flow

[0120] 14. Sidewalls of the test sample

[0121] Flow resistance of FR1 deformed layer

[0122] Flow resistance of the internal volume of FR2

[0123] FR Total Total flow resistance FR1+FR2

[0124] P pressure drop measurement value

Claims

1. A rotary cylindrical mold component (1) for molding products from food ingredients including poultry, pork, meat substitutes, and vegetarian ingredients, said mold component (1) having a longitudinal axis (A) and an outer circumference (5), comprising at least one mold body (6) having a curved outer surface forming at least a portion of the outer circumference of said mold component (1) and opposing inner surfaces (11), wherein said mold body is made of a porous material with a porous structure having interconnected holes, wherein said outer circumference is at least partially hermetically sealed, wherein each mold body (6) includes food ingredients molded therein. At least one cavity (2) is formed in a curved outer surface, the cavity including a deformable layer (8) at its porous bottom wall (3) and / or its porous sidewalls (4) and / or its boundaries, the deformable layer (8) being formed by plastic deformation, the mold body including an internal volume (10) disposed between the deformable layer (8) and the inner surface (11), the mold component further including a gas supply section that forces fluid gas through the internal volume (10) and the deformable layer (8) into the cavity to aid in the removal of the molded product from the cavity, characterized in that, The average flow resistance (FR1) of the deformable layer is 1-30% of the average flow resistance (FR2) of the internal volume.

2. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The deformed layer (8) is formed by a milling operation.

3. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average flow resistance (FR1) of the deformable layer is 3%-20% of the average flow resistance (FR2) of the internal volume.

4. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average flow resistance (FR1) of the deformable layer is 4%-15% of the average flow resistance (FR2) of the internal volume.

5. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average flow resistance (FR1) of the deformable layer is 5%-12% of the average flow resistance (FR2) of the internal volume.

6. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average porosity of the internal volume is 15%-50% of the volume.

7. The rotating cylindrical mold component (1) according to claim 6, characterized in that, The average porosity of the internal volume is 20%-45% of the volume.

8. The rotating cylindrical mold component (1) according to claim 6, characterized in that, The average porosity of the internal volume is greater than 25% and not greater than 50% of the volume.

9. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average pore size of the internal volume is 10-100µm.

10. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average pore size of the internal volume is 40-110µm.

11. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average hole size of the internal volume is determined using the linear intercept method.

12. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The cavity is a 2D cavity with a porous bottom wall (3) and a porous side wall (4).

13. The rotating cylindrical mold component (1) according to claim 12, characterized in that, The bottom wall is curved.

14. The rotating cylindrical mold component (1) according to claim 12, characterized in that, Based on area, the average open surface porosity of the deformable layer of the cavity wall is greater than 10%.

15. The rotating cylindrical mold component (1) according to claim 12, characterized in that, Based on area, the average open surface porosity of the deformable layer of the cavity wall is 15-35%.

16. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The plastic deformation of the porous sidewall is higher than that of the porous bottom wall.

17. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The cavity is a 3D cavity that includes at least a contoured bottom wall.

18. The rotating cylindrical mold component (1) according to claim 7, characterized in that, The average porosity of the deformed layer is 10-50%.

19. The rotating cylindrical mold component (1) according to claim 7, characterized in that, The average porosity of the deformed layer is 20-40%.

20. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The average thickness of the deformable layer on the cavity sidewalls and / or cavity bottom wall is 0.05-1 mm.

21. The rotating cylindrical mold component (1) according to claim 20, characterized in that, The average thickness of the deformable layer on the cavity sidewalls and / or cavity bottom wall is 0.1-0.2 mm.

22. The rotating cylindrical mold component (1) according to claim 1, characterized in that, At a gas flow rate of 50 ln / min, the total average pressure drop of each cavity is 300-400 mbr.

23. The rotating cylindrical mold component (1) according to claim 1, characterized in that, When the gas flow rate of air or N2 is 50 ln / min, the total average pressure drop of each cavity is 300-400 mbr.

24. The rotating cylindrical mold component (1) according to claim 1, characterized in that, At a gas flow rate of 20 ln / min, the total average pressure drop of each cavity is 120-160 mbr.

25. The rotating cylindrical mold component (1) according to claim 24, characterized in that, When the gas flow rate of air or N2 is 20 ln / min, the total average pressure drop of each cavity is 120-160 mbr.

26. The rotating cylindrical mold component (1) according to claim 1, characterized in that, The total average flow resistance is 102-120% of the average flow resistance (FR2) of the internal volume.

27. The rotating cylindrical mold component (1) according to claim 26, characterized in that, The total average flow resistance is 105-115% of the average flow resistance (FR2) of the internal volume.

28. The rotating cylindrical mold component (1) according to claim 1, characterized in that, A porous structure is defined, which defines a continuous fluid flow path from the internal volume outward through the wall defining the cavity. A Venturi effect is achieved through a deformable layer of the cavity, thereby increasing the velocity of the fluid from the internal volume through the deformable layer relative to the velocity of the fluid in the internal volume.

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