System and method for molding and using a patterned molded seal film

Abstract

A method is disclosed that allows a formed seal film to be embossed in various shapes (such as geometric, organic, or fractal shapes and / or combinations of shapes) and various sizes and depths. A texture or pattern is transferred from an insert to the film. During the formed-fill-seal and maturation, the pattern on the formed seal film is re-transferred to various protein surfaces, including but not limited to chicken, turkey, beef, pork, and plant proteins. Formed and / or seal inserts can form various thermoformed films with functional and / or decorative raised and / or recessed features without the need to use a knit mesh, a stretch mesh, an extruded mesh, a dense mesh, a plastic mesh, and / or a compression forming mold and / or a release agent to remove the mesh. Formed inserts are built using an additive manufacturing process, so virtually any design can be embossed into the formed seal film.

Description

[0001] Priority document

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 235,899, filed on August 23, 2021, the entire contents of which are incorporated herein by reference. Background Technology

[0003] Typically, people want to imprint designs onto the surface of meat to showcase its appearance, texture, and ability to retain specific spices or seasonings. Encasing protein in a mesh during the aging process to create an imprint on the surface can also enhance the product's texture. However, this process is wasteful because the mesh is discarded after aging. Therefore, there is a need for a molded sealing film that can directly imprint designs onto protein without requiring additional materials (such as mesh). Summary of the Invention

[0004] This invention allows molded sealing films to be embossed into various shapes (such as geometric, organic, or fractal shapes and / or combinations thereof) and various sizes and depths. Textures or patterns are transferred from the insert to the film. During molding-filling-sealing and curing, the pattern on the molded sealing film is further transferred to various protein surfaces, including but not limited to chicken, turkey, beef, pork, and plant proteins. Molded and / or sealing inserts can be molded into a variety of thermoformed films with functional and / or decorative raised and / or recessed textures without the need for woven mesh, elastic mesh, extruded mesh, densely woven mesh, plastic mesh, and / or compression molding dies and / or release agents to remove the mesh. The molded inserts are constructed using additive manufacturing processes, so virtually any design can be embossed onto the molded sealing film. Attached Figure Description

[0005] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate one or more aspects of the invention and are further used to explain the principles of the invention in conjunction with specific embodiments, thereby enabling those skilled in the art to make and use the invention.

[0006] Figure 1 An embossed film with raised printing on the inner side of the molded film is depicted.

[0007] Figure 2 The indentations transferred onto the protein during ripening are depicted.

[0008] Figure 3 The indentation on the inside of the molded film is depicted.

[0009] Figure 4 The raised marks transferred onto the protein during ripening are depicted.

[0010] Figures 5A to 5E An example depicting a pattern for a molded film application.

[0011] Figure 6 depicts a flowchart illustrating the steps used during standard packaging and curing.

[0012] Figure 7 A flowchart illustrating the steps used in the wrapping and curing process according to the present invention is provided.

[0013] Figures 8 to 10 One embodiment of the molded insert is depicted.

[0014] Figures 11 to 12 Another embodiment of the molded insert is described.

[0015] Figure 13 The molded film removed from the molded insert is depicted.

[0016] Figure 14 An example of a mature protein after the molding membrane is removed is depicted.

[0017] Specific embodiments are described below with reference to the accompanying drawings. The features and advantages of the embodiments of this disclosure will become clearer from this description. Similar reference numerals in the drawings always identify corresponding elements. Similar reference numerals in the drawings generally indicate elements that are the same, functionally similar, and / or structurally similar. Unless otherwise stated, the drawings provided throughout this disclosure are not necessarily to be interpreted as being drawn to scale. Detailed Implementation

[0018] All standard molding-filling-sealing curing processes involve a single molding step. Typically, a single molding process comprises only a single film-forming step. In contrast, the method of this invention combines a single film-forming step and a two-stage film-forming step. The single film-forming step produces an embossed film, such as… Figure 1 As shown, the embossed film has raised printing on the inner side of the molded film.

[0019] A single-stage film-forming process is preferred for simulating functional and decorative meshing imprints that are transferred to the protein surface during curing. A single-stage thermoforming process transfers the imprint to the protein surface during curing, such as... Figure 2 As shown, these become indentations or depressions on the protein.

[0020] The secondary film-forming process involves pressing indentations into the inside of the forming film bag. The secondary thermoformed shape is created from the forming film material remaining during the "primary" thermoforming process. These indentations mimic the functional and decorative patterns that transfer to the protein surface during curing. Figure 3 ).

[0021] Secondary thermoforming indentations will be transferred to the surface of the protein, becoming raised or embossed marks. Figure 4 ).

[0022] The molded sealing film is formed using the following process. First, the film is unfolded onto a molding insert. The film is heated in a controlled manner to make it flexible and easy to imprint. Then, controlled high-pressure air is used to press the film into the molding insert. This gives the film the shape of the molding insert. The protein to be sealed is then placed on top of the film and inserted into the molding insert.

[0023] like Figures 5A to 5E As shown, any pattern can be formed on the molded insert and then transferred to the molded sealing film. Various patterns can include, but are not limited to:

[0024] • Mesh or mesh pattern – transferred from molded inserts to membranes and then to proteins ( Figures 5A to 5E );

[0025] • Logos – Company logos, watermarks, brand logos, 2D / 3D layers in text or protein ( Figure 5D );

[0026] • Patterns that mimic the natural appearance of other cooking methods (such as "grilling", "wrapping", "roasting", etc.) Figure 5C and Figure 5E );

[0027] • Intentional defects, used to distinguish between the true and natural state of a product.

[0028] The molding membrane can be shaped into any shape needed to encapsulate protein (e.g., football-shaped ham, Easter egg-shaped chicken, etc.). Different patterns can also be formed by combining various styles such as geometric, organic, fractal, square, rectangular, rhombus, hexagonal, scale-shaped, branching, and wavy.

[0029] Sealing process

[0030] Figure 6 illustrates a flowchart of the standard process for wrapping and curing protein. First, in step 602, the desired mesh is placed around the protein. This step is typically manual, as the protein needs to be manually placed into the mesh and sealed. Then, in step 604, the forming sealing film is formed into a film bag using a roll packaging machine. Specifically, the forming film is placed into a forming cavity to form the film bag, and thermoforming is used to shape the forming film into the desired shape.

[0031] Step 606: Place the mesh protein into a forming membrane bag. Step 608: Seal the membrane bag and vacuum process it to create an airtight encapsulation of the protein. Step 610: During curing, the pressure generated by the vacuum on the mesh causes the mesh pattern to transfer to the protein.

[0032] After protein ripening, the membrane bag is removed in step 612, and the web is removed in step 614. The membrane bag can be removed automatically in step 612, but the web removal in step 614 requires manual intervention.

[0033] The method of this invention eliminates many steps requiring manual intervention and web formation, resulting in a significant reduction in waste and manual intervention. As previously described, the method utilizes a molded sealing film with a web pattern, which is directly transferred to the protein during curing. This eliminates the need for steps 602 and 614, which require manual addition and removal of the web.

[0034] Figure 7 A flowchart illustrating the steps used in the wrapping and curing process according to the present invention is shown. First, in step 702, a molded sealing film is placed into a molded insert to form a membrane bag for the protein. Figure 8 A perspective view of the molded insert 802 is depicted. Figure 9 A top view of the molded insert 802 is depicted. As shown, the molded insert 802 includes a top having a molded cavity 804. A molded sealing film is placed above this cavity 804, and rapid airflow molding is used to conform the molded sealing film to this pattern. The sides of the molded insert 802 include multiple ventilation structures 806 to allow exhaust. The sides also provide structural support for the molded insert 802.

[0035] Figure 13 The image depicts a molded sealing film removed from the molding insert 802. As shown, the mesh pattern taken from the molding insert 802 is directly transferred to the molded film. The 3D pattern on the molded sealing film is then transferred to the protein during the curing process. Figure 14 This eliminates the need to apply or remove a network on the protein.

[0036] Molded insert 802 can be used Figure 10 The anchor 808 shown is coupled to the roll material. The molded insert 802 is placed into the roll material sealing box and anchored to ensure proper fit and prevent displacement during the molding process. Anchoring can be accomplished in several ways, including:

[0037] • Slots, latches, bolts, or any other securing function;

[0038] • Inserts lock into the molded or sealed box from any one or more sides, from the bottom and / or top.

[0039] After forming the membrane bag using the top and bottom molding inserts 802, in step 706, the protein is placed into the molding membrane bag. In step 706, the membrane bag is sealed and vacuum-treated to create an airtight envelope of the protein. In step 708, during curing, the 3D pattern on the molding seal is transferred to the protein. After the protein has cured, in step 710, the membrane bag is first removed. Because the protein is directly transferred from the molding seal, there is no need for screen printing to add an imprint to the protein. Figure 11 (Perspective) and Figure 12 (Top view) depicts additional examples of sealing inserts with different patterns.

[0040] Molded sealing film

[0041] Figure 7 The process shown is compatible with a variety of membranes, depending on the cavity size and the desired final shape and imprint. Some shapes may require variations, such as thinner or thicker membranes, adhesive inner membranes, porous membranes, or membranes pre-shrinked to different degrees. Combinations of membranes with varying sealing requirements may also be necessary. For example, the following types of membranes are compatible:

[0042] Polyethylene

[0043] Polypropylene

[0044] ·nylon

[0045] · Ethylene-vinyl alcohol copolymer

[0046] Barrier membrane

[0047] Layered membrane combination

[0048] The molded sealing film should be usable in a variety of temperature ranges: the molding design temperature range is 90℃~145℃, and the sealing temperature range is 130℃~160℃. Physical molding of the molded sealing film using the molding insert 802 can be accomplished using any known method, including plug-assisted molding, forced ventilation, forced ventilation / vacuum-assisted molding, layered temperature control zones, high-pressure rapid airflow molding, or explosive vacuum molding.

[0049] Molded inserts

[0050] The following materials can be used for additive manufacturing and creating sealing inserts 802:

[0051] • Metals (aluminum, chromium-nickel-iron alloy, steel, titanium or other nickel-based alloys)

[0052] Shapes can be created through deposition, sintering, or other melting processes;

[0053] It can meet product size specifications of up to 400×400×400 mm;

[0054] The material should be able to withstand final finishing processes, including wire cutting, drilling, slicing, electropolishing, and coating.

[0055] The final product should be able to withstand a pressure of 100-200 psi and a temperature of 150-200°C.

[0056] It may require surface treatment, including electroless nickel plating with PTFE, nickel polishing, or nickel PTFE.

[0057] · Resin

[0058] ο Resins are selected based on tensile strength and modulus, flexural modulus, impact strength, elongation, and heat distortion temperature;

[0059] It can be used in the creation, prototyping, and / or testing phases;

[0060] Shapes can be generated through stereolithography (SLA), digital light processing (DLP), or selective laser sintering (SLS);

[0061] The final product should be able to withstand a pressure of 100–200 psi and a temperature of 150–200 °C during the testing phase.

[0062] • Plastics (ABS, PLA, PETG, Nylon)

[0063] It can be used as a low-cost alternative for testing shape feasibility in the early prototyping and testing phases.

[0064] The final product should be able to withstand a pressure of 100–200 psi and a temperature of 150–200 °C during the testing phase.

[0065] As previously mentioned, the molded insert 802 can be developed in virtually any pattern. This allows for the creation of a design that reduces metal usage while achieving the desired ventilation and shape. The dimensions of the airflow ventilation structure 806, as well as primary and secondary molding, have not yet been used in the thermoforming process. Airflow / support structure design grid (see...) Figure 8 and Figure 10 The film can be controlled within a small area of ​​the molding insert 802 by embossing / gravure printing, thereby controlling the temperature and airflow of the film to meet the requirements of the selected molding sealing film.

[0066] The variable-angle ventilation design (which allows pressure variations to create deeper embossed film pockets in primary and secondary molding) was previously difficult to achieve easily using other methods. The different sizes of these primary and secondary variable-angle vents minimize or increase airflow. By adjusting the size of the ventilation on the primary and secondary molding inserts 802, embossing and debossing can be controlled, unlike screen printing.

[0067] For example, such as Figure 8 As shown, each molding insert has multiple ventilation structures, and the current molding insert (used in conjunction with Figure 6) is made of a solid material. Enhanced ventilation in molding insert 802 eliminates the need for liquid cooling of the molding chamber in step 604. Molding insert 802 also integrates more than one function into the physical component (sealing and pattern transfer).

[0068] The edge / leg support structure on the molding insert 802 allows for support and minimizes the material required for the grid structure, ventilation, and support. It provides the necessary strength to resist internal forces during molding and guides the molding insert 802 into the molding box held by the anchoring mechanism 808.

[0069] The overall profile of the molded insert 802, as well as the multi-stage film printing and film adhesion effects, can vary based on controls and different standards. The goal is to establish stable operating conditions for each "primary thermoforming" and "secondary thermoforming" unit so that most of the original unit volume is retained when exposed to heat treatment during the product curing cycle, and to establish operating conditions that produce "controlled shrinkage" to the "primary thermoforming" cavity shape 804 to provide sufficient packaging shrinkage force to ensure that the secondary thermoforming unit pattern is transferred to the product during the curing cycle. The following is a list of standards for the molding process that help control film shrinkage:

[0070] • Selection of thermoforming materials;

[0071] • Stability of thermoforming temperature;

[0072] Temperature control of thermoforming dies;

[0073] • Molding air pressure and molding time;

[0074] • Cooling time after molding.

[0075] Producing molded inserts

[0076] Additive manufacturing requires software to generate the molded insert 802, including the following options: converting the shape into a digital form via 3D scanning; designing the shape via CAD software; and controlling the machining machine for the sealing insert used in conjunction with the present invention.

[0077] 1. 3D Scan Reference Object – Scanning software can be used to scan and view control parts to start the entire project. This can be used for any object or shape that the user wants to scan and transform into a mold.

[0078] 2. CAD software - used to build a smooth topological mesh on the reference model scan in step 1, or to create a new model and generate conformal objects.

[0079] a. Continue creating a base patterned mesh on top of the smoothed retopological mesh (therefore there are two meshes);

[0080] b. Continue making three copies of the basic pattern grid:

[0081] i. Backup copy grid;

[0082] ii. Fill the copy grid;

[0083] iii. Use the bevel tool to create a mesh pattern and extrude the mesh.

[0084] 3. CAD software assistance - Use basic pattern grids to generate mesh patterns, substrate patterns, and support materials.

[0085] a. Assemble all the parts into a single model;

[0086] b. If feasible, and if the final output is to be used for metal 3D printing, then build the frame and fixing blocks;

[0087] c. Clean, retopologically reconstruct, fill holes, and reduce the number of faces to make exporting to the printer easier;

[0088] d. Includes all grid ventilation models, including each step 2a-2b;

[0089] e. Export the mesh (overall mold design).

[0090] 4. Slicing / Building Preparation Software - Import the final mesh to verify the overall mold, establish part orientation, support structure, layer thickness, timing, and other paths and settings determined by the molding geometry.

[0091] a. The build preparation software will generate an .STL or local file, which the 3D printer will use as instructions to produce the final usable part.

[0092] It should be understood that the above embodiments illustrate certain applications of the subject matter principles of the present invention. Many modifications can be made by those skilled in the art without departing from the spirit and scope of the claimed subject matter, including combinations of features separately disclosed or claimed herein. Therefore, the scope of protection of the present invention is not limited to the foregoing description, but should be referred to the appended claims. It should also be understood that the claims may relate to features of the present invention, including combinations of features separately disclosed or claimed herein.

Claims

1. A method for forming and using a patterned sealing film, comprising the following sequential steps: Place the molded sealing film on the upper molded insert. in, The upper molded insert includes: A central cavity with a three-dimensional embossed pattern; Multiple ventilation structures surrounding the central cavity are used to create a vacuum within the central cavity, and An anchoring portion for anchoring the upper molded insert to the molding box during the molding of the patterned sealing film; Using the upper molding insert, the upper film is formed from the molding sealing film, wherein the three-dimensional embossed pattern is transferred from the central cavity to the upper film during molding; The lower film is formed in the lower molding insert; The upper film and the lower film are combined to form the patterned sealing film; The protein is placed into the patterned sealing membrane; The protein in the patterned sealing film is vacuum-treated and sealed. The patterned sealing membrane applies pressure to the vacuum-treated protein, and the protein in the patterned sealing membrane is cured at the required curing temperature. During the curing process, the three-dimensional embossed pattern is transferred from the patterned sealing film to the protein solely through vacuum pressure applied to the protein from the vacuum between the protein and the patterned sealing film at the curing temperature. The patterned sealing film is removed from the protein after the protein has matured.

2. The method according to claim 1, wherein, The three-dimensional embossed pattern includes multiple raised areas and multiple recessed areas.

3. The method according to claim 1, wherein, The three-dimensional embossed pattern is a mesh pattern.

4. The method according to claim 1, wherein, The three-dimensional embossed pattern includes a company logo or graphic.

5. The method according to claim 1, wherein, The upper molded insert is made of aluminum.

6. The method according to claim 5, wherein, The upper molding insert also includes an anchoring portion for anchoring the upper molding insert to the molding box during the molding of the upper film.

7. The method according to claim 6, wherein, The upper film does not require liquid cooling of the forming box.

8. A method for forming and utilizing a patterned sealing film, comprising: A molded sealing film is placed on an upper molded insert, wherein the upper molded insert comprises: A central cavity with a three-dimensional embossed pattern; Multiple ventilation structures surrounding the central cavity are used to create a vacuum within the central cavity; and An anchoring portion for anchoring the upper molded insert to the molding box during the molding of the patterned sealing film; Using the aforementioned upper molded insert, the upper film is formed from the molded sealing film. During the molding process at a molding temperature of 90-145℃, the three-dimensional embossed pattern is transferred to the upper film. The lower film is formed from the sealing film in the lower molding insert. The upper film and the lower film are combined to form a patterned sealing film. Protein is placed in the patterned sealing membrane. The proteins in the patterned sealing film are vacuum-treated and sealed at 130-160°C. The patterned sealing membrane applies pressure to the vacuum-treated protein, and the protein in the patterned sealing membrane is cured at the required curing temperature. During the curing process, the three-dimensional embossed pattern is transferred from the patterned sealing film to the protein solely through vacuum pressure applied to the protein from the vacuum between the protein and the patterned sealing film at the curing temperature. The patterned sealing film is removed from the protein after the protein has matured.

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