Molding method for patterned sealed film

Abstract

To provide a method for embossing / debossing forming and sealing films in various shapes, such as geometric shapes, organic shapes, fractal shapes, and / or combinations thereof, and in various sizes and depths.SOLUTION: A texture or pattern is transferred from an insert to a film. The pattern on a molding and sealing film is transferred to a surface of a protein product during the molding, filling, sealing, and cooking processes. Molding and / or sealing inserts enable the formation of various thermoformed films with functional and / or decorative embossing and / or debossing without the use of woven nets, elastic nets, extruded nets, tightly woven nets, plastic nets, and / or release agents for compression molds and / or net removal. Since the forming inserts are formed using an additive manufacturing process, it is possible to emboss / deboss almost any design onto the forming and sealing films.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 235,899, filed August 23, 2021, which is incorporated herein by reference. [Background technology]

[0002] It may be desirable to emboss a pattern onto the surface of meat for purposes such as display, texture, or retention of particular spices or flavorings. Texture is added to the product by wrapping the protein product in a netting during cooking and embossing the pattern onto the surface of the product. However, this process is wasteful because the netting is discarded after cooking. Therefore, there is a need for a forming and sealing film that can emboss a pattern directly onto the protein product without the need for additional materials such as netting. Summary of the Invention

[0003] The present invention provides a method for embossing / debossing molding and sealing films with various shapes, including geometric, organic, fractal, and / or combinations thereof, at various sizes and depths. The texture or pattern is transferred from the insert to the film. The pattern on the molding and sealing film is transferred to the surface of various protein products, including, but not limited to, chicken, turkey, beef, pork, and plant-based protein products, during the molding, filling, sealing, and cooking processes. The molding and / or sealing insert can form woven netting, elastic netting, extruded netting, tightly woven netting, plastic netting, and / or various thermoformed films with functional and / or decorative embossing and / or debossing without the use of compression molds and / or release agents for net removal. Because the molding insert is formed using an additive manufacturing process, almost any design can be embossed / debossed into the molding and sealing film. [Brief explanation of the drawings]

[0004] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more aspects of the invention and, together with the detailed description, serve to further explain the principles of the invention and enable those skilled in the art to make and use the invention.

[0005] [Figure 1] FIG. 1 shows an embossed film with raised impressions (protrusions) on the inside of the formed film. [Figure 2] Figure 2 shows the debossed depressions that are transferred to a protein product during cooking. [Figure 3] FIG. 3 shows the lower depression on the inside of the formed film. [Figure 4] Figure 4 shows the embossed impressions (raised areas) transferred to the protein product during cooking. [Figure 5A] FIG. 5A shows an example of a pattern applied to a formed film. [Figure 5B] FIG. 5B shows an example of a pattern applied to a formed film. [Figure 5C] FIG. 5C shows an example of a pattern applied to a formed film. [Figure 5D] FIG. 5D shows an example of a pattern applied to a formed film. [Figure 5E] FIG. 5E shows an example of a pattern applied to a formed film. [Figure 6] FIG. 6 is a flow chart showing the steps used in a standard packaging and cooking process. [Figure 7] FIG. 7 is a flow chart illustrating the steps used in the packaging and cooking process according to the present invention. [Figure 8] FIG. 8 shows one embodiment of a molded insert. [Figure 9] FIG. 9 shows one embodiment of a molded insert. [Figure 10]FIG. 10 shows one embodiment of a molded insert. [Figure 11] FIG. 11 shows another embodiment of a molded insert. [Figure 12] FIG. 12 shows another embodiment of a molded insert. [Figure 13] FIG. 13 shows the molded film removed from the molded insert. [Figure 14] FIG. 14 shows an example of a cooked protein product after the forming film has been removed.

[0006] Features and advantages of the disclosed embodiments will become apparent in the following detailed description taken in conjunction with the drawings, in which like reference numerals indicate corresponding elements, and generally indicate identical, functionally similar, and / or structurally similar elements. Unless otherwise noted, the drawings provided throughout this disclosure are not necessarily drawn to scale. DETAILED DESCRIPTION OF THE INVENTION

[0007] In the cooking process, all standard form, fill, and seal processes incorporate a primary forming step. Typically, the primary forming step includes only a single film forming step. In contrast, the method of the present invention incorporates primary and secondary film forming steps. In the primary forming step, an embossed film having raised impressions (protrusions) is formed on the inside of the formed film, as shown in Figure 1.

[0008] The primary film forming process is preferably used to simulate a functional and decorative net impression that is transferred to the surface of the protein product during the cooking process. The primary thermoformed embossing impression is transferred to the surface of the protein product during cooking, resulting in a debossed depression or underdepression on the protein product, as shown in Figure 2.

[0009] The secondary forming process results in a lower debossed depression inside the formed pocket. The secondary thermoformed shape is formed from the residual formed film material from the primary thermoforming process. This depression simulates the functional and decorative pattern that will be transferred to the surface of the protein product during the cooking process (Figure 3).

[0010] The secondary thermoformed debossed depressions are transferred to the surface of the protein product, resulting in an embossed or raised impression (Figure 4).

[0011] The forming and sealing film is formed using the following process: First, the film is stretched over the forming insert. The forming film is heated in a controlled manner to make it flexible and easier to form impressions. Next, controlled high pressure air is used to force the film into the forming insert, which causes the forming film to take the shape of the forming insert. The protein product to be sealed is then placed within the forming insert on the forming film.

[0012] As shown in Figures 5A-5E, any pattern can be formed on the molding insert and transferred to the molding and sealing film, including but not limited to various patterns shown below.

[0013] Net or mesh pattern: transferred from molded insert to film and then to protein product (Figures 5A-5E) Logo: Insertion of company logos, watermarks, brand marks, text, or 2D / 3D layers into protein products (Figure 5D) Patterns created to mimic what happens during different cooking styles (broiling, wrapping, grilling, etc.) (Figures 5C and 5E) Intentional defects that characterize real and naturally occurring events in a product

[0014] Formed films can take any shape capable of containing a protein product (e.g., a football-shaped ham, an Easter chicken-shaped egg, etc.) Various patterns can also be formed from combinations of geometric, organic, fractal, square, rectangular, diamond, hexagonal, tick, branch, wave, etc.

[0015] [Sealing process] Figure 6 is a flow chart illustrating a typical process used to package and cook a protein product. First, in step 602, the desired netting is placed around the protein product. This step is typically the most labor-intensive, as it requires manual labor to place and seal the protein product in the netting. Next, in step 604, a roll stock packaging machine is used to form a forming and sealing film into a pocket. Specifically, the forming film is placed into the cavity of a forming shape to form a pocket, and thermoforming is used to form the forming film into the desired shape.

[0016] The protein product contained in the netting is placed into the shaped pocket in step 606. The pocket is sealed and a vacuum is applied to airtightly package the protein product in step 608. The pressure created by the vacuum on the netting transfers the pattern of the netting to the protein product during cooking in step 610.

[0017] After the protein product is cooked, the pockets are first removed in step 612 and then the net is removed in step 614. Removal of the pockets in step 612 can be automated, while removal of the net in step 614 must be done manually.

[0018] The process of the present invention eliminates many of the steps that require manual labor and netting, resulting in a significant reduction in waste and manual labor. As noted above, the method of the present invention uses a forming and sealing film with a netting pattern that is transferred directly to the protein product during cooking. This eliminates the need for manual netting and removal steps 602 and 614.

[0019] Figure 7 is a flow chart illustrating the steps used in the packaging and cooking process according to the present invention. Initially, in step 702, a forming and sealing film is placed within a forming insert to form a pocket for the protein product. Figure 8 is a perspective view of forming insert 802, and Figure 9 is a top view of forming insert 802. As shown, forming insert 802 includes an upper portion having a forming cavity 804. A forming and sealing film is placed over cavity 804, and rapid air forming is used to ensure that the forming and sealing film conforms to the pattern of forming insert 802. The sides of forming insert 802 include a plurality of vent structures 806 to allow air to escape. The sides of forming insert 802 also provide structural support to forming insert 802.

[0020] Figure 13 shows the formed seal film removed from the molded insert 802. As shown, the pattern of the netting from the molded insert 802 is transferred directly to the formed film. Furthermore, the 3D pattern on the formed seal film is transferred to the protein product during the cooking process (Figure 14), eliminating the need to attach or remove the netting from the protein product.

[0021] The mold insert 802 can also be connected to the roll stock using anchors 808, shown in Figure 10. The mold insert 802 is placed inside the closure box of the roll stock and secured to ensure a proper fit without shifting during the film forming process. Securing can be accomplished in several ways:

[0022] Slots, latches, bolts, or other fastening features Fixing an insert into a molded or sealed box from one or more of its sides, bottom, and / or top.

[0023] After forming the pocket using the top and bottom of the molding insert 802, a protein product is placed into the formed pocket in step 706. The pocket is sealed and vacuum sealed in step 706, airtightly packaging the protein product. During cooking in step 708, the 3D pattern of the molding and sealing film is transferred to the protein product. After the protein product is cooked, the pocket is first removed in step 710. Because the impression is transferred directly from the molding and sealing film, no net is needed to apply the impression to the protein product. Figures 11 (perspective view) and 12 (top view) show additional examples of sealing inserts with different patterns.

[0024] [Molding and sealing film] The process shown in Figure 7 can be applied to a variety of films depending on the size of the cavity and the final shape and impression required. Depending on the shape, thinner films, thicker films, films with adhesive on the inside, more porous films, or films that are pre-shrunk to various degrees may be required. It is also possible to combine films depending on the sealing requirements. For example, the following types of films are compatible:

[0025] ·polyethylene ·polypropylene ·nylon Ethylene-vinyl alcohol copolymer Barrier film Film lamination combination

[0026] The forming and sealing film should be usable over a wide temperature range, with a forming set temperature range of 90°C to 145°C and a sealing temperature range of 130°C to 160°C. Physical forming of the forming and sealing film using the insert with forming insert 802 can be accomplished using any known method, including the use of plug assist, forced air, forced air with vacuum assist, graduated temperature zones, high pressure rapid air forming, or explosive forming under vacuum.

[0027] [Molding insert] The following materials can be used for additive manufacturing and creation of the sealing insert 802:

[0028] Metals (aluminum, Inconel, steel, titanium, or other nickel-based alloys) o Foams are formed by deposition, sintering, or other forms of melting and dissolution. ○ Meets product dimension specifications up to 400mm x 400mm x 400mm. o The material can withstand final finishing processes such as wire EDM (electrical discharge machining), drilling, cutting, electrolytic polishing, and coating. ○ The final build must withstand pressures of 100psi to 200psi and temperatures of 150°C to 200°C. Surface treatments such as electroless nickel plating with polytetrafluoroethylene, nickel polishing, or nickel PTFE (nickel Teflon plating) may be required.

[0029] ·resin o Resins are selected based on tensile strength and modulus, flexural modulus, impact strength, elongation, and heat deflection temperature. o Used during the conception, prototyping, and / or testing stages. o Forms can be produced by stereolithography (SLA), digital light processing (DLP), or selective laser sintering (SLS). ○ The final build must withstand pressures of 100psi to 200psi and temperatures of 150°C to 200°C throughout the testing phase.

[0030] Plastic (ABS, PLA, PETG, Nylon) o Used in early prototyping and testing stages as a low-cost alternative to test the viability of foam shapes. ○ The final build must withstand pressures of 100psi to 200psi and temperatures of 150°C to 200°C throughout the testing phase.

[0031] As discussed above, virtually any pattern can be molded into the insert 802. This allows for the creation of designs that reduce metal volume and create the required breathability and shape. The size of the airflow vent structure 806 and the primary and secondary foams have not previously been used in thermoforming processes. The airflow / support structure design grid (see Figures 8 and 10) allows for control of both the film temperature and airflow to small areas of the molded insert 802 shape through the embossments / debosses in the film to meet the requirements of the selected molding and sealing film.

[0032] Variable corner and edge designs for ventilation (which can create pressure variations and create deeper impression pockets in the primary and secondary foams) have not previously been easily created by other methods. These variable corner ventilation structures in the primary and secondary foams can range in size to minimize or maximize airflow. By adjusting the size of the ventilation structures in the primary and secondary molded inserts 802, the embossing and debossing can be controlled, unlike with netting.

[0033] For example, as shown in Figure 8, each mold insert has multiple vent structures, while current mold inserts (such as those used in Figure 6) use solid material. Increasing the amount of airflow within mold insert 802 eliminates the need for liquid cooling of the mold box in step 604. Additionally, mold insert 802 physically integrates one or more functions (sealing and pattern transfer).

[0034] The collar / leg support structure of the mold insert 802 provides support and minimizes the amount of material required for latticework, ventilation, and support, provides the strength necessary to resist internal pressure during molding, and allows for guiding the mold insert 802 within the mold box, which is held in place via anchoring mechanism 808.

[0035] The overall contour of the molded insert 802, the multi-level film impressions, and the film attachment are subject to control and vary according to different criteria. The goal is to establish conditions that stabilize the "primary thermoform" and "secondary thermoform" cells, respectively, to maintain most of the original cell volume when heat treated during the product's cook cycle, and to establish conditions that create "controlled shrinkage" in the "primary thermoform" cavity shape 804 to provide adequate package shrinkage force to ensure the secondary mold cell pattern is transferred to the product during the cook cycle. Below is a list of criteria in the molding process that help control film shrinkage:

[0036] Thermoforming material selection -Thermoforming temperature stability -Temperature control of thermoforming tools Molding air pressure and molding time Cooling time after molding

[0037] [Generate molding inserts] Additive manufacturing requires software to digitally convert the form through 3D scanning, design the form through CAD software, and generate the molded insert 802, including options to control equipment to manufacture the sealing inserts used in the present invention.

[0038] 1. 3D Scan Reference Object: To start the entire project, the scanning software can be used to scan and display a control piece. This can be used for any object or shape that the user wishes to scan and convert into a mold.

[0039] 2. CAD software: Used to build a smooth topological mesh on the scanned reference model in step 1 or to create a new model, generating a positive form object. a. Continue generating the base pattern on the smooth retopology mesh (i.e., two meshes are created) b. Continue creating three copies of the base pattern mesh i.Backup copy mesh ii. Embedded copy mesh iii. Using the Bevel Tool to Generate Net Pattern Extrusion Meshes

[0040] 3. Secondary CAD Software: Use of Base Pattern Mesh to Generate Net Pattern, Backing Pattern, and Support Material a. Combine all the pieces into one model b. If feasible, construct the frame and fixture blocks if the final output is for metal 3D printing c. Clean up, retopologize, fill holes, reduce face count to make it easier to export to a printer d. Include all grate ventilation models including all steps from 2a to 2b e. Export the mesh (overall mold design)

[0041] 4. Slicer / Build Prep Software: Imports the final mesh to validate the entire mold, establishing part orientation, support structures, layer thicknesses, timing, and other paths and settings dictated by the form geometry. a. Build preparation software generates STL or native files that the 3D printing machine uses as instructions to produce the final usable piece.

[0042] The above-described embodiments illustrate some of the applications of the principles of the present subject matter. Various modifications may be made by those skilled in the art without departing from the spirit and scope of the claimed subject matter, including combinations of features individually disclosed or claimed herein. For these reasons, the scope of the present invention is not limited to the above description, but is set forth in the appended claims, and the claims are understood to represent features of the present invention, including combinations of features individually disclosed or claimed herein.

Claims

1. A method for forming a patterned sealing film, comprising: placing a molding and sealing film onto the molding insert; forming the patterned seal film from the molding and seal film using the molding insert; Prepare for this. The molded insert comprises: a central cavity having a 3D embossed pattern; a plurality of vent structures surrounding the central cavity; an anchor portion for securing the molding insert to a molding box during molding of the patterned sealing film; Equipped with the 3D embossed pattern is transferred to the formed film; method.

2. 3. The method of claim 2, wherein the patterned encapsulant film is formed using high pressure rapid air forming.

3. The method of claim 1 , wherein the molded insert is not liquid cooled.

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