Method and device for manufacturing multilayer objects

Abstract

The present invention relates to a method for covering at least the outer edge of a functional layer with a first layer, said layer being contained in a multi-layer dose intended to form an object by compression molding, said method comprising at least the following steps: -) a step of deforming the dose; -) a step of temporarily blocking the spreading of at least the functional layer simultaneously with the step of deforming the dose, so as to form a bead of material from the first layer by spreading of the material; -) a step of stopping the temporary blocking step.

Description

[Technical Field]

[0001] Corresponding application This application claims priority to an earlier European application No. 23156718.1 filed on February 15, 2023 in the name of AISAPACK HOLDING SA, which is incorporated herein by reference in its entirety.

[0002] The present invention relates to a method for producing multi-layered objects by compression molding multi-layered doses of molten resin. [Background technology]

[0003] Japanese Patent Application Publication No. 4-169207 (JP 4-169207 A) describes a method for producing a multilayer object by compressing a dose in a mold, the layers of which are positioned perpendicular to the compression axis. According to this method, a coin-shaped dose formed of a stack of several films is positioned in the mold. The film positioned in the center of the multilayer structure has reduced permeability. The invention described in Japanese Patent Application Publication No. 4-169207 consists of forming a multilayer object by compressing the dose in a mold and confining the edges of the layers inside the object. To confine the edges of the central film, Japanese Patent Application Publication No. 4-169207 proposes compressing the dose at a temperature higher than the melting point of the film but lower than the melting point of the central film. As an example, Japanese Patent Application Publication No. 4-169207 describes a dose formed from a polyethylene film, with the central film being made of polyamide. The method described in Japanese Patent Application Publication No. 4-169207 has several drawbacks. According to Japanese Patent Application Laid-Open No. 4-169207, the central film is in a solid state during molding because the molding temperature is below the melting point of the film. As a result, the central film undergoes little or no deformation during molding. In the method described in Japanese Patent Application Laid-Open No. 4-169207, it is difficult to extend the central film forming the functional layer to the edge of the object. This method also requires the production, heating, and transfer of a thin, flat dose into the mold cavity. The operations involved in producing and handling the dose are not fully disclosed in the Japanese patent, and it appears difficult to produce objects at high production rates using this method.

[0004] U.S. Pat. No. 4,904,512 describes a multilayer object produced by compression molding multiple doses. The patent proposes the use of a cylindrical dose with the functional layer completely enclosed between layers of resin. The edges of the functional layer are confined within the dose by an extrusion process that allows for discontinuous feeding of the functional layer. However, U.S. Pat. No. 4,904,512 does not describe the compression of the dose within a mold. For example, the dimensions of the dose and how it is positioned within the mold cavity are not mentioned. The description of the invention does not describe how the dose is compressed. Nevertheless, the solution described in U.S. Pat. No. 4,904,512 presents several problems. As described in the patent, a coextrusion molding device with a shut-off valve mechanism for the functional resin controls the intermittent flow of the functional resin. However, such a shut-off valve mechanism is complex, expensive, and does not provide sufficiently precise control of the intermittent flow at high production rates.

[0005] Published PCT Publication WO 2008 / 096290 proposes a method for producing a multilayer object from a synthetic resin by compression molding a dose of a multilayer molten resin containing at least one functional layer, where each layer of the dose is in a molten state during compression. The method involves co-extruding the resin through a mold, periodically cutting the extrudate to obtain doses, and then depositing the molten doses into the mold cavity. This method thus defines the direction of extrusion and the arrangement of the functional layers parallel to the direction of extrusion in the dose. In this method, the doses are compressed along a compression axis that intersects the direction of extrusion. This publication also relates to objects obtained by the above-mentioned method, the doses used in this context, and an apparatus for carrying out the method. An advantage of this method is that it allows for the production of molded multilayer objects with thin functional layers well distributed throughout the object at high production rates. However, this method does not completely prevent the presence of functional layers on the surface of the molded object.

[0006] Compared to the teachings of the prior art, the uniqueness of the inventive method described in WO 2008 / 096290 lies in its production by extrusion of multiple doses in a direction through the layers and their compression together.

[0007] Other publications, such as, for example, WO 2017064601, WO 2020075020, WO 2020121190, WO 2021070031, WO 2021074819, WO 2021234617, WO 2022029668, disclose examples of apparatus and methods for producing objects, such as packages, from doses that are subjected to compression molding.

[0008] Subject of the Invention One object of the present invention is to improve known methods and devices.

[0009] Another object of the present invention is to propose a simple device and method by which an object can be formed by compression molding, said object comprising at least one functional layer (such as, for example, a barrier layer) encapsulated within the material of the object.

[0010] The present invention also aims to produce a multilayer object by compression molding, overcoming the problems found in the prior art, which consists in particular in encapsulating a functional layer by temporarily preventing the expansion of said layer while (in other words, during) the deformation of the dose. Summary of the Invention

[0011] The present invention relates to a compression molding method that uses multiple doses to prevent functional materials (such as those that form functional layers) from appearing on the surface of objects produced by compression molding at high production rates.

[0012] In particular, the present invention makes it possible to encapsulate within an object to be manufactured a functional layer that is not desired on the surface of the object once manufactured, even though this functional layer is present on the surface of the dose (e.g., on the side edges) before the deformation of the dose by compression molding.

[0013] The functional layer can be, for example, a barrier layer.

[0014] The functional layer may consist of several layers. To ensure adhesion between layers of different properties, a thin layer of adhesive is generally positioned on both sides of the barrier layer. In this example, the functional layer consists of three layers: two adhesive layers and a barrier layer.

[0015] A functional layer can also be a layer of recycled material, or a layer that is undesirable to have on the interior or exterior surface of an object (eg, for food-related or aesthetic reasons).

[0016] The present invention particularly involves the implementation of an encapsulation operation in which the spreading of the edges of the functional layer is at least temporarily prevented during the deformation of the dose, which has the effect of accumulating a sufficient volume of material (capable of forming the surface of the object) upstream of the functional layer, referred to in the present disclosure as a bead, said bead having the effect of encapsulating the functional layer during the process so that the functional layer is not present on the surface of the object formed by compression molding. More specifically, according to this method, a portion of the dose is deformed while at the same time the spreading of at least the edges of the functional layer is prevented during this deformation of the dose, thereby allowing the formation of a "bead" of material created by the partial deformation of the dose. The prevention of the spreading of the functional layer is then released, and compression of the entire dose, including the bead, continues, and said bead of material is used to cover the functional layer during the compression molding process, for example by covering the functional layer present on the surface of the dose.

[0017] According to an embodiment of the present invention, the encapsulation operation is performed during a compression molding process.

[0018] According to an embodiment of the present invention, the encapsulation operation is performed before compressing the dose in the mold.

[0019] According to an embodiment of the invention, the encapsulation operation is performed during the transfer of the dose into the mold.

[0020] According to an embodiment of the invention, the encapsulating operation comprises temporarily blocking the spreading of the functional layer by preventing the spreading of a portion of the flow front of the dose during deformation of the dose.

[0021] According to an embodiment of the invention, the encapsulation operation is performed in particular by temporarily blocking the expansion of the dose volume containing the functional layer, the unblocked dose volume forming, according to the invention, a bead of material that will be used to encapsulate the functional layer, for example as part of a compression molding process in a mold.

[0022] According to an embodiment of the present invention, at least the following consecutive - creating a multi-layer dose; - transferring the dose into a mold, Compression molding the dose and simultaneously temporarily preventing the spread of the functional layer; Stop blocking the functional layer - a step of encapsulation, - continuing and completing the operation of compressing the dose; - Demolding the object is executed.

[0023] According to an embodiment of the present invention, at least the following consecutive - creating a multi-layer dose; - transferring the dose into a mold, - incompletely shaping the object by partial compression of the dose, Continuing the operation of compressing the dose while temporarily preventing the spread of the functional layer, Stop blocking the functional layer - a step of encapsulation, - continuing and completing the operation of compressing the dose; - Demolding the object is executed.

[0024] According to an embodiment of the present invention, at least the following consecutive - creating a multi-layer dose; Temporarily preventing the spread of the functional layer simultaneously with the deformation due to compression of the dose before, during, or after the operation of transferring the dose into the mold. - a step of encapsulation, - compression molding the dose transferred into a mold (with or without temporarily maintaining the blocking of the spread of the functional layer), - Demolding the object is executed.

[0025] According to an embodiment of the present invention, at least the following consecutive - creating a multi-layer dose; During the operation of transporting the dose, the deformation due to compression of the dose and the expansion of the functional layer are temporarily prevented. Stopping blocking of the functional layer, Continuing and completing the operation of compressing the dose during transfer and obtaining the corrected dose - a step of encapsulation, - compression molding the modified dose transferred into a mold (with or without temporarily maintaining the blocking of the spreading of the functional layer), - Demolding the object is executed.

[0026] As can be seen from the various embodiments described, the encapsulation operation may be carried out partially in the compression mold, or in the conveying means used to transport the created dose in the mold, or even before said transport (immediately after creation of the dose), or for example at different times (all combinations are conceivable, such as a partial encapsulation operation during transport and a second encapsulation operation in the mold, or before transport and in the mold). Hardening of the dose is desirably avoided.

[0027] It is important that the dose retains its flow properties for the operation of shaping by compression. Depending on the nature of the material used, means may be used to prevent the dose from hardening after the encapsulation operation. These means depend on the nature of the material used and may include, for example, heating means, cooling means, or additives added to the material.

[0028] For example, if the material constituting the dose is a thermoplastic, a heating means may be used to prevent the dose from cooling. For example, the encapsulation tool may be set to a temperature that avoids cooling of the dose. Also, a means may be used to heat the dose after encapsulation. In general, it is advantageous to perform the encapsulation operation quickly, which limits changes in the flow characteristics of the dose and avoids the use of heating means.

[0029] For example, if the material constituting the dose is a thermosetting resin, heating of the dose during the encapsulation operation is conversely avoided and cooling means may be used during the encapsulation operation.

[0030] In the present description, the dose thickness is defined as the distance measured perpendicular to the plane defined by the functional layer.

[0031] According to an embodiment of the invention, the position of the functional layer in the dose is modified by the action of encapsulation of said functional layer resulting from the method of compression moulding according to the invention.

[0032] According to an embodiment of the present invention, the position of the functional layer in the initial dose (i.e., the dose before encapsulation) is not located in the middle of the dose thickness, but the position of the functional layer after encapsulation in the final object is located approximately in the middle of the object thickness.

[0033] According to an embodiment of the present invention, the position of the barrier layer in the initial dose is arranged at a position of 5% to 50%, preferably 10% to 30%, of the thickness.

[0034] According to an embodiment, the direction of compression is preferably perpendicular to the functional layer at the initial dose.

[0035] According to an embodiment of the present invention, the initial dose has a geometric shape similar to that of a parallelepiped with a rectangular base, said dose being compressed in a direction perpendicular to said rectangular base and said functional layer being parallel to said rectangular base. According to a preferred embodiment, the geometric shape of the initial dose is similar to that of a parallelepiped with a square base.

[0036] According to another embodiment of the present invention, the initial dose has a cylindrical geometric shape with a circular or elliptical base, said dose being compressed in a direction perpendicular to said circular or elliptical base, and said functional layer being parallel to said base.

[0037] According to another embodiment of the present invention, the initial dose has a cylindrical geometric shape with a circular or elliptical base, said dose being compressed in a direction parallel to the cylindrical base and the functional layer being perpendicular to said base.

[0038] According to another embodiment of the present invention, the initial dose has an annular geometric shape with a circular or elliptical base, said dose being compressed in a direction perpendicular to said circular or elliptical base, and said functional layer being parallel to said base.

[0039] According to another embodiment of the present invention, the initial dose has an annular geometric shape with a circular or elliptical base, said dose being compressed in a direction parallel to the cylindrical base and the functional layer being perpendicular to said base.

[0040] According to an embodiment, the invention relates to a method for covering at least the outer edge of a functional layer with a first layer, said layer being contained in a multi-layer dose intended to form an object by compression molding, the method comprising at least the following steps: -) transforming the dose; -) simultaneously with the step of deforming the dose, at least temporarily blocking the spreading of the functional layer so as to form a bead of material from the first layer by the spreading of material of the first layer; -) Step to temporarily stop the step The present invention relates to a method, comprising:

[0041] In some embodiments, only the spread of the functional layer may be inhibited, while in other embodiments the spread of the functional layer and one (or several) other layers of the dose may also be inhibited.

[0042] According to an embodiment, the deformation of the dose may occur by compression of the dose.

[0043] According to an embodiment, compression of the dose can be performed over the entire surface of the dose or over a portion of the surface of the dose.

[0044] According to an embodiment, the direction of compression intersects a plane parallel to the functional layer, for example perpendicularly or at an angle.

[0045] According to an embodiment, deformation of the dose may be performed by heating at least the first layer, or by another equivalent method, or by a combination (eg, heating and compression).

[0046] According to an embodiment, said step may be carried out during the transport of the doses by the carrier means and / or immediately after the doses have been deposited in an apparatus for compression moulding.

[0047] According to an embodiment, an additional step of deforming the dose may be performed before the joint deforming and temporary blocking.

[0048] According to an embodiment, transforming the dose continues after ceasing the temporary blocking to form the object.

[0049] According to an embodiment, the deforming is continued by compression molding.

[0050] According to an embodiment, the dose may comprise at least two functional layers and / or the functional layers may form a significant proportion of the dose.

[0051] According to an embodiment, the functional layer may be a barrier layer and / or a layer made of recycled materials.

[0052] According to an embodiment, the functional layer may be completely covered by at least the first layer.

[0053] According to an embodiment, temporary blocking means may be arranged on the conveying means and / or on the punch and / or on the die.

[0054] According to an embodiment, the deformation of the dose may be performed by a punch and a die during compression molding to obtain at least the object.

[0055] According to an embodiment, the invention relates to an apparatus for carrying out the described method, intended to form an object from a multi-layer dose of material, the dose comprising at least one functional layer and a first layer, the apparatus comprising means for transporting the dose, means for compressing the dose, means for forming the dose by compression molding, and means for temporarily preventing the expansion of the functional layer, for example an encapsulation means.

[0056] According to an embodiment, the means for deforming the dose and the means for temporarily blocking the extension of the functional layer are arranged on the means for transporting the dose.

[0057] According to an embodiment, the means for temporarily blocking the spreading of the functional layer are arranged on the mold and / or on the punch.

[0058] According to an embodiment, the punch comprises an inner part and an outer part, said parts being movable relative to each other to form said means for temporarily blocking the spreading of the functional layer.

[0059] Other embodiments will become apparent from the description and figures of the present application.

[0060] Detailed Description of the Invention The invention will be better understood hereinafter from the detailed description of some examples illustrated by the following figures.

[0061] 1 to 16 show an embodiment of the present invention. [Brief explanation of the drawings]

[0062] [Figure 1] 1 shows a first example of an encapsulation method carried out during a compression molding operation. [Figure 2] 1 shows a first example of an encapsulation method carried out during a compression molding operation. [Figure 3] 1 shows a first example of an encapsulation method carried out during a compression molding operation. [Figure 4]1 shows a first example of an encapsulation method carried out during a compression molding operation. [Figure 5] 10 illustrates a second example of an encapsulation method performed during a compression molding operation. [Figure 6] 10 illustrates a second example of an encapsulation method performed during a compression molding operation. [Figure 7] 10 illustrates a second example of an encapsulation method performed during a compression molding operation. [Figure 8] 10 illustrates a third example of an encapsulation method performed during a compression molding operation. [Figure 9] 10 illustrates a third example of an encapsulation method performed during a compression molding operation. [Figure 10] 10 illustrates a third example of an encapsulation method performed during a compression molding operation. [Figure 11] 10 illustrates a third example of an encapsulation method performed during a compression molding operation. [Figure 12] An example of a multi-layer dose with a geometry similar to that of a square-based parallelepiped is shown. Note that the barrier layer is not centered in thickness prior to the encapsulation operation. [Figure 13] 1 shows an example of a encapsulation method carried out during a dose transfer operation. [Figure 14] 1 shows an example of a encapsulation method carried out during a dose transfer operation. [Figure 15] 1 shows an example of a encapsulation method carried out during a dose transfer operation. [Figure 16] 1 shows an example of a encapsulation method carried out during a dose transfer operation. [Figure 17] 1 shows an example of a encapsulation method carried out during a dose transfer operation. [Figure 18] An example of an encapsulation method is shown that includes two encapsulation elements to prevent the spread of the dose layer. [Figure 19] An example of an encapsulation method is shown that includes two encapsulation elements to prevent the spread of the dose layer. [Figure 20] An example of an encapsulation method is shown that includes two encapsulation elements to prevent the spread of the dose layer. [Figure 21]An example of an encapsulation method is shown that includes two encapsulation elements to prevent the spread of the dose layer. [Figure 22] An example of an encapsulation method is shown that includes two encapsulation elements to prevent the spread of the dose layer. [Figure 23] 1 shows another example of a containment device with two containment elements to prevent the spread of the dose layer. [Figure 24] 1 illustrates an embodiment with two encapsulation elements within the molding system. [Figure 25] 1 illustrates another embodiment of the present invention in which the method for encapsulation of the functional layer is performed during the compression molding process rather than at the initial dose at the start of the compression process. [Figure 26] 1 illustrates another embodiment of the present invention in which the method for encapsulation of the functional layer is performed during the compression molding process rather than at the initial dose at the start of the compression process. [Figure 27] 1 illustrates another embodiment of the present invention in which the method for encapsulation of the functional layer is performed during the compression molding process rather than at the initial dose at the start of the compression process. [Figure 28] 1 illustrates another embodiment of the present invention in which the method for encapsulation of the barrier layer is performed at the end of the compression molding process. [Figure 29] 1 illustrates another embodiment of the present invention in which the method for encapsulation of the barrier layer is performed at the end of the compression molding process. [Figure 30] 1 illustrates another embodiment of the present invention in which the method for encapsulation of the barrier layer is performed at the end of the compression molding process. [Figure 31] 1 illustrates the principle of the encapsulation method according to the invention for a dose containing several functional layers. [Figure 32] 1 illustrates the principle of the encapsulation method according to the invention for a dose containing several functional layers. [Figure 33] An example of the geometry of the containment element for a multi-layer dose in the form of a square-based parallelepiped is shown in a view parallel to the compression axis of the dose. [Figure 34]Another example of the geometry of the containment element for a multi-layer dose in the form of a square-based parallelepiped is shown in a view parallel to the compression axis of the dose. [Figure 35] An example of the geometry of the containment element for a multi-layer dose in the form of a rectangular-based parallelepiped is shown in a view parallel to the compression axis of the dose. [Figure 36] Another example of the geometry of the containment element for a multi-layer dose in the form of a rectangular-based parallelepiped is shown in a view parallel to the compression axis of the dose. [Figure 37] An example is shown in which the functional layer constitutes a significant proportion of the dose and the manufactured object. [Figure 38] An example is shown in which the functional layer constitutes a significant proportion of the dose and the manufactured object. [Figure 39] An example is shown in which the functional layer constitutes a significant proportion of the dose and the manufactured object. [Figure 40] Another example is shown where the functional layer constitutes a significant proportion of the dose and the manufactured object. [Figure 41] 1 shows the principle of encapsulation according to the invention for a dose comprising holes and a functional layer arranged perpendicular to the axis of the holes. [Figure 42] 1 shows the principle of encapsulation according to the invention for a dose comprising holes and a functional layer arranged parallel to the axis of the holes. [Figure 43] 1 shows an example of a encapsulation method in which the dose is deformed radially by a deformation element. DETAILED DESCRIPTION OF THE INVENTION

[0063] Detailed Description of the Drawings Reference Number List 1 dose 2. Mold cavity 3 Molding equipment 4 Punch 5. Mold 6. Enclosed Elements 7 Beads 8. Barrier layer location 9 Dose Thickness 10. Conveyor 11 Supporting elements 12 Deformation Elements 13 Molded Objects 16 Enclosed Elements 20 doses of functional layer 20' dose second functional layer 21 Dose's First Layer 22 Dose's Second Layer 22' Third Layer of Doze

[0064] 1 to 4 show a first embodiment of the method for manufacturing an object and the means used for this purpose according to the invention.

[0065] In this embodiment, in accordance with the principles of the present invention, a dose 1 is placed in a cavity 2 of a molding device 3. Dose 1 is preferably a multi-layer dose comprising in particular a first layer ("functional" layer) 20 positioned between two other layers 21, 22 (e.g. resin layers), this dose 1 being obtained by extrusion, for example as described in publication WO 2008 / 096290. Each layer 20, 20', 21, 22 and 22' may be single-layer or multi-layer.

[0066] Said dose 1 is positioned in a cavity 2 of a molding device 3 and is intended to be compressed between a punch 4 and a die 5 which move relative to each other in a direction perpendicular to the layers 20, 20', 21, 22 and 22' of the dose 1 so as to form the desired object by a compression molding method. The position of the die 5 below the punch 4 is exemplary; the whole may be rotated by 180° with the punch 4 positioned above the die 5. Of course, other positions are possible.

[0067] In the forming apparatus 3, the dose 1 is held in an encapsulating element 6 that partially surrounds said dose 1, such that the walls of said element 6 cover at least the edge of the dose, whereby a functional layer 20 is visible at the surface of said dose 1 (e.g. on the lateral edge of the dose 1), as shown in Figure 1. This encapsulating element 6 makes it possible to keep one part of the dose 1 unchanged while another part of the dose is deformed, for example by being compressed by the relative movement of the punch 4 and the die 5 towards each other. In the example of Figure 1, it is a layer 21 of the dose 1 that is compressed and deformed to create a bead 7 that covers the encapsulating element 6, as shown in Figure 2.

[0068] Next, according to the method, as shown in Figure 3, the encapsulation element 6 is removed from the molding apparatus 3 (e.g., from the mold) and the functional layer 20 is covered by the bead 7, thus forming a dose 1 in which the functional layer 20 is fully embedded (or encapsulated) within the other layers 21 and 22. The process of compression continues (by compression molding) and the dose 1 is transformed into the desired object 13 as shown in Figure 4, with the functional layer 20 still confined (or encapsulated) within the layers 21 and 22 of the dose 1.

[0069] As can be seen in FIG. 1, functional layer 20 is located within the lower half of dose 1, in other words layer 21 is thicker than layer 22 (see proportions above), and for this reason bead 7 is preferably formed in the thickest layer (in this case layer 21).

[0070] Figures 5 to 7 show another embodiment of the present invention. As can be seen in Figure 5, a molding apparatus 3 has a mold 5 and a punch 4 on which a dose 1 of material comprising layers 20, 21, and 22 is deposited, layer 20 being a functional layer. Mold 5 includes an encapsulation device 6 that surrounds dose 1 at least to the height of functional layer 20, as shown in Figure 5.

[0071] The process of compression molding the dose 1 is carried out by the relative movement of the punch 4 towards the die 5, and the compression of said dose 1 causes it to deform and form a bead 7 from the layer 21 which, due to the presence of the encapsulation element 6, is subjected to deformation resulting from the compression, as shown in Figure 6.

[0072] In FIG. 7, the encapsulation element 6 is removed and the process of compression molding continues to form the desired object 13 with the functional layer 20 fully enclosed within layers 21 and 22 .

[0073] 8 to 11 show another embodiment of the present invention. This embodiment is similar to that shown in FIGS. 5 to 7, except that the encapsulation element 6 is formed in the punch 4 by two parts of the punch 4. As shown in FIG. 8, a dose 1 is deposited on the punch 4, which includes several layers 20, 21, and 22, with layer 20 being the functional layer described above. In this embodiment, the encapsulation element 6 is formed by the specific structure of the punch 4, which includes an outer part and an inner part, and the inner part slides within the outer part. FIG. 8 shows an embodiment in which the dose 1 is deposited on the inner part of the punch 4, and the position of the inner part relative to the outer part is such that it is the outer part of the punch that forms the encapsulation element 6 for the dose 1. The end of the outer part at least partially covers the dose 1, in particular the functional layer 20, in accordance with the principles of the present invention.

[0074] In Figure 9, punch 4 and die 5 are brought closer together to compress and deform dose 1. This deformation results in the creation of a bead 7 between punch 4 and die 5, as shown in Figure 9.

[0075] As shown in Figure 10, the inner and outer parts of the punch 4 are moved relative to each other to press against the encapsulation element. Preferably, the outer part of the punch 4 is moved while the inner part remains in place to hold the dose 1.

[0076] The compression molding action is then continued to form the desired object 13 with the functional layer 20 trapped and invisible at the surface of the object 13, as shown in FIG.

[0077] Figure 12 shows an example of a multi-layer dose that can be obtained by continuous extrusion of a multi-layer strip, which is cut perpendicular to the direction of extrusion of said strip. In this example, dose 1 comprises several layers 20, 21, and 22, including functional layer 20. Each layer 20, 21, and 22 may be single-layer or multi-layer. As shown in Figure 12, dose 1 has a geometry that approximates that of a square-based parallelepiped, with a thickness 9 and a position 8 of functional layer 20. This type of dose is particularly advantageous for producing packages with a surface of revolution (e.g., coffee capsules) at high production rates.

[0078] The present invention is not limited to the dose example shown in Figure 12. The present invention can be used with multiple dose geometries, such as, for example, doses with circular or oval or rectangular bases (see, for example, Figures 33 to 36).

[0079] 13 to 17 show another embodiment of the invention in which, in accordance with the principles of the invention, the dose is compressed while being transferred to the mold.

[0080] The dose 1 is deposited on a support element 11 within an encapsulation element 6 that surrounds the dose at least up to the height of the functional layer 20 .

[0081] The dose 1 is compressed by the relative movement of the support element 11 and the deformation element 12, which compression creates a bead 7 that covers the encapsulation element 6, as can be seen in Figure 14. Then, as can be seen in Figure 15, the encapsulation element 6 is removed, and as can be seen in Figure 16, the compression of the dose 1 continues with the functional layer 20 confined within layers 21 and 22. Finally, as can be seen in Figure 17, the compressed and deformed dose 1 is obtained in a transfer system, which can then be deposited in a molding apparatus for the continuation and completion of the compression molding method and the formation of the desired object 13.

[0082] Preferably, the molding device used after the transfer operation in which the dose has undergone the encapsulation step does not need to be equipped with the encapsulation element described in the present application, and dose 1 in Figure 17 can be directly subjected to the compression molding process. Nevertheless, in other embodiments, an encapsulation step may be performed on a dose that has undergone a first encapsulation during transfer (e.g., dose 1 in Figures 17 and 22), which may be the case if the encapsulation during transfer is partial or insufficient (e.g., the transfer time is too short). In other embodiments, it is possible to perform several successive encapsulations of the same dose.

[0083] 18 to 23 show an embodiment in which the conveying device 10 comprises two encapsulation elements 6 and 16. The operation is similar to that shown and described with reference to FIGS. 13 to 17 for the first encapsulation element 6, while the second encapsulation element 16 makes it possible to limit the shape of the bead 7 to be created, as can be seen in FIGS. 19 to 21. More specifically, in FIG. 20 it can be seen that the first encapsulation element 6 has been removed, while the second encapsulation element 16 remains in place while the compression of the dose continues (FIGS. 20 and 21). At the end of the encapsulation process (FIG. 22), the two encapsulation elements 6 and 16 are removed, so that the dose 1 can be deposited in a molding device to undergo the process of compression molding and formation of the desired object 13.

[0084] In the embodiment of Figures 18 to 22, the encapsulation elements 6 and 16 are arranged on the support element 11, whereas in Figure 23, one encapsulation element 6 is arranged on the support element 11 and the other encapsulation element 16 is arranged on the deformation element 12.

[0085] Figure 24 shows an embodiment in which the forming device comprises two encapsulation elements 6 and 16. The operation is similar to that described in Figures 18 to 23.

[0086] 25 to 27 illustrate an embodiment in which the method of encapsulation of the functional layer is performed on the initial dose 1 during (eg, during or at the end of) the compression molding process, rather than at the beginning of the compression molding process.

[0087] As shown in Figure 25, the dose 1 undergoes a compression molding step between a punch 4 and a die 5 by relative movement of these two components towards each other. At a predetermined moment, an encapsulation element 6 is used to block the advancement or spreading of the functional layer 20 (see Figure 25). The compression molding process is then continued, thereby forming a bead 7 of material, as can be seen in Figure 26.

[0088] The encapsulation element 6 is then removed and the compression molding process continues with the functional layer 20 encased until the desired object 13 is obtained, as seen in FIG.

[0089] 28 to 30 show another embodiment in which a method of encapsulation of the functional layer 20 is carried out at the end of the compression molding process, so as to obtain an object 13 with the functional layer 20 enclosed therein. As shown in FIG. 28, the dose 1 undergoes a compression molding step between a punch 4 and a die 5 by relative movement of these two components towards each other. At a predetermined moment, an encapsulation element 6 is used to block the advancement or spreading of the functional layer 20 (see FIG. 28). The compression molding process is then continued, whereby a bead of material 7 is formed, as can be seen in FIG. 29.

[0090] Figures 31 and 32 show the principle of encapsulation for a dose comprising several functional layers 20, 20'.

[0091] In Figure 31, functional layers 20, 20' are spaced apart from one another, and in this case it is preferred to use one encapsulation element 6 on the die 5 and another encapsulation element 16 on the punch. The principle of operation is the same as above: in a first stage, the relative movement of punch 4 and die 5 towards one another forms a bead of material from layer 21, while the spreading of layers 22, 22', 20, and 20' is prevented by encapsulation elements 6 and 16. Once the bead of material covers encapsulation elements 6 and 16 (as shown in Figure 2), they are removed and the compression molding process continues to encapsulate layers 20 and 20' as described above and shown in the figures.

[0092] In Figure 32, another embodiment is shown having two functional layers 20, 20' adjacent to each other so that the encapsulation method can be carried out in a single encapsulation element 6 as shown in Figure 32. This process is similar to the process shown in Figures 1 to 4 and described above, except that the progression of the two functional layers must be temporarily blocked.

[0093] 33 to 36 show examples of the geometry of the containment element 6 (or 16) and the dose 1 as viewed along the compression axis of the dose. The choice of geometry selected for the containment element 6, 16 is related, for example, to the geometry of the dose 1 and the object 13 to be produced.

[0094] 33 shows an example of a square-bottomed dose 1 used to manufacture an object with a circular bottom (the object has a plane of revolution about the compression axis). To manufacture this object, a circular geometric encapsulation element 6 is preferably used, as this allows for the encapsulation of the functional layer as well as modification of the dose geometry after the encapsulation step. The encapsulation operation transforms the square bottom of the initial dose 1 into a circular bottom, ultimately resulting in a more uniform distribution of the functional layer within the object 13.

[0095] Figure 34 shows an example (projection onto a plane perpendicular to the compression axis) in which a dose 1 with a square base is used to produce an object 13 with an even square base. In this case, in order to optimize the distribution of the functional layers within the object 13, preferably an encapsulation element 6 with a square geometric shape as shown in Figure 34 is used.

[0096] FIG. 35 shows an example of a dose 1 with a rectangular base and an encapsulation element 6 that is also rectangular for producing an object 13 with a rectangular base.

[0097] FIG. 36 shows an example of a dose 1 with a rectangular base and an elliptical encapsulation element 6 for producing an object 13 with an elliptical base.

[0098] Industrially, it is easiest to obtain doses with a rectangular base, but doses with other shapes of base (for example, circular or elliptical) are of course also possible.

[0099] 37 to 40 show examples where the functional layer 20 constitutes a significant proportion of the dose 1 and the manufactured object 13, and where the functional layer 20 is made of, for example, recycled materials.

[0100] 37 to 39 show a first example in which the functional layer 20 must not be present on the inner surface of the object 13 (for example, a package intended to contain food). In this example, the functional layer 20 constitutes the dose 1 and the majority of the object 13. The material of the layer 21 forming the bead 7 prevents the functional layer 20 from being present on the inner surface of said object 13, for example, to prevent contact between the product contained in the object (which may be a package or part of a package) and the functional layer made of recycled material. The encapsulation and compression molding methods carried out are similar or even identical to those described above in various embodiments, and the encapsulation can be carried out as described above and shown in FIGS. 1 to 32.

[0101] Figure 40 shows a second example in which the functional layer constitutes the majority of dose 1 and object 13. The proposed dose 1 and encapsulation system makes it possible to obtain an object 13 in which the functional layer 20 is completely absent from the surface (internal and external) of the object 13, thanks to the presence of layer 22 (not present in the dose 1 example of Figure 37). This configuration is particularly advantageous for producing objects in which no recycled material is present on the surface of said object. The encapsulation and compression molding methods implemented are similar or even identical to those described above in the various embodiments, and the encapsulation can be carried out as described above and shown in Figures 1 to 32.

[0102] 41 shows the principle of encapsulation according to the invention for a dose 1 comprising holes and a functional layer 20 arranged perpendicular to the axis of the holes. In the case of a dose with holes, the principle is the same as described above, with e.g. encapsulation elements 6 and 16 being used to prevent at least the functional layer 20 from spreading.

[0103] 42 and 43 show the principle of encapsulation according to the invention for a dose 1 comprising holes and a functional layer 20 arranged parallel to the axis of the holes. In these embodiments, a support element 11 is inserted into the holes of the dose 1.

[0104] FIG. 43 shows an example of a method of encapsulation in which the dose 1 is deformed radially by a deformation element 12 .

[0105] Naturally, the principle of encapsulating the dose 1 with holes as shown in Figures 41 to 43 may also be applied in the mold during and / or after the transfer of the dose 1 in the carrier means, using the means arranged as described and illustrated in this application.

[0106] In all embodiments, the relative positions of the die 5 and punch 4, or of the transport system, are exemplary and may be rotated 180° overall, i.e., the die may be above the punch, or the punch above the die. Similarly, the relative motion to achieve the compression molding effect may be achieved by moving the punch towards the die or vice versa, or by moving each of the two towards each other.

[0107] The encapsulation elements 6, 16 may be removed by sliding or in another suitable manner.

[0108] In all embodiments, the encapsulation method may be carried out in a molding apparatus or a conveying apparatus.

[0109] To form the layers 20, 20', 21, 22, 22' of dose 1, any material may be used, such as a synthetic material, a cellulosic material, etc., which is suitable for being shaped in a mold that can be heated and / or cooled.

[0110] The embodiments are described to facilitate a general understanding of the principles of the structure, operation, manufacture, and use of the systems and methods described herein. One or more of these embodiments are illustrated in the accompanying drawings. The systems and methods specifically described in this application and illustrated in the accompanying drawings are non-limiting embodiments, and the scope of the present invention is not defined solely by the claims. Features illustrated or described for one embodiment may be combined with features of other embodiments. Such modifications and variations are intended to be within the scope of the present invention. A given number of problems encountered with conventional methods and systems have been addressed herein, and the methods and systems described herein may solve one or more of these problems. Moreover, while the present invention has been described with a given number of embodiments, alternatives, modifications, equivalents, and variations that fall within the spirit and scope of the present invention are also encompassed by this application.

Claims

1. 1. A method for covering at least the outer edge of a functional layer with a first layer, said layer being contained in a multi-layer dose intended to form an object by compression molding, said method comprising at least the following steps: deforming the dose; concurrently with the step of deforming the dose, temporarily inhibiting spreading of at least the functional layer such that spreading of material forms a bead of material from the first layer; ceasing the temporarily inhibiting step; A method comprising:

2. The method of claim 1 , wherein the deforming step is caused by compression of the dose.

3. The method of claim 2 , wherein the compression of the dose is performed over the entire surface of the dose or over a portion of the surface.

4. The method according to claim 2 or 3, wherein the direction of compression intersects a plane parallel to the functional layer.

5. The method of claim 1 , wherein the step of transforming the dose is performed by heating at least the first layer.

6. The method according to any one of claims 1 to 5, wherein said step is carried out during transport of said doses by a conveying means and / or immediately after said doses have been deposited in an apparatus for compression moulding.

7. The method according to any one of claims 1 to 6, wherein an additional step of deforming the dose is performed before the joint deforming and temporary blocking steps.

8. The method of any one of claims 1 to 7, wherein the step of deforming the dose continues after the step of temporarily inhibiting has ceased to form the object.

9. The method of claim 8 , wherein the deforming step is compression molding.

10. The method according to any one of the preceding claims, wherein the dose comprises at least two functional layers and / or the functional layers form a significant proportion of the dose.

11. The method of claim 1 , wherein the functional layer is a barrier layer and / or a layer made of recycled materials.

12. The method according to any one of claims 1 to 11, wherein the functional layer is completely covered by at least the first layer.

13. The method according to any one of the preceding claims, wherein the temporary blocking means is arranged on the conveying means and / or on the punch and / or on the die.

14. The method according to any one of claims 1 to 13, wherein said step of deforming said dose is carried out by a punch and a die at least during said compression moulding to obtain said body.

15. 15. An apparatus for carrying out the method according to any one of claims 1 to 14, intended to form an object from a multi-layer dose of material, said dose comprising at least one functional layer (20, 20') and a first layer (21), said apparatus comprising means (10, 11) for transporting said dose, means (4, 5, 12) for deforming said dose, means (4, 5) for subjecting said dose (1) to compression moulding, and means (6, 16) for temporarily preventing the expansion of said functional layer (20, 20') at least during said deformation of said dose.

16. 16. Apparatus according to claim 15, wherein the means (11, 12) for deforming the dose and the means (6, 16) for temporarily blocking the spreading of the functional layer are arranged on a conveying means (10).

17. 17. Apparatus according to claim 15 or 16, wherein the means for temporarily blocking the spreading of the functional layer are arranged on the mould (5) and / or on the punch (4).

18. 18. Apparatus according to claim 17, wherein the punch (4) comprises an inner part and an outer part, said parts being movable relative to each other to form said means for temporarily blocking the spreading of the functional layer.

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