Systems and methods for forming and using patterned and encapsulated films

Abstract

A method is provided that allows forming and sealing films to be embossed / debossed with a variety of shapes, including geometric, organic, fractal, and / or combinations thereof, and with a variety of sizes and depths. The texture or pattern is transferred from the insert to the film. The pattern on the forming and sealing film is transferred to the surface of a variety of protein products, including but not limited to chicken, turkey, beef, pork, and plant protein products, during the forming, filling, sealing, and cooking process. The forming and / or sealing insert allows for the formation of knitted nets, elastic nets, extruded nets, tightly woven nets, plastic nets, and / or a variety of thermoformed films with functional and / or decorative embossed and / or debossed features without the use of compression molds and / or release agents for net removal. The forming insert is formed using an additive manufacturing process, allowing for the formation of almost any design into the forming and sealing film.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of priority based on U.S. Provisional Patent Application No. 63 / 235,899, filed on August 23, 2021, which is incorporated herein by reference.

Background Art

[0002] In some cases, it may be desirable to emboss a pattern on the surface of meat products for purposes such as display, texture application, retention of certain spices or flavorings. By wrapping a protein product in a net during cooking and embossing the surface of the product, texture is added to the product. However, since the net is discarded after cooking, this process is wasteful. Therefore, there is a need for a forming and sealing film that can directly emboss a pattern on a protein product without the need for additional materials such as nets.

Summary of the Invention

[0003] The present invention provides a method that enables an embossing / de - embossing process to be performed on a forming and sealing film with various shapes such as geometric shapes, organic shapes, fractal shapes, and / or combinations thereof, and with various sizes and depths. The texture or pattern is transferred from an insert to the film. The pattern on the forming 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 forming, filling, sealing, and cooking processes. The forming and / or sealing insert can form various thermoformed films that have been subjected to functional and / or decorative embossing and / or de - embossing without using a knitted net, elastic net, extruded net, closely woven net, plastic net, and / or a release agent for net removal. Since the forming insert is formed using an additive manufacturing process, it is possible to emboss / de - emboss almost any design onto the forming and sealing film.

Brief Description of the Drawings

[0004] The accompanying drawings are incorporated herein and form a part hereof, and together with the detailed description of the invention, illustrate one or more aspects of the invention, further explaining the principles of the invention and enabling those skilled in the art to practice and utilize the invention.

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[0006] The features and advantages of the disclosed embodiments will be made apparent in the following detailed description, together with the drawings. In the drawings, like reference numerals indicate corresponding elements, and like reference numbers generally indicate elements that are identical, functionally similar, and / or structurally similar. Unless otherwise noted, the drawings provided throughout this disclosure are not necessarily to scale.

Best Mode for Carrying Out the Invention

[0007] In the cooking process, all standard forming, filling, and sealing processes incorporate a primary forming process. Usually, the primary forming process includes only a single film forming process. In contrast, the method of the present invention incorporates primary and secondary film forming processes. In the primary forming process, as shown in FIG. 1, an embossed film having a raised impression (convex portion) on the inside of the formed film is formed.

[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 primarily thermoformed embossed impression is transferred to the surface of the protein product during cooking and becomes a debossed depression (concave portion) or a lower depression (concave portion) of the protein product, as shown in FIG. 2.

[0009] The secondary forming process provides a lower debossed depression (concave portion) inside the formed pocket. The secondarily thermoformed shape is formed from the residual formed film material resulting from the primary thermoforming process. This concave portion simulates a functional and decorative pattern that is transferred to the surface of the protein product during the cooking process (FIG. 3).

[0010] The secondarily thermoformed bosses (recesses) are transferred onto the surface of the protein product and become embosses or raised impressions (protrusions) (Figure 4).

[0011] The forming and sealing film is formed through the following steps. First, the film is spread over the entire forming insert. The forming film is heated in a controlled manner to impart flexibility to the film and make it easier to form impressions (protrusions). Next, controlled high-pressure air is used to push the film into the forming insert. As a result, the forming film takes the shape of the forming insert. Next, the protein product to be sealed is placed within the forming insert on the forming film.

[0012] As shown in FIGS. 5A to 5E, any pattern can be formed on the forming insert and transferred to the forming and sealing film. Various patterns are included, but are not limited to, those shown below.

[0013] · Net or mesh pattern: transferred from the forming insert to the film and then to the protein product (FIGS. 5A to 5E) · Logo: company logo, watermark pattern, brand mark, text, or insertion of 2D / 3D layers into the protein product (FIG. 5D) · Patterns formed to mimic events occurring with different cooking styles (grilling, wrapping, grilling, etc.) (FIGS. 5C and 5E) · Intentional defects that characterize realistic and natural events occurring in the product

[0014] The forming film can take any shape that can accommodate the protein product (for example, a soccer ball-shaped ham, an egg shaped like a chicken for Easter, etc.). Various patterns can also be formed from combinations of geometric shapes, organic shapes, fractal shapes, squares, rectangles, rhombuses, hexagons, graduated shapes, branch shapes, wavy shapes, etc.

[0015] [Sealing process] Figure 6 is a flowchart showing standard processes used for the packaging and cooking of protein products. First, at step 602, a desired net is placed around the protein product. This step usually requires the most labor as it involves manually placing and sealing the protein product in the net. Next, at step 604, a roll stock packaging machine is used to form a pocket with a forming and sealing film. Specifically, the forming film is placed within a cavity of a forming shape to form a pocket, and the forming film is formed into a desired shape using thermoforming.

[0016] At step 606, the protein product contained in the net is placed into the formed pocket. At step 608, the pocket is sealed to create a vacuum state, hermetically packaging the protein product. Due to the pressure on the net caused by the vacuum, the net pattern is transferred to the protein product during cooking at step 610.

[0017] After cooking the protein product, first at step 612, the pocket is removed, and at step 614, the net is removed. The removal of the pocket at step 612 can be automated, but the removal of the net at step 614 needs to be done manually.

[0018] In the process of the present invention, many processes that require manual work or nets are eliminated, enabling a significant reduction in waste and manual work. As described above, the method of the present invention uses a forming and sealing film having a net pattern that is directly transferred to the protein product during cooking. This eliminates the need to perform steps 602 and 614 of manually attaching and removing the net.

[0019] Figure 7 is a flowchart showing the steps used in the packaging and cooking process according to the present invention. First, in step 702, a forming and sealing film is placed within a forming insert to form a pocket for the protein product. FIG. 8 is a perspective view of the forming insert 802, and FIG. 9 is a plan view of the forming insert 802. As shown, the forming insert 802 includes an upper portion having a forming cavity 804. The forming and sealing film is placed over the cavity 804, and rapid air forming is used so that the forming and sealing film conforms to the pattern of the forming insert 802. The sides of the forming insert 802 include a plurality of vent structures 806 for discharging air. Also, the sides of the forming insert 802 provide structural support to the forming insert 802.

[0020] FIG. 13 shows the formed and sealed film removed from the forming insert 802. As shown, the net pattern by the forming insert 802 is directly transferred to the forming film. Further, the 3D pattern on the formed and sealed film is transferred to the protein product during the cooking process (FIG. 14), eliminating the need to attach or remove a net to the protein product.

[0021] The forming insert 802 can also be connected to a roll stock using the anchor 808 shown in FIG. 10. The forming insert 802 is placed within a sealing box of the roll stock and secured to fit properly without shifting during the film forming process. The securing operation can be performed in several ways as follows.

[0022] · Slots, latches, bolts, or other securing features · Secure the insert within the forming or sealing box from its single or multiple sides, bottom, and / or top.

[0023] After forming pockets using the top and bottom of the forming insert 802, in step 706, a protein product is placed into the formed pockets. In step 706, the pockets are sealed to create a vacuum and the protein product is hermetically packaged. During cooking in step 708, the 3D pattern of the forming and sealing film is transferred to the protein product. After cooking the protein product, in step 710, the pockets are first removed. Since the impressions (protrusions) are directly transferred from the forming and sealing film, a net for making impressions on the protein product is not required. FIGS. 11 (perspective view) and 12 (plan view) show additional examples of sealing inserts with different patterns.

[0024] [Forming and sealing film] The process shown in FIG. 7 can be applied to various films depending on the cavity size, the required final shape, and the impressions (protrusions). Depending on the shape, a thinner film, a thicker film, a film with adhesiveness on the inner surface, a more porous film, etc. may be required, or the film may need to be pre - shrunk to various degrees. It is also possible to combine films according to the sealing requirements. For example, the following types of films are compatible.

[0025] · Polyethylene · Polypropylene · Nylon · Ethylene - vinyl alcohol copolymer · Barrier film · Combinations of film laminates

[0026] The forming and sealing film needs to be usable within a wide temperature range. The forming set temperature range is 90°C to 145°C, and the sealing temperature range is 130°C to 160°C. The physical forming of the forming and sealing film using the forming insert 802 can be achieved using any known method including plug assist, forced air, forced air with vacuum assist, stepped temperature control zones, high-pressure rapid air forming, or explosive forming in a vacuum state.

[0027] [Forming Insert] The following materials can be used for the additive manufacturing and creation of the sealing insert 802.

[0028] · Metals (aluminum, inconel, steel, titanium, or other nickel-based alloys) ○ The foam is formed by deposition, sintering, or other forms of melting and dissolution. ○ Meets product dimension specifications up to a maximum of 400mm × 400mm × 400mm. ○ It is a material that can withstand final finishing such as wire EDM (electrical discharge machining), drilling, cutting, electropolishing, and coating. ○ The final build needs to withstand pressures of 100 psi to 200 psi and temperatures of 150°C to 200°C. ○ Surface treatments such as electroless nickel plating using polytetrafluoroethylene, nickel polishing, or nickel PTFE (nickel Teflon plating) may be required.

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

[0030] · Plastics (ABS, PLA, PETG, nylon) ○ Used in the initial prototyping and testing phases as a low-cost alternative to test the feasibility of the foam shape. ○ The final build must withstand pressures of 100 psi to 200 psi and temperatures of 150 °C to 200 °C throughout the testing phase.

[0031] As described above, the insert 802 can be formed using substantially any pattern. This reduces the amount of metal and allows for the creation of a design that generates the required breathability and shape. The size of the air flow ventilation structure 806, and the primary and secondary forms, have not been used in previous thermoforming processes. The air flow / support structure design grid (see FIGS. 8 and 10) allows for the control of both the temperature of the film and the air flow to a small area of the film via embossing / debossing of the insert 802 shape to meet the requirements of the selected forming and sealing film.

[0032] Variable designs for the corners and edges for ventilation (which causes pressure variations and allows for the formation of deeper impression (boss) pockets in the primary and secondary forms) could not have been easily made by other methods heretofore. These variable corner ventilation structures in the primary and secondary forms can be of various size ranges to minimize or maximize the air flow rate. By adjusting the size of the ventilation structures of the primary and secondary forming inserts 802, embossing and debossing can be controlled, unlike when using a net.

[0033] For example, as shown in FIG. 8, each forming insert has a plurality of ventilation structures, while the current forming insert (used in FIG. 6) uses solid materials. By increasing the ventilation amount in the forming insert 802, the need to liquid-cool the forming box in step 604 is eliminated. Also, with the forming insert 802, one or more functions are physically integrated (sealing and pattern transfer).

[0034] The flange / leg support structure of the forming insert 802 enables such support and can minimize the materials required for the lattice structure, ventilation, and support. This structure provides the strength necessary to resist the internal pressure during forming and enables guiding the forming insert 802 into the forming box held via the anchor mechanism 808.

[0035] The overall outer shape of the forming insert 802, the impressions (protrusions) for the films at multiple levels, and the film adhesion vary according to control and different criteria. The goal is to establish conditions to stabilize the "primary thermoforming" cell and the "secondary thermoforming" cell, respectively, in order to maintain most of the original cell volume when heat treatment is performed during the product cooking cycle, and to establish conditions to generate "controlled shrinkage" in the "primary thermoforming" cavity shape 804 to provide appropriate package shrinkage force so that the cell pattern of the secondary forming is reliably transferred to the product during the cooking cycle. The following is a list of criteria in the forming process that assist in controlling film shrinkage.

[0036] · Selection of thermoforming material · Stability of thermoforming temperature · Temperature management of thermoforming tool · Forming air pressure and forming time · Cooling time after forming

[0037] [Generation of forming insert] Additive manufacturing requires software for generating a molding insert 802, including options for digitally converting a form through 3D scanning, designing the form with CAD software, and controlling the apparatus for manufacturing the sealing inserts used in the present invention.

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

[0039] 2. CAD Software: Construct a smooth topo mesh on the reference model scanned in Step 1 or use it to create a new model and generate a positive form object. a. Continue to generate a base pattern on the smooth retopology mesh (i.e., two meshes are created) b. Continue to create three copies of the base pattern mesh i. Backup copy mesh ii. Embedded copy mesh iii. Use of bevel tools to generate a net pattern extrusion mesh

[0040] 3. Secondary CAD Software: Use the base pattern mesh to generate a net pattern, a backing pattern, and support material. a. Combine all pieces into one model b. If feasible, construct a frame and fixed blocks if the final output is for metal 3D printing c. Perform cleanup, retopologization, hole filling, and face count reduction to facilitate export to the printer d. Include all lattice ventilation models including all steps from 2a - 2b e. Export the mesh (overall mold design)

[0041] 4. Slicer / Build Preparation Software: Imports the final mesh to verify the entire mold and establishes other paths and settings determined by the part orientation, support structure, layer thickness, timing, and form geometry. a. Generates an STL or native file by the build preparation software for use as instructions for the 3D printer to produce a final usable piece.

[0042] The embodiments described above illustrate some applications of the principles of the subject matter of the present invention. Those skilled in the art can make various modifications without departing from the spirit and scope of the subject matter described in the claims, including the features individually disclosed herein or combinations of features recited in the claims. For these reasons, the scope of the present invention is not limited to the above description, but is as set forth in the claims, and the claims are understood to represent the features of this specification, including the features individually disclosed herein or combinations of features recited in the claims.

Claims

1. A method of forming and using a sealed film with a pattern, comprising: placing the forming and sealing film on an upper forming insert, wherein the upper forming insert comprises a central cavity having a 3D embossing pattern, using the upper forming insert to form an upper film from the forming and sealing film, forming a lower film, combining the upper film and the lower film to form a film pocket, inserting a protein product into the film pocket, evacuating and sealing the protein product within the film pocket, cooking the protein product within the film pocket, during cooking, the 3D embossing pattern is transferred to the protein product, and after cooking the protein product, removing the film pocket, a method comprising the above.

2. The method according to claim 1, wherein the upper film and the lower film are formed by high-pressure rapid air forming.

3. The method according to claim 2, wherein the 3D embossing pattern is transferred to the upper film during forming.

4. The method according to claim 1, wherein the 3D embossing pattern comprises a plurality of raised regions and a plurality of recessed regions.

5. The method according to claim 1, wherein the 3D embossing pattern is a mesh pattern.

6. The method according to claim 1, wherein the 3D embossing pattern comprises a company logo or a figure.

7. The method according to claim 1, wherein the upper forming insert is aluminum.

8. The method according to claim 1, wherein the upper forming insert comprises a plurality of ventilation structures surrounding the cavity.

9. The method according to claim 8, wherein the upper forming insert further comprises an anchor portion for fixing the upper forming insert to a forming box during forming of the upper film.

10. The method according to claim 9, wherein forming the upper film does not require liquid cooling of the forming box.

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