Compression forming method and apparatus

Abstract

A method of forming an object comprises the steps of providing a mold (1; 101; 201; 301; 401; 501) including first and second mold parts (2; 102; 202; 302; 502) located opposite each other, and a plurality of sectors (8; 108; 208; 308; 508) included in either of the first and second mold parts, the sectors defining a variable volume generating region of the mold and forming at least a lateral portion of the object; displacing the first and second mold parts toward each other in a forming direction (D), and displacing the first and second mold parts by abutment surfaces (71, 72) of the first and second mold parts extending transversely to the forming direction. 72; 571, 572) to define a closed forming chamber between the first and second mold parts. The method further comprises reducing the variable volume generating region by moving the sector transversely to the forming direction. The mold comprises forming parts (15; 115; 215; 315; 515) that compress the moldable material in a forming direction by penetrating the variable volume generating region.

Description

[Technical Field]

[0001] The present invention relates to a method and apparatus for producing an object by compression molding a formable material. [Background technology]

[0002] Formable materials that can be manipulated in the methods and devices according to the present invention are, for example, synthetic polymeric materials.

[0003] Compression molding devices for producing objects in polymeric materials are known. The known devices include an extruder from which a continuous extrudate of polymeric material flows, and one or more cutting sections for cutting the continuous extrudate to separate successive unit portions of the polymeric material from the successive unit portions. The known devices further include one or more molds for receiving corresponding unit portions of the polymeric material and for creating objects from each unit portion.

[0004] The unit doses used in known devices usually have a simple shape, for example a sphere or a cylinder, for reasons related to their manufacturing method. The shape of the unit dose is often very different from the object to be produced. This can sometimes be disadvantageous, since it is difficult to insert the unit dose correctly into a mold.

[0005] In particular, it may occur that a mold has a forming cavity with lateral dimensions that are small relative to the dimensions of the unit dose because the corresponding dimensions of the object to be produced are small, and it may even be impossible to introduce the unit dose into the forming cavity because the lateral dimensions of the forming cavity are smaller than the corresponding lateral dimensions of the unit dose.

[0006] When this occurs, the object cannot be produced by compression molding unless a unit dose having a relatively complex shape that more closely matches the shape of the forming cavity is used, which is not always possible and in any case requires complex equipment to produce the unit dose.

[0007] Patent Document 1 discloses a mold for producing a container, such as a crate, by forming a plastic material. The plastic material is injected into a mold cavity while the mold is in a closed position. A portion of the mold cavity's sidewall is then moved to reduce the cavity's volume and form the container.

[0008] Patent Document 2 discloses a method for making a mold from powder, in which the mold has an undercut portion. A casting mold is used that includes two movable plate-like members that move away from each other to disengage from the undercut portion of the object and allow the object to be pulled out of the mold. The plate-like members are thus movable to increase the volume of the forming chamber from which the formed object must be removed.

[0009] Patent Document 3 discloses an apparatus for compressing an optical fiber, which includes six sectors arranged around an axis and a steel ring that acts on the sectors to move them closer to the axis and reduce the distance between pairs of opposing sectors. The apparatus includes a housing and a cover that can be removed to introduce an optical fiber between the sectors and then reused. Patent Document 3 does not define the forming direction. Furthermore, the apparatus disclosed in Patent Document 3 does not apply an axial compression action to the optical fiber because the distance between the two graphite blocks arranged above and below the optical fiber is constant. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] US Patent Application Publication No. 2006 / 0034973 [Patent Document 2] US Patent Application Publication No. 5,378,416 [Patent Document 3] French Patent No. 1549502 Summary of the Invention [Problem to be solved by the invention]

[0011] SUMMARY OF THE INVENTION It is an object of the present invention to provide improved compression molding apparatus and methods for producing objects from formable materials, such as synthetic polymeric materials.

[0012] A further object is to improve the method of introducing unit doses of formable material into molds used to manufacture objects.

[0013] Another object is to enable the compressive forming of a unit quantity of formable material to produce objects having transverse dimensions that are small relative to the dimensions of the unit quantity of formable material. [Means for solving the problem]

[0014] In one aspect of the present invention, there is provided a method of forming an object, the method comprising: - providing a mold including first and second opposed mold parts and a plurality of sectors, included in either the first or second mold part, that define a variable volume generating region of the mold and form at least a lateral portion of the object; - providing a quantity of moldable material between the first mold part and the second mold part; displacing the first and second mold parts toward each other in a forming direction and contacting abutment surfaces of the first and second mold parts extending transversely to the forming direction to define a closed forming chamber between the first and second mold parts; The method further includes the step of decreasing the volume of the variable volume generating region by moving the sector in a direction transverse to the forming direction.

[0015] Thanks to the first aspect of the invention, a variable volume forming region is available in the mold. A unit quantity of moldable material having a relatively large size and a shape completely different from the object to be obtained can be introduced into the variable volume forming chamber. This allows the compression molding technique to produce multiple objects of different shapes and sizes starting from unit quantities that have simple geometries and are therefore easy to obtain and manipulate.

[0016] In one embodiment, the unit dose of moldable material is placed between the first and second mold parts while the mold is in an open position, i.e., the first and second mold parts are spaced apart from each other.

[0017] In some embodiments, the mold includes a formation that penetrates the variable volume forming region to compress the moldable material in the forming direction.

[0018] The forming portion allows for a gradual reduction in the size of the forming chamber along the forming direction, in other words, the forming portion allows for a gradual reduction in the thickness of the object being formed measured in a direction parallel to the forming direction.

[0019] Thus, it is possible to compress the moldable material both parallel to the forming direction and transverse to the forming direction.

[0020] In one variant, the step of moving the sectors across the forming direction begins before the closed forming chamber is defined, i.e., before the abutment surfaces of the first and second mold parts come into contact with each other.

[0021] This allows the volume of the variable volume forming region to begin decreasing immediately after the unit dose of moldable material is introduced into the mold without waiting for the forming chamber to close.

[0022] In particular, the step of moving the sectors may also commence before the first mould part and the second mould part begin to displace towards each other to define the closed forming chamber.

[0023] In one embodiment, the plurality of sectors are movable between a first position and a second position, where in the first position the plurality of sectors define an expanded state of the variable volume forming region, and in the second position the plurality of sectors define a final state of the variable volume forming region.

[0024] In one embodiment, the unit dose is deposited on a portion selected from the first mold part and the second mold part, and a minor dimension of the unit dose transverse to (more specifically, perpendicular to) the forming direction is smaller than a corresponding dimension of the variable volume forming region in the expanded state transverse to (more specifically, perpendicular to) the forming direction.

[0025] This prevents the unit dose from coming into insufficient contact with the sector, which would result in unintended deformation of the unit dose and / or making it impossible to accurately position the unit dose in the mold.

[0026] In one embodiment, the second position is achieved before the closed forming chamber is defined.

[0027] In this case, the first mold part and the second mold part come into contact with each other only after the final state of the variable volume forming region is achieved.

[0028] In one embodiment, the sectors (contained within one of the first and second mold parts) face the other of the first and second mold parts so as to contact the other of the first and second mold parts after the closed forming chamber is defined.

[0029] By placing the sector in the second position - corresponding to the final state of the variable volume forming region - it is possible to prevent the sector from sliding in contact with the mold part opposite it while the sector is in the second position before defining the closed forming chamber.

[0030] In one embodiment, the mold parts facing the sectors comprise block parts intended to engage with end regions of the unit portions and thereby press them against the formations with which the sectors are associated, so as to block the unit portions from contacting the formations of the mold parts while the unit portions are being molded.

[0031] The blocking portion prevents unintentional displacement of the unit dose during formation.

[0032] In an alternative embodiment, the step of moving the sectors transverse to the forming direction can begin before the closed forming chamber is defined, but the second position of the sectors is achieved after the forming chamber is closed.

[0033] In another alternative embodiment, the step of moving the sectors transversely to the forming direction begins after the closed forming chamber has been defined.

[0034] This prevents unintended flow of the moldable material from the mold due to movement of the sectors.

[0035] In one embodiment, the first mold part is a female mold part, while the second mold part is a male mold part.

[0036] The first mold part may be positioned below the second mold part.

[0037] Alternatively, the first mold part may be positioned above the second mold part.

[0038] Thus, the female mold part may be positioned below the male mold part, or the female mold part may be positioned above the male mold part.

[0039] Providing a unit quantity of moldable material between the first mold part and the second mold part can include depositing the unit quantity on one mold part selected from the first mold part and the second mold part, the one mold part being positioned below the other mold part selected from the first mold part and the second mold part.

[0040] The sectors may be contained within the first mold part or the second mold part.

[0041] The sectors may thus be associated with the female mold part or the male mold part.

[0042] In one embodiment, the step of displacing the first mold part and the second mold part toward each other in the forming direction occurs by a drive device that moves at least one mold part selected from the first mold part and the second mold part toward another mold part selected from the first mold part and the second mold part.

[0043] In one embodiment, the sectors are associated with the mold parts that are moved by the drive.

[0044] This embodiment also allows the movement generated by the drive to be used to move the sectors transversely to the forming direction, so that the sectors can be moved transversely to the forming direction by interaction with a machine control associated with the other mold part, i.e., the mold part opposite the one moved by the drive.

[0045] In a second aspect of the present invention, there is provided an apparatus for forming an object. The apparatus comprises at least one mold. The at least one mold includes first and second mold parts located opposite each other, and a plurality of sectors included in either the first or second mold part to define a variable volume generation region of the mold and to form at least a side surface of the object. The apparatus further comprises a drive device for moving the first and second mold parts toward each other along the forming direction so that the first and second mold parts contact each other along respective contact surfaces disposed transverse to the forming direction to define a closed forming chamber between the first and second mold parts. The apparatus further comprises extrusion means for moving the sectors transverse to the forming direction to reduce the volume of the variable volume generation region.

[0046] The apparatus provided by the second aspect of the invention makes it possible to obtain the advantages mentioned above for the method according to the first aspect of the invention.

[0047] In a third aspect of the present invention, there is provided a method of forming an object, the method comprising: providing a mold including first and second mold parts positioned opposite each other and a plurality of sectors, the plurality of sectors being included in either the first or second mold parts to define a variable volume generating region of the mold and to shape at least a lateral portion of the object; disposing a unit quantity of moldable material between the first and second mold parts; defining a closed forming chamber between the first and second mold parts by displacing the first and second mold parts toward each other in a forming direction until the first and second mold parts contact; and reducing a volume of the variable volume generating region to form the object, wherein reducing the volume of the variable volume generating region includes moving the plurality of sectors transverse to the forming direction after defining the closed forming chamber.

[0048] In the method of the third aspect of the invention, before the forming chamber is closed, the sectors may be positioned at a relatively large distance from one another, which allows the mould to accommodate a unit dose of mouldable material having large dimensions relative to the size of the formed object, thereby enabling objects to be produced by compression moulding that are not obtainable with conventional compression moulding machines.

[0049] Because the sectors are displaceable transverse to the forming direction to reduce the volume of the closed forming chamber, the forming chamber may initially have a shape significantly different from the shape of the finished object, thereby making it possible to utilize unit quantities of simple shapes, which allows for the production and obtaining of objects with fairly complex geometric shapes.

[0050] By providing a forming chamber that is larger than the object to be produced, the risk of the moldable material unintentionally interacting with the mold, for example by insufficiently abutting the sides of the forming chamber, which may affect the quality of the resulting object, is reduced, thus allowing for improved introduction of the unit dose into the mold.

[0051] In one embodiment, when the first mold part and the second mold part come into contact, a contact portion contained in the second mold part comes into contact against a contact surface of the sector contained in the first mold part.

[0052] In one embodiment, the contact portion is a columnar member that surrounds a forming portion contained within the second mold part.

[0053] In one embodiment, after the forming chamber is closed, the forming portion and the columnar member may be moved relative to each other to cause the forming portion to enter the first mold portion.

[0054] In this manner, it is possible to shape the moldable material received within the first mold part.

[0055] In one embodiment, the sector is contained within the first mould part, the first mould part further comprising an end forming part which together with the sector defines a forming cavity.

[0056] In this way it is possible to shape the outer surface of the object to be produced in the first mould part.

[0057] In particular, the forming cavity may have a side surface and a cross section arranged at one end of the side surface and closing the side surface at one end.

[0058] The side surface may be completely defined by the sector, in which case the end forming portion defines only the cross section of the forming cavity.

[0059] In an alternative embodiment, a portion of said side surface is defined by said sector and said edge formation.

[0060] In this case, the end forming portion comprises a recess in which a part of the inner wall of the object can be formed.

[0061] The end formation also defines the cross section of the forming cavity.

[0062] This makes it possible to obtain objects with large dimensions in said direction of formation, as occurs for example in the case of container preforms.

[0063] In one embodiment, the object produced is a hole.

[0064] The first mold part has a protrusion that protrudes from the end forming part so as to form the interior of the hole.

[0065] In one embodiment, the providing step includes disposing the unit amount at a side of the protrusion in a non-central position relative to the sector.

[0066] When the sector moves transversely to the forming direction, thereby reducing the volume of the closed forming chamber, the unit volume is flattened around the protrusion, thereby allowing the formation of a hole in the object being manufactured.

[0067] This allows for a perforated object to be obtained without starting with a unit dose of moldable material having an annular shape.

[0068] In a fourth aspect of the present invention, there is provided an apparatus for forming an object. The apparatus includes a mold. The mold includes first and second mold parts located opposite each other, and a plurality of sectors included in either the first mold part or the second mold part to form at least a side surface of the object. The apparatus further includes a drive device for bringing the first mold part and the second mold part into mutual contact with each other along the forming direction to define a closed forming chamber between the first mold part and the second mold part. The apparatus further includes pushing means for moving the sectors transversely to the forming direction to reduce the volume of the variable-volume forming region.

[0069] As already explained in the third aspect of the invention, the apparatus provided by the fourth aspect of the invention also allows for the placement of the unit dose between the first and second mould parts and an extension of the range of objects that can be produced.

[0070] In a fifth aspect of the present invention, there is provided a method of forming an object, the method comprising the steps of: - providing a mold including first and second opposed mold parts; - disposing a unit quantity of moldable material between the first and second mold parts; and - displacing the first and second mold parts toward each other in a forming direction to form an object from the unit quantity by compression molding, wherein end regions of the unit quantity are blocked between the first and second mold parts before displacement of a central region of the unit quantity begins.

[0071] This can prevent unintended deformation of the unit dose during molding, such as preventing the unit dose from shrinking or becoming non-centered within the mold while being deformed between the first and second mold parts.

[0072] In a sixth aspect of the present invention, there is provided an apparatus for forming an object from a moldable material, the apparatus comprising at least one mold including first and second mold parts positioned opposite each other, and a drive for displacing the first and second mold parts toward each other in a forming direction to form an object from the unit portion by compression molding, wherein a mold part selected from the first and second mold parts comprises a blocking part intended to engage an end region of the unit portion to block the other mold part selected from the first and second mold parts from contacting the other mold part while the unit portion is being molded.

[0073] The blocking portion prevents unintentional displacement of the unit dose during formation. [Brief explanation of the drawings]

[0074] The invention may be more fully understood and implemented with reference to the accompanying drawings, which show, by way of non-limiting example, some variants of its implementation.

[0075] [Figure 1] 1 is a cross-sectional view of a mold for producing an object, the cross-section being taken in a plane containing the axis of the mold. [Figure 2] 2 is a cross-sectional view taken along the plane II-II of FIG. 1. In the figure, unit amounts of sliding material are not shown. [Figure 3] 2 is a cross-sectional view similar to FIG. 1 at a stage where a closed forming chamber is defined in the mold. [Figure 4] 2 relating to the stage of FIG. 3. FIG. [Figure 5]2 is a cross-section similar to FIG. 1 for the step of bringing sectors closer together to reduce the volume of the closed forming chamber. [Figure 6] FIG. 2 is a cross-sectional view similar to FIG. 1, illustrating an end portion forming step. [Figure 7] FIG. 7 is a cross-sectional view similar to FIG. 2 relating to the situation of FIG. 6. [Figure 8] 1 is a cross-sectional view of a mold for producing an object according to an alternative modification, the cross-section being taken in a plane containing the axis of the mold; [Figure 9] FIG. 9 is a view from above of the first part of the mold of FIG. 8. [Figure 10] 9 is a cross-sectional view similar to FIG. 8, but at a stage where a closed forming chamber has been defined in the mold. [Figure 11] 11 is a view from above like FIG. 9 related to the stage of FIG. 10. [Figure 12] 9 is a cross-sectional view similar to FIG. 8 of the step of reducing the volume of the closed forming chamber by bringing the sectors closer together. [Figure 13] 13 is a view from above like FIG. 9 related to the stage of FIG. 12. [Figure 14] FIG. 9 is a cross-sectional view similar to FIG. 8 relating to an end portion forming step. [Figure 15] 15 is a view from above like FIG. 9 related to the stage of FIG. 14. [Figure 16] 1 is a cross-sectional view of a mold for producing an object according to another alternative modification, the cross-section being taken in a plane containing the axis of the mold; [Figure 17] FIG. 17 is a top view of the first part of the mold of FIG. 16. [Figure 18] 17 is a cross-sectional view similar to FIG. 16, but at a stage when a closed forming chamber has been defined in the mold. [Figure 19] 17 is a top view like FIG. 17 related to the step of FIG. 18. [Figure 20] 17 is a cross-sectional view similar to FIG. 16 illustrating the step of reducing the volume of the enclosed forming chamber by bringing the sectors closer together. [Figure 21]20. FIG. 21 is a top view like FIG. 17 related to the stage of FIG. [Figure 22] 17 is a cross-sectional view similar to FIG. 16 relating to the edge forming step. [Figure 23] 23 is a top view like FIG. 17 related to the stage of FIG. 22. [Figure 24] 1 is a cross-sectional view of a mold for producing an object according to a further alternative variant relating to three successive stages of operation of the mold, the cross-section being taken in a plane containing the axis of the mold; [Figure 25] 1 is a cross-sectional view of a mold for producing an object according to a further alternative variant relating to three successive stages of operation of the mold, the cross-section being taken in a plane containing the axis of the mold; [Figure 26] 1 is a cross-sectional view of a mold for producing an object according to a further alternative variant relating to three successive stages of operation of the mold, the cross-section being taken in a plane containing the axis of the mold; [Figure 27] 2 is a schematic cross-sectional view similar to FIG. 1 relating to a mold having a multi-layer material processed therein. [Figure 28] 28 is a schematic cross-sectional view similar to FIG. 27, but relating to the stage where a closed forming chamber has been defined. [Figure 29] 28 is a schematic cross-sectional view similar to FIG. 27 relating to the step of reducing the volume of the closed forming chamber by bringing the sectors closer together. [Figure 30] FIG. 28 is a schematic cross-sectional view similar to FIG. 27 relating to an end portion forming step. [Figure 31] 10 is a schematic view of a mold according to an alternative variant in an open state. FIG. [Figure 32] 32 is a schematic diagram of the mold of FIG. 31 relating to the step of reducing the volume of the variable volume forming region by bringing multiple sectors closer to each other. [Figure 33] FIG. 32 is a schematic view of the mold of FIG. 31 in relation to the stage where a closed forming chamber has been defined. [Figure 34] 32 is a schematic diagram of the mold of FIG. 31 in relation to the edge forming step. [Figure 35] FIG. 35 is a schematic enlarged, interrupted view showing a detail of FIG. 34; DETAILED DESCRIPTION OF THE INVENTION

[0076] 1-7 show a schematic representation of a mold 1 of a forming apparatus for producing an object by compression molding a formable material. In the illustrated embodiment, the formable material is a synthetic thermoplastic material that has been pre-extruded in an extrusion apparatus (not shown). The extruded material is then cut into separate unit portions or unit portions 100 from the formable material having a predetermined mass. Each unit portion 100 is intended to generate an object. In the illustrated example, the unit portions 100 have a substantially spherical shape, although other shapes of the unit portions 100 are also possible, such as cylindrical or prismatic shapes.

[0077] The forming apparatus may comprise a transport device (not shown) for transporting each unit dose 100 to a mold 1 after it has been separated from the material exiting the extruder apparatus. The forming apparatus may comprise a plurality of molds 1 mounted, for example, on a peripheral region of a carousel rotatable about an axis of rotation.

[0078] In the illustrated example, mold 1 is intended to form a preform for a container. The preform is intended to be blow-molded or stretch-blow-molded to obtain the container. The preform comprises a hollow body with a side wall, which may be cylindrical or tron-conical. The side wall is closed by a transverse wall, which may be dome-shaped. The preform further comprises a neck, which may be externally provided with fastening means for removably fastening a cap to the neck of the container obtained from the preform. The fastening means may, for example, comprise one or more screw threads.

[0079] The mold 1 comprises a first mold part 2 and a second mold part 3 facing each other. A drive device (not shown) is arranged to move the first mold part 2 and the second mold part 3 relative to each other along the forming direction D, bringing the first mold part 2 and the second mold part 3 closer to each other or, alternatively, moving them away from each other. The drive device may be hydraulic, mechanical or other. An example of a hydraulic drive device is a hydraulic actuator. An example of a mechanical drive device is a cam device.

[0080] A driver may be associated with the first mold part 2 to move the first mold part 2 toward or away from the second mold part 3, which remains fixed along the forming direction D. Alternatively, a driver may be associated with the second mold part 3, while the first mold part 2 remains fixed along the forming direction D. A driver may be associated with both the first mold part 2 and the second mold part 3, such that both are movable along the forming direction D.

[0081] Furthermore, the forming direction D, which is vertical in the illustrated example, may also be non-vertical, for example horizontal or oblique.

[0082] In the illustrated example, the first mold part 2 is a female mold part and the second mold part 3 is a male mold part.

[0083] In the illustrated example, the first mold part 2 is arranged below the second mold part 3, but this condition is not necessary and other relative arrangements of the first mold part 2 and the second mold part 3 are possible.

[0084] The first mold part 2 has a forming cavity 24 in which the outer surface of the object can be formed. The forming cavity 24 can have a Y axis.

[0085] In the illustrated example, the first mold part 2 comprises a plurality of sectors 8 and an end forming portion 14. The plurality of sectors 8 and the end forming portion 14 interact to define a forming cavity 24.

[0086] In particular, the sector 8 is configured adjacent to the second mold part 3 to define a variable volume forming region 4 of the forming cavity 24. The end forming portion 14 is arranged to form at least one end wall of the object extending transversely to the forming direction D. In the example shown, the end forming portion 14 included in the forming cavity 24 is provided with a recess 70. The recess 70 defines a portion of the forming cavity 24 having a constant volume.

[0087] The sector 8 is interposed between the end forming part 14 and the second mould part 3 .

[0088] The sectors 8 and the end formers 14 are arranged to form the outer surface of the object to be manufactured. More specifically, if the object to be manufactured is a preform, the sectors 8 are intended to form at least the preform neck from the outside, while the end formers 14 are arranged to form the end wall of the preform from the outside, in addition to the hollow body interposed between the neck and the end wall.

[0089] The variable volume forming region 4 is defined by side surfaces 5 which surround a central region 6. The side surfaces 5 are intended to externally form at least the preform neck.

[0090] The sectors 8 are suitable for defining the side surfaces 5 of the variable volume forming region 4 .

[0091] In the illustrated example, four sectors 8 are provided: a first sector 8a, a second sector 8b, a third sector 8c, and a fourth sector 8d.

[0092] Each sector 8 is in contact with two adjacent sectors 8. For example, in the illustrated variant, a first sector 8a is in contact with a second sector 8b and a fourth sector 8d that are adjacent to the first sector 8a.

[0093] In alternative embodiments not shown, it is possible to provide a number of sectors 8 other than four.

[0094] The sectors 8 may have the same shape.

[0095] Each sector 8 comprises a body 9 which may have a substantially parallelepiped shape. Forming appendages 10 project from the body 9, protruding from the part of the body 9 directed towards the central region 6. The body 9 is defined by forming surfaces 11 facing the forming region 4 and which, together with the forming surfaces 11 of all sectors 8, are intended to define the side surfaces 5 of the variable volume forming region 4.

[0096] In the example shown, the forming surface 11 defines the forming appendage 10 of the corresponding sector 8 .

[0097] The forming surface 11 may be curved.

[0098] In the example shown, each forming surface 11 has the shape of a cylinder, more specifically a quarter cylinder, with recessed and / or raised portions for forming threads or other fastening means on the preformed neck.

[0099] Each sector 8 is further defined by a sliding surface 12 disposed adjacent to the forming surface 11. Adjacent sectors 8 slide along the sliding surface 12 of the sector 8, as will be better explained below. The sliding surface 12 is formed as a continuation of the forming surface 11. The sliding surface 12 may be seamlessly continuous with the forming surface 11. The sliding surface 12 may be tangent to the forming surface 11. In the illustrated example, each sliding surface 12 has a substantially flat shape.

[0100] Each sector 8 also has a contact surface 13 arranged on the opposite side of the forming surface 11 relative to the sliding surface 12, i.e., on the part of the forming appendage 10 opposite the forming cavity 24. The contact surface 13 of a sector 8 is intended to slide along the sliding surface 12 of an adjacent sector 8. In the example shown, the contact surface 13 has a substantially flat shape.

[0101] The forming device further comprises a plurality of pressing devices (not shown) arranged to apply a force to the corresponding sector 8 so as to press each sector 8 towards the central region 6 of the variable volume forming region 4 .

[0102] Each pressing device may comprise, for example, a hydraulic, electric, or pneumatic actuator. Alternatively, each pressing device may comprise, for example, a cam-type mechanical actuator. The pressing devices allow the sectors 8 to be moved between a first position P1 shown in FIGS. 1 and 2 and a second position P2 shown in FIGS. 6 and 7. In the first position P1, the sectors 8 define an expanded state C1 of the variable volume forming region 4. In the second position P2, the sectors 8 define a final state C2 of the variable volume forming region 4.

[0103] In the final state C2, the variable volume forming region 4 has a shape corresponding to the outer shape of the preformed neck. In the expanded state C1, the variable volume forming region 4 instead has dimensions that are larger than the dimensions of the preformed neck, i.e., larger relative to the dimensions that the variable volume forming region 4 has in the final state C2. To switch from the expanded state C1 to the final state C2, the volume of the variable volume forming region 4 decreases.

[0104] It is possible to provide a number of pushing devices equal to the number of sectors 8, ie a pushing device associated with each sector 8, so that each sector 8 is moved by a corresponding pushing device.

[0105] 4, the first pressing device (not shown) may be configured to apply a first force F1 directed along a first direction D1 to the first sector 8a, the first force F1 being such that the first sector 8a moves towards the central region 6 of the variable volume forming region 4, in particular by reducing the distance between the sliding surface 12 of the first sector 8a and the Y axis.

[0106] When the first sector 8a moves towards the forming axis Y, the contact surface 13 of the first sector 8a slides along the sliding surface 12 of the second sector 8b. The first force F1 and the corresponding first direction D1 are in fact directed parallel to the contact surface 13 of the first sector 8a and the sliding surface 12 of the second sector 8b.

[0107] Furthermore, the part of the sliding surface 12 of the first sector 8a that is in contact with the fourth sector 8d presses the fourth sector 8d (in particular its contact surface 13) by moving the forming appendage 10 of the fourth sector 8d towards the forming axis Y, i.e. towards the central region 6 of the variable volume forming region 4. This occurs because the sliding surface 12 of the first sector 8a and the contact surface 13 of the fourth sector 8d are arranged transversely, in particular perpendicularly, to the first direction D1 of the first force F1.

[0108] At the same time, the second pushing device acts on the second sector 8b and applies to the second sector a second force F2 directed along a second direction D2 arranged transversely to the first direction D1.

[0109] In the illustrated example, the second direction D2 is perpendicular to the first direction D1.

[0110] Therefore, the second sector 8b is pushed toward the central region 6 of the variable volume forming region 4, i.e., toward the Y axis. At this time, the contact surface 13 of the second sector 8b slides along the sliding surface 12 of the third sector 8c.

[0111] The second sector 8b is in contact with the first sector 8a because the contact surface 13 of the first sector 8a is in contact with the sliding surface 12 of the second sector 8b. These two surfaces are arranged transversely, specifically perpendicularly, to the second direction D2. Thus, under the action of the second pushing device, the second sector 8b transmits a second force F2 to the first sector 8a.

[0112] In this way, the force applied to the first sector 8a, given by the combination of the first force F1 and the second force F2, pushes the forming surface 11 (particularly the forming appendage 10) of the first sector 8a toward the Y axis along a trajectory that is obliquely disposed relative to the first direction D1 and the second direction D2. For example, the forming surface 11 of the first sector 8a may move in the Y axis direction along a direction that is inclined at 45° relative to the first direction D1 and the second direction D2.

[0113] The same situation occurs with reference to the other pair of sectors 8. For example, a third force F3 directed along a third direction D3 is applied to the third sector 8c by a third pressing device. The third direction D3 may be the same as or opposite to the first direction D1.

[0114] The third force F3 pushes the third sector 8c toward the central region 6 of the variable volume forming region 4, while the contact surface 13 of the third sector 8c slides along the sliding surface 12 of the fourth sector 8d. At the same time, the sliding surface 12 of the third sector 8c contacts the contact surface 13 of the second sector 8b, so that the third force F3 is transmitted to the second sector 8b, which contacts the third sector 8c. A force resulting from the combination of the second force F2 and the third force F3 is applied to the second sector 8b.

[0115] The fourth pushing device applies a fourth force F4 to the fourth sector 8d, directed along a fourth direction D4, which in the illustrated example is the same as and opposite to the second direction D2, and is therefore arranged transversely, in particular perpendicularly, to the first direction D1 and the third direction D3.

[0116] Thus, the fourth sector 8d moves toward the Y axis and slides along the first sector 8a in a direction parallel to the fourth direction D4. At the same time, the fourth sector 8d transmits a fourth force F4 to the third sector 8c. The resulting force, given by the combination of the third force F3 and the fourth force F4, which is directed along a direction inclined relative to the third direction D3 and the fourth direction D4, acts on the latter.

[0117] The first force F1 from the first sector 8a is also transmitted to the fourth sector 8d, resulting in the forming appendage 10 of the fourth sector 8d moving toward the Y-axis under the combined action of the first force F1 and the fourth force F4.

[0118] Generally, a force directed toward the Y-axis is applied to each of the sectors 8, which pushes the forming appendage 10 of the corresponding sector 8 toward the central region 6 of the variable-volume forming region 4. At the same time, the contact surface 13 of the sector 8 under consideration may be parallel to the force applied to that sector and slides along the sliding surface 12 of the adjacent sector 8. The sliding surface 12 of the sector 8 under consideration is arranged transversely (e.g., perpendicularly) relative to the contact surface 13 of another adjacent sector 8, and transmits the force applied to the sector 8 under consideration to the other adjacent sector 8, pushing the forming appendage 10 of the other adjacent sector toward the Y-axis. Thus, two forces are applied to each sector 8, one of which is exerted by a pressing device associated with the sector 8 under consideration and the other by a sector 8 adjacent to the sector under consideration. The result of these two forces pushes the forming surface 11 of the sector 8 under consideration toward the Y-axis along a trajectory that may be radial to the Y-axis. In this way, the sectors 8 make it possible to reduce the volume of the variable volume forming region 4 in which the formable material is already located.

[0119] In the above-described embodiment, a pressing device is provided for each sector 8. In an alternative variant not shown, the number of pressing devices may be different from, and in particular may be less than, the number of sectors 8. For example, in an embodiment not shown, only two pressing devices may be provided, acting on the first sector 8a and the second sector 8b respectively, while the third sector 8c and the fourth sector 8d are arranged in a fixed position.

[0120] The sector 8 is slidable in contact with the end former 14 and moves from a first position P1 to a second position P2.

[0121] The second mold part 3 extends along the Y-axis and comprises a male forming element shaped like a punch, arranged to penetrate the variable volume forming region 4 so as to form the object to be produced from within. In other words, the male forming part 15 allows the formable material to be compressed along a direction parallel to the Y-axis. An abutment 16, against which the male forming part 15 can slide, is arranged on the outside of the male forming part 15.

[0122] The abutment portion 16 is positioned to abut against the first mold part 2 for reasons that will be explained below. The abutment portion 16 may be formed as a tubular element, i.e., have a hole therein that receives the male mold forming element.

[0123] In an alternative embodiment not shown, the male forming part 15 is arranged inside the abutment part 16 with one or more parts interposed between the male forming part 15 and the abutment part 16 .

[0124] The abutment portion 16 is defined by a front surface 71 extending transversely, in particular perpendicularly, to the Y axis. The front surface 71 faces the sector 8, more particularly facing the abutment surface 72 that defines the sector 8.

[0125] During operation, the mold 1 is initially in an open position, i.e., the first mold part 2 and the second mold part 3 are in the spaced apart position shown in FIG. 1 , in which the abutment part 16 is removed from the first mold part 2. In particular, the front face 71 of the tubular element 16 is not in contact with the abutment face 72 of the sector 8. The forming cavity 24 is open at the top, and a transport device (not shown) may be introduced between the first forming part 2 and the second forming part 3 to deposit a unit dose 100 of formable material into the forming cavity 24. The male forming part 15 is in a retracted position relative to the abutment part 16 and does not protrude from the abutment part 16.

[0126] Sector 8 is positioned at first position P1 and defines expanded state C1 of variable volume forming region 4. Sector 8 therefore defines variable volume forming region 4 having a relatively large volume, which can receive unit portions 100 of formable material having significant dimensions, measured transversely to forming direction D. In particular, unit portions 100 may have a transverse dimension (e.g., diameter, in the case of a spherical unit portion 100) that is greater than the outer diameter of a preformed neck formed by unit portion 100.

[0127] In the example shown, the unit dose 100 is received between the sectors 8 and is initially positioned on the upper region of the end formation 14. The unit dose 100 is therefore initially spaced from the bottom of the recess 70.

[0128] Furthermore, the unit portion 100 has a lateral dimension (e.g., diameter, in the case of a spherical unit portion 100) that is smaller than the corresponding lateral dimension of the variable volume forming region 4 when the latter is in the expanded state C1. Thus, when the unit portion 100 is deposited in the first mold part 2, the unit portion 100 is spaced apart from the sector, and in particular from the side surface 5 of the variable volume forming region 4.

[0129] 3, the first mold part 2 and the second mold part 3 are moved towards each other until the abutment 16 abuts against the sector 8. A drive, not shown, acts on the first mold part 2, displacing it towards the second mold part 3 and bringing the abutment surface 72 of the sector 8 into contact with the abutment 16, in particular with the front face 71 of the latter. The front face 71 therefore acts as a further abutment surface against which the abutment surface 72 abuts.

[0130] When the sector 8 and the second mold part 3 come into contact with each other, i.e. when the respective abutment surfaces 71, 72 of the first mold part 2 and the second mold part 3 come into contact, a closed forming chamber 17 is defined between the first mold part 2 and the second mold part 3, which has a volume much larger than the final volume of the object to be produced, i.e. the preform, as shown in Figure 3. More specifically, the forming chamber 17 is defined between the end forming part 14, the sector 8, the abutment part 16 and the male forming element 15.

[0131] The male forming part 15 is still in the retracted position and does not protrude from the abutment 16 .

[0132] The sector 8 is still in the first position P1, as shown in Figure 4. Therefore, the unit quantity 100 has not yet undergone any significant deformation.

[0133] The drive continues to press the first mold part 2 towards the male former 15. In this way, the abutment 16 in contact with the first mold part 2 is also retracted, for example by compressing one or more springs not shown.

[0134] The male forming part 15 may be disposed in a fixed position in the forming direction D. Thus, as the abutment part 16 continues to be displaced rearward (i.e., upward in FIG. 5 ) from the first mold part 2, the male forming part 15 begins to protrude from the abutment part 16 and penetrate the forming cavity 24. First, the male forming part 15 penetrates the variable volume forming region 4 and then also enters the recess 70, as shown in FIG. 5 . Thus, the formable material is gradually compressed along the forming direction D, i.e., parallel to the Y-axis.

[0135] At the same time, the sectors 8 that were initially in the first position P1 begin to approach one another in the manner described above, as shown in Figure 5. In particular, each sector 8 moves in motion under the action of the forces exerted on it by the corresponding pressing device and by the adjacent sectors 8, so that the corresponding forming surface 11 approaches the Y axis and displaces itself along a trajectory that may be linear, for example, inclined at 45° to the direction of the two forces exerted on the sector 8 under consideration.

[0136] The volume of the forming chamber 17 gradually decreases and formable material, not shown in FIGS. 5-7, gradually forms between the first mold part 2 and the second mold part 3.

[0137] The first mold part 2, male forming element, sector 8, continues to move towards the Y axis until it reaches the state shown in Figures 6 and 7. In this state, sector 8 has reached second position P2 and the male forming part 15 is at a distance from the bottom region of recess 70 that is substantially equal to the thickness of the end wall of the preform.

[0138] A preform is thus obtained from the unit quantity 100. The latter remains in the mould 1 and is cooled by cooling means (not shown) for a time sufficient to reach a degree of hardness that allows it to be handled without damage. Subsequently, by a series of steps opposite to those described above, the mould 1 is opened, the preform is removed and a new forming cycle can be started.

[0139] As is clear from a comparison between FIG. 4 and FIG. 7, not only the volume but also the shape of the variable volume forming region 4 changes from the expanded shape C1 to the final shape C2.

[0140] More specifically, in the illustrated example, in the expanded state C1, the side surface 5 of the variable volume forming region 4 is defined by a plurality of curved portions corresponding to the forming surfaces 11, with respective flat portions corresponding to the sliding surfaces 12 interposed therebetween.

[0141] In the final state C2, each forming surface 11 adjoins the forming surface 11 of the adjacent sector 8, and each sliding surface 12 is covered or hidden by the forming appendage 10 of the adjacent sector, so that the sliding surface 12 no longer faces the forming area 4. The mold 1 makes it possible to obtain good quality objects with curved side walls, for example circular.

[0142] 8 to 15 show mold 301 according to an alternative variant, which makes it possible to obtain objects having a non-circular shape in plan view, for example a polygonal shape. In the example shown, mold 301 in particular makes it possible to produce spoons shaped like scoops, in particular for ice cream, yogurt or other cream products. However, molds similar to mold 301 can also be used to produce objects other than spoons. Parts of mold 301 that are similar to parts of mold 1 described above are designated by the same reference numerals already used in FIGS. 1 to 7 and will not be described in further detail.

[0143] The mold 301 is also particularly suitable for producing objects in synthetic polymeric materials from unit doses 100 of the synthetic polymeric materials, which were separated from the continuous extrudate emerging from the extrusion device and subsequently transported towards the mold 301 via a transport device, not shown.

[0144] In the illustrated example, the unit dose 100 has a substantially spherical shape, although other shapes for the unit dose 100 are possible.

[0145] The unit dose 100 has a relatively large dimension relative to the size of the resulting object. In the illustrated example, the unit dose 100 has a diameter larger than the transverse dimension W of the object to be formed, shown in FIG.

[0146] The mold 301 also comprises a first mold part 302 and a second mold part 303 which are movable relative to each other along a forming direction D, which is vertical in the illustrated example. The first mold part 302 and the second mold part 303 are similar to the first mold part 2 and the second mold part 3 described above.

[0147] In particular, in the illustrated example, first mold part 302 is the female part and is positioned below second mold part 303 .

[0148] The first mold part 302 comprises a plurality of sectors 308 adapted to define sides 5 that define a variable volume forming region 4 .

[0149] In the illustrated example, the sectors 308 have different shapes.

[0150] In particular, in the illustrated example, there are four sectors 308, although the number of sectors 308 may be different from four.

[0151] In the depicted example, a first sector 308a, a second sector 308b, a third sector 308c, and a fourth sector 308d may be identified as shown in FIG.

[0152] Each sector 308 is defined by a forming surface 311 facing the variable volume forming region 4 .

[0153] In the illustrated example, first sector 308a and third sector 308c each have a substantially flat forming surface 311, while second sector 308b and fourth sector 308d have forming surfaces 311 that are not flat but have, for example, steps 56, to define enlarged portions of the spoons to be formed, which are dispense portions for dispensing material, e.g., food products, from the container.

[0154] Each sector 308 also has a sliding surface 312 disposed adjacent to the forming surface 311 of that sector. The sliding surface 312 may be a continuation of the forming surface 311. The sliding surface 312 faces the variable volume forming region 4.

[0155] Each sector also has a contact surface 313 adapted to slide along the sliding surface 312 of an adjacent sector.

[0156] The sliding surface 312 and the contact surface 313 may both be flat. The contact surface 313 of a sector 308 is arranged transversely, in particular perpendicularly, to the sliding surface 312 of the same sector 308. The forming surface 311 is interposed between the contact surface 313 and the sliding surface 312 of the sector 308. In this way, an end region of the forming surface 311 adjoins the sliding surface 312, while a further end region of the forming surface 311 opposite to the aforementioned end region adjoins the contact surface 313.

[0157] A plurality of pushing devices, not shown, are further provided for applying respective forces to the sectors 308 directed towards the central region 6 of the variable volume forming region 4 .

[0158] In particular, the pushing device is configured to apply a first force F1, a second force F2, a third force F3, and a fourth force F4 to the first sector 308a, the second sector 308b, the third sector 308c, and the fourth sector 308d, respectively, as already described above with reference to Figures 1 to 7.

[0159] Each sector 308 is displaceable towards the central region 6 of the variable volume forming region 4 by the result of two different forces: one of these forces is exerted on the sector 308 by a corresponding pressing device, while the other force, directed laterally (in particular perpendicularly) to the previous one, is transmitted to the sector 308 by the adjacent sector.

[0160] Under the action of the force exerted on each sector 308 by the respective pushing device, the latter moves towards the central region 6, as a result of which the contact surface 313 of the sector 308 under consideration slides along the sliding surface 312 of the adjacent sector. At the same time, the adjacent sector 308 transmits a force to the sector 308 under consideration, as a result of which the sliding surface 312 of the sector 308 under consideration flows along the contact surface 313 of the further sector 308 adjacent to the sector 308 under consideration. The first mold part 302 further comprises an end forming portion 314 along which the sector 308 can slide. The end forming portion 314 defines, from the opposite side of the second mold part 303, a variable volume forming region 4 transversely to the forming direction D.

[0161] The end forming portion 314 together with the sector 308 defines the forming cavity 24, which in the illustrated example is open upwards.

[0162] In the illustrated example, the end forming portion 314 is of a slab type. Unlike what occurs in the mold 1 shown in Figures 1 to 7, the end forming portion 314 is not provided with any recesses into which a formable material can be formed.

[0163] 8-15, the forming cavity 24 extends about the Y axis and has sides defined by sectors 308. The forming cavity 24 further has lateral surfaces defined by end forming portions 314. The lateral surfaces of the forming cavity 24 may be flat.

[0164] The second mold part 303 includes a forming part 315 adapted to penetrate the forming cavity 24 to form the desired object by applying a compressive action to the formable material in a direction parallel to the Y axis, i.e., along the forming direction D.

[0165] The forming part 315 is arranged inside an abutment part 316, which in the example shown has a central hole in which the forming part 315 is received. The abutment part 316 is adapted to abut against the sector 308 to close the forming chamber 17 defined between the first mold part 302 and the second mold part 303.

[0166] The forming component 315 is slidably movable along the forming direction D relative to the abutment portion 316 .

[0167] In operation, the mold 301 is initially in an open position, i.e., the first mold part 302 and the second mold part 303 are initially in a spaced apart position, as shown in Figure 8. The front surface 71 of the abutment part 316 is spaced apart from the abutment surface 72 of the sector 308. A transport device, not shown, can thus deposit a unit dose 100 of formable material into the forming cavity 24.

[0168] The sectors 308 are in a first position P1, as shown in Figure 9. Thus, a variable volume forming region 4 is defined between the sectors 308 and has dimensions that are larger than the size of the unit dose 100, so that the unit dose 100 can be received within the variable volume forming region 4 without interfering with the sectors 308.

[0169] The drive device moves the first mold part 302 and the second mold part 303 towards each other in the forming direction D, so that the first mold part 302 and the second mold part 303 come into contact to define therebetween a closed forming chamber 17. In particular, the first mold part 302 and the second mold part 303 come into contact when the abutment surface 72 comes into contact with the front surface 71, which can be considered a further abutment surface.

[0170] In the example shown, the drive is associated with the first mold part 302 and pushes the first mold part towards the second mold part 303. When the abutment surface 72 of the sector 308 contacts the front surface 71 of the abutment part 316, a closed forming chamber 17 is defined between the end forming part 314, the sector 308, the abutment part 316 and the forming part 315. The latter is still in a retracted position in which it does not protrude from the abutment part 316 towards the end forming part 314, as shown in Figure 10.

[0171] As shown in FIG. 11, the sector 308 is still in the first position P1 and has not yet begun to interact significantly with the unit quantity 100.

[0172] 12 and 13, a pressing device (not shown) acts on sector 308 to bring sector 308 into second position P2, which causes a gradual decrease in the volume of variable volume forming region 4 and thus the volume of closed forming chamber 17.

[0173] While sector 308 is moved to second position P2, the drive device continues to move first mold part 302 toward second mold part 303. Sector 308, pushed toward second mold part 303 by the drive device, retracts abutment portion 316 relative to forming element 315. Thus, forming element 315 begins to protrude from abutment portion 316, penetrating forming cavity 24 and pushing formable material toward end forming element 314 in forming direction D. The formable material is gradually forced to fill the entire closed forming chamber 17 to produce the desired object. Note that forming element 315 penetrates forming cavity 24 by sliding in contact with sector 308 to form a flat object; i.e., no formable material is interposed between forming element 315 and sector 308.

[0174] The driver continues to press the first mold part 302 toward the second mold part 303, while the forming element 315 gradually protrudes from the abutment 316. In this manner, the forming element 315 continues to approach the end forming portion 314 until it reaches a distance from the end forming portion 314 equal to the thickness of the resulting object, as shown in Figure 14. The mold 301 remains in this state long enough for the object to become rigid enough to be handled without damage, after which the first mold part 302 and the second mold part 303 move away from each other and the object is removed to allow a new unit dose 100 to be introduced into the variable volume forming region 4.

[0175] This makes it possible to obtain by compression forming objects having relatively small dimensions transverse to the forming direction D, but which require relatively large unit quantities, i.e. have initial transverse dimensions larger than the corresponding dimensions of the finished object.

[0176] 16 to 23 show a mould 101 according to an alternative variant, which makes it possible to obtain perforated objects, in particular objects with through holes.

[0177] The mold 101 comprises a first mold part 102 and a second mold part 103 that face each other and are movable relative to each other in a forming direction D, similar to those described for the first mold part 2 and the second mold part 3 shown in Figures 1 to 7.

[0178] The first mold part 102 comprises a plurality of sectors 108 adapted to define the side walls 5 of the variable volume forming region 4. In the example shown, there are four sectors 108 that have the same shape as each other.

[0179] The sectors 108 are functionally similar to the sectors 8 described with reference to Figures 1 to 7, but their shape differs from that of the sectors 8, as it is specific to the particular object to be manufactured. In particular, each sector 108 comprises a forming surface 111, which in the illustrated example has the shape of a cylindrical section. The forming surfaces 111 are intended to cooperate with one another to form the side walls of the object from the outside. Each sector 108 further comprises a sliding surface 112, which may be flat. The sliding surface 112 of the sector 108 is adjacent to the forming surface 111.

[0180] When the sectors 108 are in the first position P1, they define the expanded state C1 of the forming cavity 24, and the forming surface 111 and the sliding surface 112 of each sector 108 define the side surface 5 of the variable volume forming region 4.

[0181] Each sector 108 also has a contact surface 113 intended to slide along the sliding surface 112 of an adjacent sector 108 when the sector 108 moves to reduce the volume of the variable volume forming region 4, as already described with reference to Figures 1 to 7.

[0182] The contact surface 113 may be flat and faces the sliding surface 112 of the adjacent sector 108 and therefore does not face the variable volume forming region 4 .

[0183] The sector 108 can be moved between a first position P1 shown in Figures 17 and 19 and a second position P2 shown in Figures 21 and 23 by a pressing device (not shown), as described above with reference to Figures 1 to 7.

[0184] The first mold part 102 further comprises, on the side opposite the second mold part 103, an end forming part 114 that defines a variable volume forming region 4 transversely to the forming direction D. The sector 108 is arranged in contact with the end forming part 114 and is slidable relative to the end forming part.

[0185] The core 73 protrudes from the end forming part 114 and protrudes towards the second mould part 103. The core 73 is intended to form the interior of the cavity of the object to be produced. In the example shown, the core 73 has a cylindrical shape.

[0186] The core 73 may have a dimension along the forming direction D that is greater than the corresponding dimension of the sector 108. In this case, the core 73 protrudes towards the second mould part 103 relative to the sector 108.

[0187] An annular forming cavity 24 is formed between the core 73 and the sector 108. The forming cavity 24 is open at the top.

[0188] The second mold part 103 comprises an abutment part 116 adapted to abut against the sector 108 to close the forming chamber 24. A forming part 115 is housed inside the abutment part 116 and is adapted to form an edge region of the object opposite to that which would be formed in contact with the end forming element 114.

[0189] The forming part 115 has a guide hole 74 arranged to receive a portion of the core 73 associated with the end forming part 114. The guide hole 74 can in particular engage in a formed connection with the core 73.

[0190] The forming component 115 may be provided with a through hole 75. The through hole 75 may extend between the guide hole 74 and the surface of the forming component 115 that is farther from the forming cavity 24. The through hole 75 can function, for example, as a vent hole for the escape of air present between the core 73 and the forming component 115.

[0191] The forming element 115 is slidable against an abutment 116 parallel to the forming direction D.

[0192] In operation, the mold 101 is initially open. The first mold part 102 and the second mold part 103 are positioned in a spaced apart position, as shown in Figure 16. In this position, a transport device, not shown, may be inserted between the first mold part 102 and the second mold part 103, which transports the unit dose 100 separated from the continuous extrudate exiting the extrusion device and deposits it within the forming cavity 24.

[0193] As shown in FIG. 17, since the sector 108 is at the first position P1, the volume of the variable volume forming region 4 is at its maximum, and the variable volume forming region 4 can easily accommodate the unit dose 100.

[0194] In particular, the distance between the core 73 and the side surfaces 5 of the variable volume forming region 4 is, at least in some respects, greater than the transverse dimension of the unit quantity 100. In the example shown, the variable volume forming region 4 has, in plan, the approximate shape of a quadrilateral (in particular a square) with rounded vertices. Each side of the quadrilateral is defined by a sliding surface 112 and a forming surface 111 of a sector 108. The rounded vertices of the quadrilateral correspond to the forming surfaces 111 located near the vertices of the quadrilateral.

[0195] The distance between the vertex regions of the quadrilateral and the core 73 is greater than a transverse dimension of the unit dose 100. As shown in Figure 17, the unit dose 100 of formable material may then be placed at a non-central position within the variable volume forming region 4, near an edge region of the variable volume forming region 4. In the example shown, the distance between the side 5 of the variable volume forming region 4 and the core 73 is in fact greater than a transverse dimension of the unit dose 100, in particular the diameter of the latter, at least along the diagonal of the quadrilateral defined in plan by the side 5.

[0196] After the unit portion 100 is received in the variable volume forming area 4, the first mold part 102 and the second mold part 103 move toward each other until they come into contact with each other. In particular, in the illustrated embodiment, the drive device moves the first forming part 102 toward the second forming part 103 in the forming direction D, as shown in FIG. 16. The sector 108 is thus brought into contact with the abutment 116, as shown in FIG. 18. The forming part 115 is housed inside the abutment 116 and, in the illustrated embodiment, does not yet protrude from the abutment 116 toward the first forming part 102.

[0197] The core 73 has already partially passed through the guide hole 74 and is engaged in the formed connection with the guide hole, which allows the first mold part 102 to be guided more effectively than the second mold part 103.

[0198] As shown in FIG. 19, sector 108 is still in first position P1.

[0199] When the first mold part 102 and the second mold part 103 come into contact with each other, a closed forming chamber 17 is defined between the first mold part 102 and the second mold part 103, as shown in FIG. 18. The forming chamber 17 is defined at its end (the lower end in the illustrated example) by an end forming portion 114. At its opposite end, the forming chamber 17 is further defined by an abutment portion 116 and a forming portion 115. Finally, the forming chamber 17 is laterally defined by a sector 108 (outside) and a core 73 (inside). Next, the sector 108 is moved laterally relative to the forming direction D, for example, according to the method described above with reference to FIGS. 1 to 7, and approaches the core 73. Thus, the unit portion 100 begins to deform between the sector 108 and the core 73 to fill the forming chamber 17.

[0200] As the sector 108 approaches the core 73, the volume of the variable volume forming region 4 decreases, and the volume of the closed forming chamber 17 also decreases.

[0201] Furthermore, the first mold part 102 and the second mold part 103 continue to move towards each other. More specifically, the drive device continues to move the first mold part 102 towards the second mold part 103. The abutment part 116, which abuts the sector 108, therefore moves together with the first mold part 102 in the forming direction D (upwards in the illustrated example). The forming element 115 instead remains in a fixed position along the forming direction D. The core 73 therefore penetrates deeper into the guide hole 74 of the forming element 115. The latter begins to enter the forming cavity 24, i.e., forms an end region of the object opposite the further end region formed by the part of the end forming part 114 interposed between the sector 108 and the core 73 and from which the core 73 protrudes.

[0202] This process is shown in FIGS.

[0203] In one variant, the sector 108 is first brought to the second position P2, after which the forming element 115 begins to protrude from the abutment 116 so as to be interposed between the sector 108 and the core 73. However, this condition is not essential, and the forming element 115 can begin to be interposed between the sector 108 and the core 73 even before the sector 108 reaches the second position P2.

[0204] The driver continues to move the abutment 116 toward the first mold-forming component part 115, which presses against it. This causes the forming chamber 17 to further enter the variable-volume forming region 4, further reducing the volume of the previously closed forming chamber 17, until it reaches its final forming position, as shown in FIG. 22, where the forming chamber 17 has a shape corresponding to the object to be manufactured. In particular, while the volume of the forming chamber 17 is being reduced, the forming portion 115 compresses the formable material in the forming direction D, while the sectors 108 compress the formable material transversely to the forming direction D. The mold 101 remains in the position shown in FIGS. 22 and 23 for a time sufficient to solidify the object. The mold 101 is then returned to its open position, and the formed object can be removed from the mold 101 to form a new object.

[0205] In this way, a tubular body having through holes originating from the core 73 was obtained.

[0206] It was made from unit quantities of formable material having perfect shapes, particularly spherical or cylindrical shapes, which can be relatively easy to manufacture and transport, rather than from unit quantities of formable material having an annular shape, which can be quite complicated to manufacture and manipulate.

[0207] In an alternative variation not shown, the mold 101 can be used to produce not only perforated objects but also hollow objects with non-through indentations, such as container preforms or heads for crushable tube containers with closed ends. In this case, the first mold part 102 comprises a core 73 in its final forming position but not in contact with the second mold part 103 to form the closed end of the object.

[0208] 24 to 26 show a mould 201 according to an alternative variant. The mould 201 comprises a first mould part 202 and a second mould part 203, which can be moved towards each other or away from each other along the forming direction D. This can happen thanks to a drive device (not shown) similar to that described above with reference to the variants already described. In the example shown, the drive device is connected to the second mould part 203, which is movable along the forming direction D, while the first mould part 202 remains fixed in that direction.

[0209] The first mold part 202 is a female mold part, while the second mold part 203 is a male mold part. Unlike what occurs in the variants described with reference to Figures 1 to 23, the first mold part 202 is arranged above the second mold part 203. The mold 201 is adapted to form a concave object, for example a container such as a capsule for coffee or other substances, and starts with a unit dose 100 of formable material, which is shown spherical in the example. However, other shapes of the unit dose 100 are also possible.

[0210] The unit doses 100 may be cut from a continuous extrudate emerging from an extrusion device, not shown, and transported to the mold 201 by a transport device, not shown.

[0211] The first mold part 202 comprises a plurality of sectors 208 adapted to define the sides 5 of the variable volume forming region 4. The sectors 208 may have a shape similar to the sectors 8 shown in Figures 1 to 17. The sectors 208 may be movable by respective pressing devices similar to those described with reference to the preceding figures between a first position P1 shown in Figure 24 and a second position P2 shown in Figure 26.

[0212] The first mold part 202 further comprises, on the side opposite the second mold part 203, an end forming portion 214 which defines a variable volume forming region 4 transversely to the forming direction D. The forming cavity 24 is defined by a sector 208 and an end forming portion, which in the illustrated example faces downwards.

[0213] The second mold section 203 includes a male forming part 215 defined at its upper end by a support surface 76 upon which a unit dose 100 of formable material can be placed.

[0214] The second mold part 203 further comprises an abutment part 216 surrounding the male forming element. The abutment part 216 may have a tubular shape. The abutment part 216 is adapted to abut against the sector 208 to close the forming chamber 17 defined between the first mold part 202 and the second mold part 203. In particular, the abutment part 216 is defined across the forming direction D by a front surface 71 adapted to abut against an abutment surface 72 of the sector 208.

[0215] The front surface 71 and the abutment surface 72 extend transversely, in particular perpendicularly, to the forming direction D. In the embodiment shown, the front surface 71 and the abutment surface 72 are substantially flat. During operation, the mold 201 is initially in an open position, i.e. the first mold part 202 and the second mold part 203 are initially in the spaced apart position shown in FIG. 24 , and a transport device can be introduced to transport the unit dose 100 of formable material between the first mold part 202 and the second mold part 203. The sector 208 is positioned in a first position P1 where the volume of the variable volume forming region 4 is at its maximum.

[0216] The transport device deposits the unit dose 100 into the mold 201, in particular by placing the unit dose 100 on the support surface 76 of the male forming component 215, the latter protruding from the abutment portion 216 towards the first mold part 202.

[0217] The driver then begins to move the second mold section 203 toward the first mold section 202. The male forming part 215 approaches the forming cavity 24 and, at some point, begins to penetrate into the forming cavity to compress the formable material in the forming direction D. The abutment portion 216 then abuts the sector 208. When this occurs, the forming chamber 17 is defined between the first and second mold sections 202, 203, which are closed, as shown in FIG. 25 . The forming chamber 17 is defined by, among other things, the end forming portion 214, the sector 208, the male forming portion 215, and the abutment portion 216. The sector 208 is still in the first position P1.

[0218] After the forming chamber 17 is closed, the abutment portion 216 remains in a fixed position along the forming direction D, as it abuts against the sector 208 and then contacts the end forming portion 214 .

[0219] Sector 208 is moved transversely to forming direction D to approach male forming part 215 and reach second position P2 shown in FIG. 26. In this way, the volume of variable volume forming region 4 gradually decreases. The drive further moves male forming part 215 toward end forming part 214 until male forming part 215 reaches a distance from end forming part 214 equal to the thickness of the cross wall of the object to be produced. At this point, mold 201 is in its final forming position. First mold part 202 and second mold part 203 remain in this position long enough for the formed object to cool properly, after which mold 201 opens and the object can be removed.

[0220] Figures 27 to 30 show a forming mold 401 which is completely similar to the forming mold 1 shown in Figures 1 to 7 and which is used to produce an object, in particular a preform, by compression forming, starting from a unit quantity 400 of formable material having a geometry different from that of the unit quantity 100 shown so far.

[0221] More specifically, the unit dose 400 has a planar shape, which may be square, rectangular, cylindrical, or polygonal. The height of the unit dose 400, i.e., its dimension along the forming direction D, may be smaller than the dimension of the unit dose 400 transverse to the forming direction D.

[0222] The unit dose 400 may be formed from a single material, or may have a multi-layer construction, as in the illustrated example.

[0223] In particular, the unit dose 400 can include an intermediate layer 77 interposed between two outer layers 78. The intermediate layer 77 can include, for example, a material having barrier properties to oxygen, and / or gas, and / or light, and / or flavorings. Alternatively, the intermediate layer 77 can be made, at least in part, from recycled polymeric materials.

[0224] The outer layer 78 may be formed of a material whose purpose is to impart desired mechanical and aesthetic properties to the object. One or more layers of a compatibilizing material adapted to improve adhesion between the intermediate layer 77 and the outer layer 78 may be interposed between the outer layer 78 and the intermediate layer 77.

[0225] 27, the mold 401 is initially in an open position, with the first mold part 2 spaced apart from the second mold part 3. The sector 8 is in a first position P1, corresponding to the expanded state C1 of the variable volume forming region 4. Here, the unit portion 400 is inserted into the mold 401 by delivering it to the first mold part 2, in particular, so that the unit portion 400 is supported on the support surface 79 of the end forming portion 14 at a position spaced apart from the bottom of the recess 70. More specifically, the support surface 79 has an annular shape and can support an edge region of the unit portion 400. The support surface 79 is surrounded by the sector 8.

[0226] In the illustrated embodiment, the support surface 79 has an area that decreases as the sector 8 passes from the first position P1 to the second position P2. At the second position P2, the support surface 79 is intended to form the inner surface of an annulus that projects radially from the neck of the preform. The unit dose 400 is thus surrounded by the sector 8, still positioned at the first position P1, defining a relatively wide variable volume forming region 4 in which the unit dose 400 can be positioned without contacting the sector 8. More specifically, despite having a transverse dimension larger than that of the recess 70, the sector 8 at the first position P1 defines a variable volume forming region 4 whose transverse dimension is larger than that of the unit dose 400, so that the unit dose 400 can be introduced into the mold without being substantially deformed.

[0227] The unit dose 400 is introduced into the first mould part 2, for example by supporting it on the shoulder 79 in an orientation in which the intermediate layer 77 is disposed transversely, in particular perpendicularly, to the forming direction D.

[0228] Now, the first mold part 2 and the second mold part 3 are moved towards each other so as to define between them a closed forming chamber 17 shown in Figure 28. The closed forming chamber 17 is defined when the sector 8 abuts the abutment part 16. In particular, the abutment surface 72 of the sector 8 abuts a further abutment surface or front surface 71 of the abutment part 16.

[0229] At this point, as shown in Figure 29, the sector 8 is moved to a second position P2 by applying to the sector 8 respective forces Fi directed transversely, in particular perpendicularly, to the forming direction D. The forces Fi can be applied as described with reference to Figures 1 to 7. It is also possible to use sectors 8 having a different geometry than that shown in Figures 1 to 7 and passing from the first position P1 to the second position P2 along a different trajectory.

[0230] In either case, the force Fi moves the sectors 8 along respective directions disposed transversely to the forming direction D. In the illustrated embodiment, the sectors 8 are moved perpendicular to the forming direction D relative to the end formers 14.

[0231] In the second position P2, the sector 8 defines a side surface 5 of the variable volume forming region 4, the side surface 5 having the shape of part of the outer surface of the object to be obtained, in particular the neck of the preform.

[0232] As sector 8 moves from first position P1 to second position P2, first mold part 2 and second mold part 3 continue to move toward each other. In particular, first mold part 2 moves relative to male forming part 15 in mold forming direction D. Abutment part 16, which contacts sector 8, also moves relative to male forming part 15 in forming direction D. Thus, male forming part 15 penetrates between sectors 8 and subsequently into recess 70, internally forming the object.

[0233] 29 shows the situation where the unit dose 400, deformed by the male forming part, reaches the bottom of the recess 70 and gradually generates a preform. During deformation of the unit dose 400, the intermediate layer 77 also deforms and becomes substantially distributed throughout the body to be formed. In this way, the properties imparted by the intermediate layer 77 are substantially uniform throughout the object.

[0234] As shown in FIG. 30, the male forming element 15 continues to penetrate the recess 70 as a result of the upward movement of the first mold part 2 and abutment part 16 (i.e., towards the male forming element 50) until the preform reaches its final shape, at which point a maximum compressive force is applied to the first mold part 2 to keep the mold 401 in the forming position and obtain the desired object.

[0235] After the preform has cooled sufficiently within the mold 401, the mold is returned to the open position and the preform is removed from the mold for further processing.

[0236] In the examples described so far, the sector was moved transversely to the forming direction D so that it was moved to the second position P2 only after the closed forming chamber 17 was defined, i.e. after the first mold part and the second mold part had come into contact with each other.

[0237] However, this condition is not necessary and it is possible to start moving the sectors to reduce the volume of the variable volume forming region 4 even when the first and second mold parts are still spaced apart from each other.

[0238] The above example is shown in Figures 31 to 34, which show a mould 501 according to an alternative variant, in which the sectors reach a second position P2 before closing the mould.

[0239] In the illustrated embodiment, the mold 501 is configured to produce capsules for coffee or other substances intended for beverage or food preparation by forcing an extraction fluid through the capsule. However, it will be understood that molds similar to those of Figures 31 to 34 can be used to produce recessed objects such as caps, containers, preforms for containers, etc.

[0240] The mold 501 also comprises a first mold part 502 and a second mold part 503 which are movable relative to each other along a forming direction D, which is vertical in the example shown.

[0241] In the illustrated embodiment, the first mold part 502 is positioned below the second mold part 503, although this condition is not essential.

[0242] The first mold part 502 is a female mold part, while the second mold part 503 is a male mold part.

[0243] The first mold part 502 may comprise an end forming part 514 in which a recess 570 is formed. The recess 570 is arranged to form, from the outside, a bottom wall of the capsule, e.g., a substantially flat side wall, and, e.g., a frusto-conical side wall.

[0244] The first mold part 502 further comprises a plurality of sectors 508, for example similar to the sectors 8 described above. More specifically, the sectors 508 are in contact with the upper surface of the end forming part 514 and are slidable transversely (particularly perpendicularly) to the forming direction D.

[0245] The end former 514 is defined at its top by a support surface 579 adapted to supportively receive the unit dose 500 of formable material. The support surface 579 may be flat or may be arranged transversely, in particular perpendicularly, to the forming direction D.

[0246] A support surface 579 surrounds the recess 570 and is interposed between the sectors 508. The support surface 579 is annular. The sectors 508 are movable between a first position P1 and a second position P2, for example, thanks to pressing means (not shown), in a similar manner to that described in the previous variant.

[0247] As the sectors 508 move from the first position P1 to the second position P2, the volume of the variable volume forming region 4 defined between the sectors 508 decreases. At the same time, the area of ​​the support surface 579 decreases. At the second position P2, the support surface 579 is configured to form the lower surface of the capsule flange. The flange protrudes outward from the upper region of the capsule body.

[0248] The sectors 508 are configured to form the sides of the flange, ie, flange faces that extend around the axis of the capsule and may be parallel to such axis.

[0249] The second mold part 503 comprises a male forming element adapted to form the bottom and side walls of the capsule from the inside through the recess 570. The male forming part 515 allows the formable material to be compressed in a direction parallel to the forming direction D.

[0250] The second mould part 503 further comprises an abutment 516 adapted to come into contact with the first mould part 502 , in particular with the sector 508 , to close the mould 501 , i.e. to define a closed forming chamber 17 within the mould 501 .

[0251] More specifically, each sector 508 is defined by an abutment surface 572 positioned facing the abutment portion 516 .

[0252] The abutment surface 572 is adapted to abut against a further abutment surface 571 (or front surface) which defines the abutment portion 516 in a position facing the first mould part 502 .

[0253] The abutment surface 572 and the further abutment surface 571 extend transversely, in particular perpendicularly, to the forming direction D.

[0254] The abutment 516 surrounds the male forming part 515. In a variant not shown, additional members may be present between the abutment 516 and the male forming part 515.

[0255] The abutment part 516 comprises a blocking portion 580 which projects from the further abutment surface 571 towards the first mould part 502. The blocking portion 580 has an annular geometric shape and may, for example, be shaped like a circular crown.

[0256] The blocking portion 580 may be defined by, for example, a flat blocking surface 581 extending transversely, in particular perpendicularly, to the forming direction D.

[0257] The blocking portion 580 is adapted to contact the unit dose 500 and press it against the end formation 514, in particular against the support surface 579. More particularly, the blocking portion 580 is intended to block the end region of the unit dose 500 against the end formation 514, so that the unit dose 500 remains in a central position relative to the recess 570 even when the male formation 515 deforms the unit dose 500.

[0258] In operation, the mold 501 is initially in an open position, as shown in Figure 31. The first mold part 502 is moved away from the second mold part 503 so that a unit dose 500 of polymeric material can be inserted into the mold 501. The unit dose 500 can be released into the mold 501, for example, by a transport element (not shown) temporarily interposed between the first mold part 502 and the second mold part 503.

[0259] In the illustrated embodiment, the unit dose 500 has a multi-layer structure, including an intermediate layer interposed between at least two outer layers of polymeric material, as previously described with reference to the unit dose 400 shown in Figures 27 and 28.

[0260] The unit portion 500 is supported on the support surface 579 with only its edge region in contact with the first mold part 502, while the central region of the unit portion 500 is initially spaced from the bottom of the recess 570 and does not contact the first mold part 502.

[0261] When the unit dose is placed on the support area 579, the intermediate layer is placed transversely, in particular perpendicularly, to the forming direction D.

[0262] In a version not shown, the mold 501 may also be used in combination with a unit dose having a single layer structure, i.e., formed from a single synthetic polymer material.

[0263] The sectors 508 are arranged in a first position P1 corresponding to the expanded state C1 of the variable volume forming region 4. In the first position P1, the variable volume forming region 4 has a transverse dimension (i.e., measured transversely to the forming direction D) that is larger than the transverse dimension of the unit portion 500. As a result, the unit portion 500 is not prematurely deformed by the sectors 508 when it is introduced into the mold 501 by supporting it on the support surface 579.

[0264] Subsequently, as shown in Figure 32, a respective force Fi is applied to the sectors 508 to move the sectors 508 closer to the central region of the variable volume forming region 4 until the sectors 508 reach a second position P2. The force Fi can be applied in the manner shown in Figures 1 to 7 or in other manners, for example, by applying a single force to each sector 508 directed toward the central region of the variable volume forming region 4.

[0265] Thus, sector 508 begins to deform the edge area of ​​unit quantity 500 .

[0266] When sector 508 reaches second position P2, first mold part 502 is still spaced apart from second mold part 503. To be precise, first mold part 502 and second mold part 503 have not yet started to move towards each other.

[0267] The first and second mold parts 502, 503 then begin to move towards each other. In the illustrated embodiment, this is done by moving the first mold part 502 along the forming direction D and holding the second mold part 503 in a fixed position along the forming direction D.

[0268] This results in a situation where the abutment surface 572 of the sector 508 comes into contact with a further abutment surface 571 of the abutment portion 516, as shown in FIG.

[0269] At this point, a closed forming chamber 17 is defined between the first mold part 502 and the second mold part 503 .

[0270] The block portions 580 are interposed between the sectors 508 so that the blocking surfaces 579 act on the edge regions of the unit quantity 500 , crushing such edge regions and forcing them against the end formations 514 .

[0271] In effect, the blocking portion 580 exerts a sort of "stapling" effect on the edge region of the unit dose 500, which remains firmly blocked between the blocking portion 580 and the end forming portion 514, even when the unit dose 500 is deformed by the male forming part 515.

[0272] The first mold part 502, together with the abutment 516 against which it abuts, continues to move the male forming part 515, in particular by approaching such part. As the male forming part 515 is positioned in a fixed position along the forming direction D, it penetrates the recess 570 and deforms the unit portion also in the central region of the latter, until it reaches the forming end position shown in Figure 34. At this position, the capsule is fully formed and can be removed from the mold 501 after it has cooled sufficiently.

[0273] By clamping the edge regions of unit dose 500 between block portion 580 and first mold part 502, unit dose 500 can be maintained in a centered position relative to recess 570 even when the central region of unit dose 500 is deformed by male forming part 515. Furthermore, if unit dose 500 has a multi-layer structure, intermediate layers of the unit dose that flow outside the unit dose at the edge regions can be prevented from appearing on the outer surface of the formed object and being visible on such object.

[0274] It should be noted that the blocking portion 580 that blocks the edge region of the unit portion 500 for the first mold part 503 can also be used in molds in which no sectors 508 exist, i.e., in which a forming cavity having a fixed dimension transverse to the forming direction D is created in the first mold part 503.

[0275] It should be noted that in the type of mold shown in Figures 1 to 30, as well as in the mold variant described with reference to Figures 31 to 35, it is possible to start moving the sector laterally relative to the forming direction D to bring it into second position P2 before the forming chamber is closed, i.e., even before the closed forming chamber 17 is defined between the first and second mold parts. If the sector is moved before closing the forming chamber, second position P2 can be reached before or after the closed forming chamber 17 is defined.

[0276] In all of the mold variations mentioned, the sectors can be moved between a first position and a second position by interaction between the mold section in which they are contained and the other mold section. For example, each sector can be provided with a roller or a set of levers that interact with the mold section opposite the one in which the sector is contained to displace the sector from the first position to the second position. Thus, the sector associated with a mold section can be moved between a first position and a second position on the other mold section. In one variation, the sectors can also be moved from the first position to the second position non-axisymmetrically, for example, following paths that are not oriented at 45° to the direction of the applied force or that have different lengths from each other.

[0277] The sector can be further moved between the first and second positions in a different manner to those described so far, for example due to the effect of a simple actuator that moves the sector in a direction corresponding to the applied force.

[0278] In the above description, reference is always made to sectors contained in the female part. In an alternative form not shown, the sectors defining the variable volume forming area may be contained in the male part.

[0279] In the preceding description, reference has always been made to unit doses of formable material, in particular synthetic polymeric material, obtained by cutting a continuous extrudate emerging from an extrusion device. However, it is also possible to use unit doses of synthetic polymeric material obtained in other ways, for example by cutting a sheet or film of synthetic polymeric material.

[0280] Alternatively, the formable material forming the unit doses may be at least partly derived from natural fibers, for example cellulose, in the form of powder, granules, or supplemented with a specific liquid substance, for example to obtain a certain paste, or in the form of a wadding, preform or other element cut from a film.

[0281] In this case, the starting material has a relatively low density and needs to be pressed with a high degree of compression to provide a good quality finished product. This means that the initial volume of the material, at least in part derived from natural fibers, is much larger than the volume of the finished object. Therefore, it is useful to have a mold with the above-mentioned sectors movable between a first position where the variable volume forming area is relatively large, a first position where it can accommodate a low-density material that occupies a lot of space, and a second position where the material is compressed and reaches the shape and size of the finished object.

[0282] Consequently, the unit doses can be prepackaged, ie prepared (eg by cutting, pressing or otherwise) separately from the mould and inserted into the open mould.

[0283] The methods and apparatus described herein make it possible to obtain good quality objects starting from unit quantities having dimensions, measured in particular transversely to the forming direction D, that are larger than the corresponding transverse dimensions of the formed object.

[0284] In summary, in a first variant of the first aspect of the present invention there is provided a method of forming an object, the method comprising: - providing a mold (1; 101; 201; 301; 401; 501) comprising a first mold part (2; 102; 202; 302; 502) and a second mold part (3; 103; 203; 303; 503) located opposite each other, and a plurality of sectors (8; 108; 208; 308; 508) contained in either the first mold part (2; 102; 202; 302; 502) or the second mold part (3; 103; 203; 303; 503) defining a variable volume generating region (4) of the mold and shaping at least a lateral portion of the object; - providing a unit quantity (100; 400; 500) of mouldable material between said first mould part (2; 102; 202; 302; 502) and said second mould part (3; 103; 203; 303; 503); displacing the first mould part (2; 102; 202; 302; 502) and the second mould part (3; 103; 203; 303; 503) towards each other in a forming direction (D) to define a closed forming chamber (17) between the first mould part and the second mould part; The method further comprises a step of reducing the volume of the variable volume generating region (4) by moving the sector (8; 108; 208; 308; 508) in a direction transverse to the forming direction (D).

[0285] The unit dose (100; 400; 500) of moldable material is provided between the first mold part (2; 102; 202; 302; 502) and the second mold part (3; 103; 203; 303; 503) while the mold is in an open position.

[0286] The closed forming chamber (17) may be defined by contacting the respective abutment surfaces (71, 72; 571, 572) of the first mold part (2; 102; 202; 302; 502) and the second mold part (3; 103; 203; 303; 503) extending transversely to the forming direction (D).

[0287] In a second variant, a method according to the first variant is provided, wherein the sectors (8; 108; 208; 308; 508) are movable transversely to the forming direction (D) between an expanded state (C1) and a final state (C2), and the unit dose (100; 400; 500) is released between the first mould part (2; 102; 202; 302; 502) and the second mould part (3; 103; 203; 303; 503) while their lateral dimensions, measured perpendicular to the forming direction (D), are smaller than the lateral dimensions of the variable volume forming region (4) in the expanded state (C1).

[0288] In a third variant, a method according to the first or second variant is provided, wherein the step of moving the sectors (8; 108; 208; 308; 508) transversely to the forming direction (D) begins before the closed forming chamber (7) is defined.

[0289] In a fourth variant, a method according to any one of the first to third variants is provided, wherein the step of moving the sectors (8; 108; 208; 308; 508) transversely to the forming direction (D) begins after the closed forming chamber (7) has been defined.

[0290] In a fifth variant, a method according to the first or second variant is provided, wherein the step of moving the sectors (8; 108; 208; 308; 508) transversely to the forming direction (D) begins after the closed forming chamber (7) has been defined.

[0291] In a sixth variant, there is provided a method according to any one of variants 1 to 5. The step of displacing the first mold part (2; 102; 202; 302; 502) and the second mold part (3; 103; 203; 303; 503) towards each other in the forming direction (D) is caused by a drive device which moves at least one mold part selected from the first mold part (2; 102; 202; 302; 502) and the second mold part (3; 103; 203; 303; 503) towards another mold part selected from the first mold part (2; 102; 202; 302; 502) and the second mold part (3; 103; 203; 303; 503). The sectors (8; 108; 208; 308; 508) are contained within the mould part which is moved by the drive.

[0292] In a seventh variant, a method according to any one of variants 1 to 6 is provided, wherein the closed forming chamber (17) is defined by the plurality of sectors (8; 108; 208; 308; 508) and, facing the plurality of sectors, an abutment part (16; 116; 216; 316; 516) of a mold part selected from the second mold part (3; 103; 203; 303; 503) and the first mold part (2; 102; 202; 302; 502) in mutual contact. Opposite the sectors (8; 108; 208; 308; 508) of the mould part, the closed forming chamber (17) further comprises a forming part which is at least partially surrounded by the abutment part (16; 116; 216; 316; 516).

[0293] In an eighth variant, a method according to the seventh variant is provided, wherein the abutment surfaces (71, 72; 571, 572) comprise an abutment surface (72; 572) of the abutment portion (16; 116; 216; 316; 516) and another abutment surface (71; 571), and the abutment surface (72; 572) and the other abutment surface (71; 571) come into contact with each other to close the forming chamber (17).

[0294] In a ninth variant, there is provided a method according to the seventh or eighth variant, wherein after the sectors (8; 108; 208; 308; 508) and the abutment portions (16; 116; 216; 316; 516) have come into contact with each other, at least one of the first mould part (2; 102; 202; 302; 502) and the second mould part (3; 103; 203; 303; 503) is moved in the forming direction (D) so that the forming portion (15; 115; 215; 315; 515) penetrates between the sectors (8; 108; 208; 308; 508) to form the object.

[0295] In a tenth variant, there is provided a method according to any one of variants 7 to 9, wherein the forming portion (15; 115; 215; 315; 515) is a male forming portion (15; 215; 515), and the mouldable material flows between the sectors (8; 108; 208; 308; 508) and the male forming portion (15; 215; 515) to generate a sidewall of the object.

[0296] In an eleventh variant, a method according to the tenth variant is provided, wherein the male forming part (215) is contained within the second mould part (3; 103; 203; 303; 503) and is disposed below the first mould part (2; 102; 302; 402; 502), and the unit portion (100) is disposed on a support surface (76) defining the upper end of the male forming part (215). .

[0297] In a twelfth variant, there is provided a method according to any one of variants seven to ten, wherein in the final forming position, the forming portion (315) defines the closed forming chamber (17) transverse to the forming direction (D) and is in contact with the sectors (8; 108; 208; 308; 508), thereby preventing the moldable material from flowing between the forming portion (315) and the sectors (8; 108; 208; 308; 508).

[0298] In a thirteenth variant, a method according to any one of variants 1 to 12 is provided, wherein before starting deformation of the central region of the unit portion (500), the end regions of the unit portion (500) are blocked between the first mould part (2; 102; 302; 402; 502) and the second mould part (3; 103; 203; 303; 503).

[0299] In a fourteenth variant, a method according to the thirteenth variant is provided. When the features of the seventh variant are included in the thirteenth variant, the sectors (8; 108; 208; 308; 508) are contained within the first mould part (2; 102; 302: 402; 502), and the end regions of the unit portions (500) are supported on the first mould part (2; 102; 302: 402; 502) and blocked between the first mould part (2; 102; 302: 402; 502) and the second mould part (3; 103; 203; 303; 503) before the forming part (15; 115; 215; 315; 515) starts to interact with the end regions of the unit portions (500).

[0300] In a fifteenth variant, a method according to the thirteenth or fourteenth variant is provided, which includes the features of the seventh variant. The sectors (8; 108; 208; 308; 508) are contained within the first mould part (2; 102; 302: 402; 502), and the end regions of the unit portions (500) are blocked between the first mould part (2; 102; 302: 402; 502) and the second mould part (3; 103; 203; 303; 503) by fixing the unit portions (500) between blocking portions (580) protruding from the abutment portions (16; 116; 216; 316; 516) and a support surface (79; 579) of the first mould part (2; 102; 302: 402; 502), and the sectors (8; 108; 208; 308; 508) is slidable along said support surface (79; 579) so as to reduce the volume of said variable volume forming area (4).

[0301] In a sixteenth variant, a method according to the fifteenth variant is provided, wherein the block portion (580) is interposed between the sectors (8; 108; 208; 308; 508) and thereby fixes the unit amount (500) against the support surface (79; 579).

[0302] A seventeenth variant provides a method according to any one of variants 1 to 16. The sectors (8; 108; 208; 308; 508) are movable between a first position (P1) where the volume of the variable volume formation region (4) is maximum and a second position (P2) where the volume of the variable volume formation region (4) is minimum, and the unit amount (100; 400; 500) is provided between the first mold part (2; 102; 202; 302; 502) and the second mold part (3; 103; 203; 303; 503) while the sectors (8; 108; 208; 308; 508) are at the first position (P1).

[0303] In an 18th variant, there is provided a method according to any one of variants 1 to 17, wherein the first mould part (2; 102; 202; 302; 502) further comprises an end forming part (14; 114; 214; 314; 514) which defines the closed forming chamber (17) transversely to the forming direction (D) on the opposite side to the sectors (8; 108; 208; 308; 508) and the second mould part (3; 103; 203; 303; 503).

[0304] In a 19th variant, a method according to the 18th variant is provided, wherein the sectors (8; 108; 208; 308; 508) are slidable transversely to the forming direction (D) to reduce the volume of the closed forming area (4) while in contact with the end forming portions (14; 114; 214; 314; 514).

[0305] In a twentieth variant, there is provided a method according to the eighteenth or nineteenth variant, wherein the first mould part (2; 102; 202; 302; 502) has a forming cavity (24) including the variable volume forming area (4) defined by the sectors (8; 508) and a recess (70) made in the end forming part (14; 514).

[0306] In a 21st variant, there is provided a method according to the 18th or 19th variant, wherein the first mould part (2; 102; 202; 302; 502) comprises a protruding core (73) protruding from the end forming part (14; 114; 214; 314; 514) towards the second mould part (3; 103; 203; 303; 503), and the unit quantities (100; 400; 500) are provided in the first mould part (2; 102; 202; 302; 402) at the side of the protruding core (73) in a position not central with respect to the sectors (8; 108; 208; 308; 508), so that the mouldable material is distributed in the sectors (8; 108; 208; 308; 508). 508) and the protruding core (73) to create an object with a hole or hollow portion.

[0307] The 22nd variant provides a method according to the 21st variant when the 18th variant includes the features of the 17th variant. The protruding core (73) protrudes from the sectors (8; 108; 208; 308; 508) towards the second mould part (3; 103; 203; 303; 503) and thereby engages with a guide hole (74) made in the forming part (115).

[0308] A 23rd variant provides a method according to any one of variants 1 to 22. Each of the sectors (8; 108; 208; 308; 508) moves transversely to the forming direction (D) to reduce the volume of the variable volume forming region (4) under the action of a force provided by a combination of a first force (F1) applied to the sector (8; 108; 208; 308; 508) by an extrusion device and a second force (F2) applied to the sector (8; 108; 208; 308; 508) by a sector (8; 108; 208; 308; 508) adjacent to the sector (8; 108; 208; 308; 508).

[0309] In a 24th variant, there is provided a method according to any one of variants 1 to 23, further comprising the steps of extruding the mouldable material to produce a continuous extrudate of mouldable material, separating unit portions (100; 400; 500) from the continuous extrudate, and transporting the unit portions (100; 400; 500) into the mould (1; 101; 201; 301; 401; 501).

[0310] In a 25th variant, there is provided a method according to the 24th variant, wherein the extrudate comprises at least two layers (78, 79) of polymeric material, each of the two layers (78, 79) extending transversely to the forming direction (D), preferably substantially perpendicular to the forming direction, when the unit dose (400; 500) is introduced into the mold (401; 501).

[0311] In a first variant of the second aspect of the present invention, there is provided an apparatus for forming an object. The apparatus comprises at least one mould (1; 101; 201; 301; 401; 501), the at least one mould (1; 101; 201; 301; 401; 501) being comprised in a first mould part (2; 102; 202; 302; 402; 502) and a second mould part (3; 103; 203; 303; 403; 503) located opposite each other, and the first mould part (2; 102; 202; 302; 402; 502) and the second mould part (3; 103; 203; 303; 403; 503) being comprised in either the mould (1; 101; 201; 301; 401; and a plurality of sectors (8; 108; 208; 308; 508) defining a variable volume generating region (4) of the object and forming at least a side surface of the object, the apparatus further comprising: a first mould part (2; 102; 202; 302; 402; 502) and a second mould part (3; 103; 203; 303; 403; 503) in contact with each other along respective contact surfaces arranged transverse to a forming direction (D) to define a closed forming chamber (17) between the first mould part (2; 102; 202; 302; 402; 502) and the second mould part (3; 103; 203; 303; 403; 503). a drive device for moving said sector (8; 108; 208; 308; 508) and said second mould part (3; 103; 203; 303; 403; 503) towards each other along said forming direction (D), said device further comprising extrusion means for reducing the volume of said variable volume forming region (4) by moving said sector (8; 108; 208; 308; 508) transversely to said forming direction (D).

[0312] In a second variant of the second aspect, there is provided an apparatus according to the first variant of the second aspect. The sectors (8; 108; 208; 308; 508) are contained within the first mould part (2; 102; 202; 302; 402; 502), and the second mould part (3; 103; 203; 303; 403; 503) comprises abutment parts (16; 116; 216; 316; 516) adapted to contact the sectors (8; 108; 208; 308; 508) to define the closed forming chamber (17), and forming parts (15; 115; 215; 315; 515) at least partially surrounded by the abutment parts (16; 116; 216; 316; 516), and the forming parts (15; 115; 215; 315; 515) and said abutment portion (16; 116; 216; 316; 516) are separate from each other and displaceable relative to each other.

[0313] In a third variant of the second aspect, there is provided an apparatus according to the second variant of the second aspect, wherein the second mould part comprises a blocking part (280) adapted to be interposed between a plurality of sectors (8; 108; 208; 308; 508) so as to block end regions of the unit portion (500) before initiation of deformation of the central region of the unit portion (500).

[0314] In a fourth variant of the second aspect, there is provided a device according to the third variant of the second aspect, wherein the block portion (280) projects from the abutment portion (16; 116; 216; 316; 516) to fix the unit dose (500) against a support surface (79; 579) of the first mould part (2; 102; 202; 302; 402; 502), and the sectors (8; 108; 208; 308; 508) are slidable along the support surface (79; 579) to reduce the volume of the variable volume forming region (4).

[0315] In a fifth variant of the second aspect, there is provided a device according to any one of the first to fourth variants of the second aspect. The sectors (8; 108; 208; 308; 508) are contained within the first mould part (2; 102; 202; 302; 402; 502), the first mould part (2; 102; 202; 302; 502) further comprising end forming parts (14; 114; 214; 314; 514) defining the closed forming chamber (17) transversely to the forming direction (D) on the opposite side to the second mould part (3; 103; 203; 303; 503), and the protruding core (73) has unit portions (100; 400; 514) disposed at a side of the protruding core (73) that are not centrally positioned with respect to the sectors (8; 108; 208; 308; 508). Starting from the end forming part (14; 114; 214; 314; 514) and projecting towards the second mould part (3; 103; 203; 303; 503) to produce an object with a hole or hollow part.

[0316] In a first variant of the third aspect of the present invention, there is provided a method of forming an object, the method comprising: - providing a mold (501) comprising a first mold part (502) and a second mold part (503) located opposite each other; - providing a unit dose of moldable material (500) between the first mold part (502) and the second mold part (503); - displacing the first mould part (502) and the second mould part (503) towards each other in the forming direction (D) by means of a compression moulding means until they come into contact, blocking the end regions of the portion (500) between the first mould part (2; 102; 302; 402; 502) and the second mould part (3; 103; 203; 303; 503) before initiating deformation of the central region of the portion (500).

[0317] In a first variant of the third aspect of the invention, there is provided a method according to the first variant of the third aspect of the invention, wherein the first mould part (502) comprises a forming cavity (24), and the end region of the unit portion (500) is blocked between the first mould part (502) and the second mould part (503) when it moves away from the bottom of the forming cavity (24).

[0318] In a third variant of the third aspect of the invention, there is provided a method according to the first or second variant of the third aspect of the invention, wherein the second mould part (503) comprises an abutment part (516) adapted to contact the first mould part (502) so as to define a closed forming chamber (17) between the first mould part (502) and the second mould part (503), the second mould part (503) comprises a forming part (515) at least partially surrounded by the abutment part (516), the forming part (515) and the abutment part (516) are separate from each other and displaceable relative to each other, and the unit portion (500) is blocked between the first mould part (502) and the second mould part (503) by a blocking part (280) protruding from the abutment part (516) and pressing the unit portion (500) against the first mould part (502).

[0319] In a first variant of the fourth aspect of the present invention, there is provided an apparatus for forming an object from a unit portion (500) of a moldable material. The apparatus comprises at least one mold including a first mold part (502) and a second mold part (503) positioned opposite each other, and a drive for displacing the first mold part (502) and the second mold part (503) towards each other in a forming direction to form an object from the unit portion (500) by compression molding. A mold part selected from the first mold part (502) and the second mold part (503) comprises a blocking part (280) intended to engage an end region of the unit portion (500) to prevent the other mold part selected from the first mold part (502) and the second mold part (503) from contacting the other mold part while the unit portion (500) is being molded.

[0320] In a second variant of the fourth aspect of the invention, there is provided an apparatus according to the first variant of the fourth aspect of the invention, wherein the block part (280) is contained within the second mould part (503) and the first mould part (502) is a female mould part.

[0321] In a third variant of the fourth aspect of the present invention, there is provided an apparatus according to the second variant of the fourth aspect of the present invention, wherein the second mould part (503) comprises an abutment part (516) adapted to contact the first mould part (502) so as to define a closed forming chamber (17) between the first mould part (502) and the second mould part (503), the second mould part (503) comprises a forming part (515) at least partially surrounded by the abutment part (516), the forming part (515) and the abutment part (516) are separate from each other and displaceable relative to each other, and the unit portion (500) is blocked between the first mould part (502) and the second mould part (503) by a blocking part (280) protruding from the abutment part (516) and pressing the unit portion (500) against the first mould part (502).

Claims

1. 1. A method of forming an object, comprising: providing a mold including first and second opposed mold parts, the first or second mold part including a plurality of sectors for molding at least lateral portions of the object, the plurality of sectors defining variable volume forming regions of the mold, each of the plurality of sectors being defined by a forming surface facing the variable volume forming region and a sliding surface adjacent the forming surface; - providing a quantity of moldable material between the first and second mold parts while the mold is in an open state; - displacing the first and second mould parts towards each other in a forming direction and bringing abutment surfaces of the first and second mould parts, which extend transversely to the forming direction, into contact with each other, thereby defining a closed forming chamber between the first and second mould parts; further comprising the step of moving the sectors in a direction transverse to the forming direction; the mold includes a forming portion that compresses the moldable material in a forming direction by entering the variable volume forming region; During the step of moving the sectors, each of the plurality of sectors slides along a sliding surface of an adjacent sector, thereby reducing the variable volume forming region. method.

2. 10. The method of claim 1, the plurality of sectors define sides of the variable volume forming region; the plurality of sectors are movable between a first position where the volume of the variable volume forming region is maximum and a second position where the volume of the variable volume forming region is minimum, the unit dose is disposed between the first mold part and the second mold part while the plurality of sectors are in the first position; method.

3. 3. The method of claim 1 or 2, the closed forming chamber is defined by the sectors and the abutting portions of the first mold part or the second mold part contacting each other and facing each other; The forming portion is included in a mold portion of the first mold portion or the second mold portion that faces the plurality of sectors, and is disposed inside the abutment portion. method.

4. 4. The method of claim 3, After the sectors and the abutment portion come into contact with each other, one of the first and second mold portions is further displaced in the forming direction, so that the forming portion penetrates between the sectors to form the object. method.

5. The method according to any one of claims 1 to 4, the forming portion is a male forming portion, the moldable material flows between the sectors and the male forming portion to create a sidewall of the object; the sidewall includes the lateral portion; method.

6. 6. The method of claim 5, the male mold forming portion is provided below the first mold portion, the unit dose is provided on a support surface that defines an upper end of the male forming portion; method.

7. 5. The method of claim 1, wherein in a final forming position, the forming portion defines the closed forming chamber transverse to the forming direction and contacts the sectors to prevent flow of the moldable material between the forming portion and the sectors.

8. 8. The method of claim 1, wherein the first mold part further comprises an end forming part defining the closed forming chamber transversely to the forming direction on an opposite side to the second mold part.

9. 9. The method of claim 8, wherein the sectors are slidable in a direction transverse to the forming direction to reduce the variable volume forming area while in contact with the end forming portion.

10. 10. The method of claim 8 or 9, the first mold part has a forming cavity; the forming cavity includes the variable volume forming region defined by the plurality of sectors and a recess formed in the end forming portion; method.

11. The method according to any one of claims 8 to 10, the first mold part includes a protrusion core protruding from the end forming part toward the second mold part, the unit dose is positioned in the first mold section to the side of the projection core and off-center with respect to the sectors, such that the moldable material flows between the sectors and the projection core to produce an object having a hole or hollow. method.

12. 12. The method of claim 11, wherein the protruding cores project from the sectors into the second mold section to engage guide holes made in the forming section.

13. 13. The method of claim 1, wherein each of the plurality of sectors moves in a direction transverse to the forming direction to reduce the variable volume forming area under the action of a force provided by a combination of a first force applied to the sector by an extrusion device and a second force applied to the sector by a sector adjacent to the sector.

14. A method according to any one of claims 1 to 13, extruding the moldable material to produce a continuous extrudate of moldable material; Separating unit portions from the continuous extrudate; transporting said unit dose into said mold; further comprising method.

15. 15. The method of claim 14, the continuous extrudate comprises at least two polymeric material layers; When the unit dose is introduced into the mold, each of the two layers extends in a direction transverse to the forming direction. method.

16. 10. The method of claim 1, the plurality of sectors are movable transversely to the forming direction between an expanded state and a final state of the variable volume forming region; the unit dose is released between the first mold part and the second mold part while the sectors are in the expanded state; the unit dose has a lateral dimension that is smaller than a lateral dimension of the variable volume-forming region in the expanded state; the lateral dimensions of the unit dose and the lateral dimensions of the variable volume forming region in the expanded state are measured perpendicular to the forming direction; method.

17. 17. The method according to any one of claims 1 to 16, providing a unit quantity of moldable material between the first mold part and the second mold part includes placing the unit quantity at a location on a mold part selected from the first mold part and the second mold part; At the one position, the unit quantity is at least partially surrounded by and spaced apart from the plurality of sectors; The sectors then move in a direction transverse to the forming direction to contact the unit quantities. method.

18. 3. The method of claim 2, wherein the step of moving the sectors transversely to the forming direction begins before the closed forming chamber is defined.

19. 20. The method of claim 18, wherein the second position is achieved before the closed forming chamber is defined.

20. The method according to any of the preceding claims, wherein the step of moving the sectors transversely to the forming direction is initiated after the closed forming chamber has been defined.

21. 21. The method according to claim 1, wherein the step of displacing the first mold part and the second mold part toward each other in the forming direction is caused by a drive device that moves at least one mold part selected from the first mold part and the second mold part toward another mold part selected from the first mold part and the second mold part; the plurality of sectors are contained within the mold section that is moved by the drive device; method.

22. 22. The method of any one of claims 1 to 21, further comprising blocking end regions of the unit portion between the first mold part and the second mold part before initiating deformation of the central region of the unit portion.

23. 23. The method of claim 22, the first mold part has a forming cavity; the end region of the unit portion is blocked between the first mold part and the second mold part when spaced apart from the bottom of the forming cavity; method.

24. 24. The method of claim 22 or 23, the plurality of sectors are contained within the first mold part; the end region of the unit portion is placed on the first mold part and blocked between the first mold part and the second mold part before the forming part begins to interact with the end region of the unit portion. method.

25. 4. The method of claim 3, blocking end regions of the unit portion between the first mold part and the second mold part before initiating deformation of the central region of the unit portion; the plurality of sectors are contained within the first mold part; the end region of the unit portion is blocked between the first and second mold parts by fixing the unit portion between a block portion projecting from the abutment portion and a support surface of the first mold part; the plurality of sectors are slidable along the support surface to reduce the volume of the variable volume forming region; method.

26. 26. The method of claim 25, wherein the blocking portion secures the unit dose against the support surface by interposing between the sectors.

27. An apparatus for forming an object, the apparatus comprising: at least one mold; the at least one mold includes a first mold part and a second mold part located opposite each other, and a plurality of sectors included in either the first mold part or the second mold part that define a variable volume forming region of the mold and form at least a side surface of the object; the apparatus further comprising a drive device for moving the first and second mold parts toward each other along the forming direction so that they contact each other along respective contact surfaces disposed transverse to the forming direction to define a closed forming chamber between the first and second mold parts; The device further comprises a pushing means for moving the sectors transversely to the forming direction, so that each of the plurality of sectors slides along a sliding surface of an adjacent sector, thereby reducing the volume of the variable volume forming region; each of the sectors is defined by a forming surface facing the variable volume forming region and a sliding surface adjacent to the forming surface; Device.

28. 28. The apparatus of claim 27, the first mold part further comprises an end forming part defining the closed forming chamber transverse to the forming direction on an opposite side to the second mold part; a projection core protruding from the end forming portion toward the second mold portion to produce an object having a hole or hollow portion from a unit portion located off-center with respect to the plurality of sectors on a side of the projection core in the first mold portion; Device.

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