JP2024056948A - Hinge product and apparatus and method for forming the hinge product - Patents.com - Google Patents

Abstract

An alternative hinged product made with natural polymers is provided. A product made with a mass containing natural polymers includes at least a first product part and a second product part connected by a hinge structure, the hinge structure including at least one flexible sheet element and one bridge part made of the mass containing natural polymer, the hinge structure being designed such that prior to a first hinge connection, the at least one bridge part forms a stronger connection between the first product part and the second product part than the flexible sheet element, and the hinge connection breaks the bridge part, so that the first and second product parts are connected substantially only by the at least one flexible strip. [Selected Figure]

Description

The present invention relates to an article of manufacture comprising at least first and second article portions fabricated with a mass comprising a natural polymer and connected to one another by a hinge structure. The present invention further relates to an apparatus and method for forming such an article of manufacture.

No. 5,376,320 discloses a hinged product including a first product part and a second product part connected to the first product part by a hinge, the hinge being formed by a flexible strip that fills the gap between the separate first and second product parts. In an apparatus for forming such a product, two separate mould cavities are provided:
The first and second product portions are provided with a separating wall therebetween. Each cavity has at least one injection opening. During manufacture, a label is placed on top of the separating wall and folded over both edges of the separating wall. A closing mold part is placed into and over each of the mold cavities while simultaneously securing the label between the top of the separating wall and the closing mold part. As the product is formed and removed from the mold, one product portion can be folded over the other product portion by folding a label portion extending between the first and second product portions.

WO 00/39214 discloses hinged products such as clamshells manufactured using a mass of natural polymers formed in a mould, in which hinges are formed by the mass containing the natural polymers by locally influencing the material composition of the product, so that the material properties of the associated parts deviate from those of the adjacent parts.

It is an object of the present disclosure to provide an alternative hinge product made using natural polymers. It is an object of the present disclosure to provide a hinge product that is easy to manufacture. It is an object of the present disclosure to provide a product that is easy to handle, especially after the product has been molded. It is an object of the present disclosure to provide a hinge product that is easy to handle, particularly after the product has been molded.
It is an object of the present disclosure to provide a method for forming hinged products using natural polymers. It is an object of the present disclosure to provide an apparatus for forming hinged products using natural polymers, and in particular for molding such products. It is an object of the present disclosure to provide a package having each hinge portion made using a natural polymer that can be easily handled during packaging of the product.

At least one of these and other objects may be achieved individually or in combination using products, methods, and/or apparatus according to the present disclosure.

In one aspect, a product according to the present disclosure can be manufactured using a mass containing natural polymers, the product comprising at least a first and a second product part connected by a hinge structure. The hinge structure comprises at least one flexible sheet element, e.g., a strip, and one bridge portion made of the mass containing said natural polymers. The hinge structure is first
and prior to hinging the second product portion to one another, the at least one bridge portion is designed to form a stronger connection between the first and second product portions compared to one or more flexible sheet elements, and by hinging the first product portion to the second product portion for the first time, the bridge portion is severed, e.g. at least partially torn, sheared and/or broken, such that the first and second product portions are connected to one another substantially only by the at least one flexible sheet element.

In the product according to the present disclosure, when the product is removed from the mold in which it is formed, the one or more bridges preferably form a relatively rigid connection between the first and second product parts, preferably at least sufficiently rigid to prevent one product part from moving, in particular pivoting, under the influence of gravity relative to the other product part. This allows for easy handling, for example during demolding, stacking, unloading, and handling, for example during product filling. After demolding, when the first product part is pivoted relative to the second product part by the hinge structure, the bridges lose their rigidity, in particular by breaking, tearing, and/or shearing, so that the first and second product parts are connected to each other substantially only by at least one flexible strip, allowing for easy and repeatable hinge connection.

In each embodiment, one or more bridges may be provided such that said at least one flexible sheet element, such as one or more strips, is at least partially covered on at least one surface by said mass forming a bridge. In the same or respective different embodiments, at least two flexible sheet elements, such as strips, may be provided, with a bridge at least partially provided between each of said flexible sheet elements, and/or at least two bridges may be provided, with at least one flexible sheet element, such as a strip, provided extending between each of said bridges.

In one aspect, the method of the present disclosure may comprise introducing a mass comprising at least a natural polymer such as starch into a mould, the mass in the mould being heated, so that the mass comprises cross-links of at least the natural polymer. The mould comprises at least two product part forming parts connected by a bridge, and at least one flexible sheet element such as a strip is placed in and/or on said bridge, preferably before introducing said mass into said mould. The at least one flexible sheet element is arranged to extend at least partially into said product part forming parts on both sides of the bridge and is connected to the mass introduced into the mould. The mould used is such that during the introduction of the mass into the mould, at least a part of the mass flows over the bridge, over and/or along said at least one flexible sheet element, so that at least one bridge is formed in the product being formed.

In each embodiment, the mass covers at least a portion of at least one surface of the flexible sheet element and connects each product portion formed in said product portion forming portion, such that a bridge portion can form a layer on at least one surface of the flexible sheet element.

In each embodiment, at least one flexible sheet element is pinned on at least one and preferably a series of pins in and/or on said bridge portion, said at least one flexible sheet element being held in position during introduction of the mass into the mould. In each such embodiment, the at least one flexible sheet element is preferably pinned on at least one pin such that a surface of the flexible sheet element abuts the mould surface when the mould is closed, so that the mass can only flow over the other surface of the flexible sheet element involved in the formation of the bridge portion.

In each embodiment, each of the mold sections can be designed to form a shell portion having a first wall portion connected to a bridge portion, with at least one flexible sheet element disposed in and/or on the bridge portion and having a longitudinal direction, and both sides of the at least one flexible sheet element designed to be folded over the respective walls of the associated mold section to respectively form the inner surface of the associated product portion formed therein.

In one aspect, the apparatus according to the present disclosure may comprise a mould comprising at least two product part forming parts connected by a bridge part, the apparatus preferably comprising a sheet system for arranging at least one flexible sheet element in and/or on said bridge part prior to introducing said mass into said mould, said at least one flexible sheet element extending at least partially into the product part forming parts on either side of the bridge part,
and connecting the mass introduced into the mould, preferably so that the mass covers at least a portion of at least one surface of the flexible sheet element to connect the product portions formed within each of said product portion forming portions and/or the mass forms at least one bridge adjacent to said at least one flexible sheet element.

To further clarify the present invention, embodiments thereof are disclosed and described below with reference to the drawings, in which:

FIG. 1 is a perspective view of an embodiment of a hinged product in an open position.

FIG. 2 is a top view of the product of FIG. 1 .

1A is a cross-sectional view of the product of FIG. 1 taken along line II-II in FIG.

FIG. 2 is a close-up view of the hinge structure of the product in the first embodiment according to the present disclosure prior to a first hinge connection.

FIG. 3B is a close-up view of the hinge structure of the product according to the present disclosure as shown in FIG. 3A after the first hinge connection.

3B shows an enlarged view of the hinge structure of FIG. 3A.

FIG. 13 is a perspective view of an alternative embodiment of a hinged product in an open position.

5 shows the product of FIG. 4 in a closed position.

1 shows a portion of an apparatus for forming a product according to the present disclosure, with an open mold and sheet system in position to pick up each flexible sheet element.

FIG. 7 shows the apparatus of FIG. 6 with the sheet system in position to pick up each flexible sheet element and place each flexible sheet element onto a respective mold.

FIG. 7 shows the apparatus of FIG. 6 with the sheet system in position to pick up each flexible sheet element and place each flexible sheet element onto a respective mold.

FIG. 13 is a partial cross-sectional view of a mold portion showing pins for holding flexible sheet elements.

1 shows a flexible sheet element such as a strip pinned onto a pin.

1 illustrates various embodiments of alternative hinge structures.

1 illustrates various embodiments of alternative hinge structures.

1 illustrates various embodiments of alternative hinge structures.

In this description, embodiments of the invention are shown and disclosed for illustrative purposes only. They should not be interpreted or understood in any way to limit the scope of the invention. In this description, identical or similar elements are designated with identical or similar reference numerals. In this description, embodiments of the invention shall be described with reference to starch-based natural polymers as the natural polymer for illustrative purposes only. Other natural polymers may be used in such mass in addition to starch or as a substitute for starch.

In this disclosure, mainly packaging products are described as examples of illustrative products. However, other hinge products are also included within the scope of the claims. In this disclosure, a hinge connection should be understood to include pivoting of at least a first product part relative to a second product part connected to the first product part via a hinge structure, in particular about a pivot line or a series of pivot lines provided by the hinge structure. Such pivot lines may be solid or imaginary lines,
It may be straight or curved. Hinging should at least be understood to include moving a first product portion from a position substantially adjacent to a second product portion connected thereto via a hinge structure to a position substantially above said second product portion by flexing and/or folding a flexible sheet element connecting the two product portions.

In the present disclosure, a packaging product should be understood to include at least, but not be limited to, a product capable of packaging other products, for example, for storage, transport and/or display. In the present disclosure, a hinge product, such as a packaging product, preferably allows the first and second product portions to be opened and closed several times without coming apart, at least with the first and second product portions being held together by said at least one flexible sheet element, such as one or more flexible strips.

In this disclosure, a sheet should be understood as an element having a longitudinal direction and a width direction perpendicular thereto, and a thickness direction perpendicular to both the longitudinal direction and the width direction. The length in the longitudinal direction and the width in the width direction are substantially greater than the thickness in the thickness direction. A strip should be understood to mean at least, but not limited to, a relatively flat, elongated band of flexible sheet material having a longitudinal direction, as well as a width and a thickness. The length in the longitudinal direction is greater than the width measured in the width direction when the strip is substantially flat. The thickness is less than the width.

Flexible in the present disclosure may be understood to mean that a flexible sheet element such as a strip can be repeatedly folded, at least in a direction substantially perpendicular to the longitudinal direction, through an angle of at least 45 degrees, preferably at least 90 degrees, for example at least about 180 degrees, with a bending radius less than or equal to the width of the strip in a flat position. Flexible sheet material in the present disclosure may be understood to mean that the flexible sheet material used in a hinge structure in a product according to the present disclosure is more flexible than any bridge portion in the same product.

The flexible sheet element such as a strip may be made of any suitable material such as paper, textile, polymer, etc., and may be a single layer or a laminate. The material used to make the flexible sheet element such as a strip is preferably biodegradable, more preferably with respect to the material of each product part to which it is connected. The flexible sheet element such as a strip has two sides in the thickness direction, at least one of which is preferably suitable for adhering to the mass used to form the product, for example to a natural polymer in the mass. In each embodiment, the flexible sheet material such as a strip may be porous or perforated to allow part of the mass to pass into and/or through the flexible sheet material.

In the present disclosure, a mass containing a natural polymer may be understood to include, but is not limited to, at least a batter or suspension containing a natural polymer, such as, but not limited to, starch or tapioca. In this case, the mass preferably contains moisture, so that the mass is flowable before heating and allows gelling and cross-linking of the natural polymer in said mass during heating in a mold. Examples of suitable masses are described, for example, in WO 2004/033179, U.S. Pat. No. 5,376,320, WO 00/39214 and WO 2004/033179.
No. 096/30186, all of which are incorporated herein by reference insofar as they disclose masses such as suspensions containing natural polymers suitable for molding products according to the present disclosure.

In this disclosure, an apparatus is described for forming the product according to the disclosure, comprising a mould. In the examples, a closed mould is mainly described into which a mass containing a natural polymer can be introduced under pressure and which can be heated to obtain at least cross-linking of the natural polymer in the mass. Such moulds and mould systems are described, for example, in International Publication No. WO 2004/03.
No. 3,179, U.S. Pat. No. 5,376,320, International Publication No. WO 00/39214 and International Publication No. WO 96/30186, all of which are incorporated by reference in their entirety by Bartolomeo et al., The Netherlands.
Insofar as it discloses a molding apparatus for molding a mass based on natural polymers, such as Paperfoam®, a product material manufactured by Paperfoam Co., Neveld, it is incorporated herein by reference. However, products according to the present disclosure can also be formed, for example, using the disclosed method, in various molding systems and apparatus, for example in a mold in which the mass is introduced without pressure and pressurized through one or more mold cavities by closing the mold. Such molding systems are known, for example, from US Patent No. 4,417,508 by Franz Haas.

For illustrative purposes, in each embodiment of the molding apparatus described below, a mold is shown having each mold cavity for forming two articles simultaneously, however, it will be apparent that other numbers of mold cavities may also be provided, such as for forming more than one or two articles in a molding cycle.

In each embodiment of the manufacturing method and apparatus according to the present disclosure described below, at least one
Two flexible sheet elements are placed in the mould, so that at least one flexible sheet element is adhered to the product or at least integrated into the product during moulding, although it is also possible to adhere the flexible sheet element as an intermediate product to the product after moulding, for example by using an adhesive, preferably a non-toxic, more preferably a biodegradable adhesive, for example a starch-based adhesive, so that the flexible sheet element connects the first and second product parts.

1 illustrates in perspective view a hinged product 1, which in this embodiment is shown for purposes of illustration only as an egg carton. Product 1 includes a first product portion 2 connected to a second product portion 3 by a hinge structure 4, as will be described below. The first product portion 2 and the second product portion 3
may both be substantially shell-shaped, with one or more relatively thin walls defining spaces within such first and second product portions 2, 3. Upon closing of the product 1, such spaces join together to form a space enclosed by such product 1.

The first product part 2 in the embodiment of Figures 1, 1A and 2 comprises respective receiving spaces 5 for eggs (not shown) in which the eggs can be placed in a known manner. The spaces 5 are arranged in two parallel rows 6, each row 6 comprising six such spaces 5 in the present embodiment. Between the two rows 6, and extending above each space 5, two posts 7 are provided which are suitable for supporting the second product part 3 when the product 1 is closed.
The first product part 2 has a first edge 8 opposite the hinge structure 4, whereas the second product part 3 has a second edge 9 opposite the hinge structure 4. The first edges 8 include respective first locking elements 10, whereas the second edges 9 include respective second locking elements 11. As a result, in the closed position of the packaging product 1, the first locking elements 10 and the second locking elements 11 can be engaged with each other to releasably lock the first product part 2 and the second product part 3 in the closed position.

The product 1 is made from a mass containing a natural polymer, such as starch, that has been heated to allow cross-linking of the natural polymer and to allow evaporation of some of the liquid fraction of the mass, providing a relatively rigid foam wall structure. The product 1 is preferably molded using a closed mold into which the mass is fed under pressure.

The hinge structure 4 includes at least one or a series of flexible sheet elements 12 and one or a series of bridge portions 13, as can be seen, for example, in Figures 2 and 3.
The two flexible sheet elements 12 are connected to the first product part 2 and the second product part 3. At least one bridge part 13 is also connected to the first product part 2 and the second product part 3 and is made of a mass comprising a cross-linked natural polymer. The at least one bridge part 13, which may also be referred to as bridge element 13, is preferably integral with the first product part 2 and the second product part 3 and made of the same mass as them.

At least one bridge portion 13 is preferably connected to at least one flexible sheet element 1
2, so that when the second product part 3 is hinged onto the first product part 2 by the hinge structure 4, in particular for closing the product 1 as a packaging product 1, the at least one flexible sheet element 12 is flexed and/or folded, while
At least one bridge portion 13 is cut, e.g. broken, sheared and/or torn, at least to an extent that the stiffness of such bridge portion 13 is significantly reduced, preferably at least one bridge portion 13 is broken, such that the first product portion 2 and the second product portion 3 are subsequently connected to each other only by the at least one flexible sheet element 12. The flexible sheet element or elements 12 after cutting the bridge portion or portions 13 allow repeated hinge connection of the second product portion 3 to the first product portion 2, whereas prior to cutting said bridge portion or portions 13 such hinge connection is substantially prevented by the at least one bridge portion 13.

FIG. 3A shows, for illustrative purposes, the first product portion 2 after molding and before initial hinging.
3A shows a cross section of the hinge structure 4 between the first product part 2 and the second product part 3; FIG. 3C shows the same on an enlarged scale. Here, the bridge part 13 is shown extending between and integrally formed with the second wall 14 of the first product part 2 and the first wall 15 of the second product part 3. The bridge part 13 in this embodiment is made of the same material as the first product part 2 and the second product part 3. In the embodiment of FIG. 3A, the bridge part 13 abuts against a first surface 16 of the flexible sheet element 12, while the opposite second surface 17 of said flexible sheet element 12 is free. In this embodiment, the bridge part 13 has a substantially flat surface 18 abutting against the flexible sheet element 12 and an opposite surface having a generally grooved shape, said opposite surface being formed by a grooved groove 18 ...
For example, it has a substantially V-shaped cross-section in a plane perpendicular to a longitudinal axis X that extends perpendicular to the plane of the paper in Figure 3C and parallel to and/or coincident with the hinge line S. Thus, the central portion 19 of the bridge portion 13 is the thinnest and therefore most likely to break first upon hinging, thereby substantially defining the hinge line S for flexing or folding the flexible sheet element 12.

Figure 3B shows the same product cross-section as Figures 3A and 3C, but after hinged connection of the second product portion 3 to the first product portion 2. In Figure 3B, the flexible sheet element 12 has been flexed or folded at or near the bend or hinge line S, while the bridge portion 13 has been broken (at said thinnest portion 19), significantly reducing the stiffness of the hinge structure 4 connecting the first product portion 2 with the second product portion 3. The flexible sheet element 12 remains connected to the first product portion 2 and the second product portion 3.

As can be appreciated from this disclosure, the flexible sheet element 12 and bridge portion 13 may, for example, allow the second product portion 3 to pivot relative to the first product portion 2 (see, for example, FIGS. 3A and 3B ).
Preferably, the bridge portion 13 is designed and configured such that it is cut, in particular broken, without cutting the flexible sheet element 12 when the hinge structure 4 is deflected by bending the hinge structure 4 (as shown in FIG. 1). The bridge portion 13 is, for example, less flexible than the flexible sheet element 12,
and/or may be highly brittle.

In the embodiment of Figures 1 and 1A, the flexible sheet element 12 is provided as a strip 12A extending over the longitudinal length L of the second wall 14 of the first product portion 2 and the first wall 15 of the second product portion 3. The flexible sheet element 12 fills the gap 20 between the first product portion 2 and the second product portion 3. In Figures 9A to 9C, various alternative embodiments are shown, for example in which multiple bridges 13 and/or multiple flexible sheet elements 12 are provided. For example, Figure 9A shows a top view of a hinge structure 4 comprising two spaced apart bridges 13A between three spaced apart flexible sheet elements 12B. Figure 9B shows a top view of a hinge structure comprising two flexible sheet elements 12C between three spaced apart bridges 13B. Figure 9C shows an embodiment of a hinge structure 4 comprising a strip 12A of flexible sheet material covering five spaced apart bridges 13C. It will be apparent that many other combinations of flexible sheet elements 12 and bridge portions 13 are possible within the scope of the present disclosure.

The flexible sheet element 12 in the present disclosure can be made of any suitable flexible and/or foldable material, such as, but not limited to, paper, plastic, textile, etc., and can be a single layer sheet or a laminate of different layers of the same or different materials. The flexible sheet material is preferably biodegradable and comprises natural materials.

At least one bridge portion 13 extends over an angle of more than 45° after the product 1 is demolded.
When deflected through an angle of at least 90°, more preferably at least about 180°
Preferably, the flexible sheet material 12 is fabricated to break when it is bent over an angle of 15°. In each embodiment, the product 1 can be designed and constructed such that at least one layer of material made of the polymeric mass covering the flexible sheet material 12 breaks when the flexible sheet material is folded over the hinge line S. In each embodiment shown in Figures 1 to 3, at least one bridge portion 13 has a substantially symmetrical cross-section (as shown in Figures 3A to 3C), such that the hinge line S is substantially in the center of the gap 20 between each wall portion 14 and 15. The location of the hinge line S can be adjusted by designing the bridge portion(s) differently.

4 and 5 show, in a schematic manner, an alternative embodiment of the product 1 according to the present disclosure.
also has a first product portion 2 connected to a second product portion 3 by a hinge structure 4 .
The hinge structure 4, as shown diagrammatically in an enlarged cross-section in Figure 4A, also comprises a flexible sheet element 12 connected to the first product part 2 and the second product part 3, and, similar to the embodiment of Figures 1 to 3, is provided with a bridge part 13 which extends over said flexible sheet element 12 after demoulding and before the first hinge connection and connects the first product part 2 and the second product part 3. However, in this embodiment, the bridge part 13 is designed to have two thin parts 19 formed by the undersides of two substantially parallel grooves 21 with a substantially V-shaped cross section. Between each of said grooves 21, a raised thicker part 22 is provided.

1 to 3, in the open position as shown in FIG. 4, immediately after molding, i.e. before the second product portion 3 is tilted for the first time relative to the first product portion 2, the bridge or bridges 13 are relatively rigid compared to the flexible sheet element 12 and preferably only one of the first product portion 2 and the second product portion 3.
and has sufficient rigidity to be able to engage the other of the second product portions 3 with respect to the first product portion 2 without significant tilting due to gravity acting on said other product portion, thereby lifting the product to a substantially horizontal position. Here, "without significant tilting" should be understood to mean at least without sufficient tilting to break the bridge portion or at least one of the bridge portions. Such bridge portion(s) may thus facilitate demoulding, stacking, unloading, etc. of the open product, as well as handling, e.g. by a robot, when transporting such product 1 to a filling station for filling it with the product to be packaged therein.

When the second product portion 3 of the product 1 of Figures 4 and 5 is tilted relative to the first product portion 2 to close the product 1 in the position as shown in Figure 5, the bridge portion 13 (or each bridge portion 13) is cut, e.g. broken or torn, at both thin portions 19 to allow a double hinge connection of two substantially parallel hinge lines _S1 and _S2 located at or near each said thin portion 19. As can be seen in Figure 5, in the closed position, the thicker portions 22 extend substantially vertically when the facing surfaces 23 and 24 of the first product portion 2 and second product portion 3, respectively, are substantially parallel to each other in a substantially horizontal position.

In the embodiment shown in Figures 4 and 5, the first product portion 2 includes a series of ridges 25 and the second product portion 3 includes a series of grooves 26, so that a substantially cylindrical product (not shown), such as, for example, a cigar, pen, etc., can be packaged in the product 1.

Figure 6 shows diagrammatically an apparatus 40 for forming a product 1 according to the present disclosure, together with an open mould 30 for shaping the product 1. In this example, the mould is designed together with a part of a supply 31 for flexible sheet material 12, in particular a strip 12A of such flexible sheet material 12, and a transfer device 35 for transferring said strip 12A to the mould 30, so as to form two side-by-side products 1 according to Figure 1. In this embodiment, the supply 31 comprises two rolls 32, each of a predetermined length of said material 12. From each roll 32, the strip 12A is fed over a guide 33 to a substantially vertical position in front of two parallel pick-up devices 34 of a transfer device 35, which each engage the strip 12A of length L cut from the associated roll 32.

7A and 7B show a first mold half 30A and a second mold half 30B in a conventional manner.
6A and 6B, a first mold half 30A is shown in FIG.
7A shows a transport apparatus 35 in a position for picking up flexible sheet material 12 such as strips 12A. The transport apparatus 35 may include, for example, a rail or arm system 36 by means of which each pickup apparatus 34 can be moved from the position shown in FIG. 7A to the position in FIG. 7B and vice versa. In use, each pickup apparatus 34 picks up two strips 12A in the position of FIG. 7A and transports those strips 12A to the position shown in FIG. 7B where each strip 12A is moved to the position shown in FIG.
are transferred from each pick-up device 34 into the mould 30, in particular to a position where they are formed into the product 1, as will be explained in more detail below. Each pick-up device 34 can then be returned to the position of Fig. 7A and the mould 30 can be closed for a moulding cycle. In the moulding cycle, a mass can be injected into the closed mould 30, which is then heated to cross-link at least the natural polymers in the mass, after which each product 1 can be removed from the mould 30, for example, using an ejector (not shown) or other demoulding system and equipment known in the art. During the moulding of the product 1, the flexible sheet material 12, in particular the strip 12A, is securely connected to the product 1.

The mould 30 according to the present disclosure preferably comprises at least one retainer or retainer system 41 for keeping the at least one flexible sheet element 12 in a fixed or at least predetermined position at least during the introduction of the mass into the mould 30, in particular when the mass is passed over the at least one flexible sheet element 12. In figures 8 and 8A an embodiment of a retainer 41 forming part of the retainer system 41 is shown. In this embodiment, the retainer 41 shown is formed by a sharp pin 42 extending above a surface 43 forming part of a bridge 50 extending between the mould part 30(2) for moulding the first product portion 2 and the second mould part 30(3) for moulding the second product portion 3. Said surface 43 is designed such that the outer surface 18 of the strip 12A can be placed against it. In this embodiment, the surface 43 is substantially flat, but it can also be designed differently, for example curved in cross section. The width W of the surface 43 between the first product portion 2 forming portion 30(2) and the second product portion 3 forming portion 30(3)
may be, for example, approximately the same as the width (perpendicular to the longitudinal axis X) of the strip 12A.
In FIG. 8A, the width W of surface 43 is shown to be less than the width W12 of strip 12A, so that both sides 44 of strip 12A are spaced apart from first product portion forming portion 30(2).
and are folded against respective wall forming portions 45 and 46 of second product portion forming portion 30(3).

When the strip 12A is transferred into the die 30, the strip 12A is pressed against at least one retainer, in particular against at least one pin 42, thereby creating a hole in the strip 12A. Thus, the strip 12A released by the transfer device 35 is held in the die 30 by the at least one pin 42.

As seen in FIG. 8A, mold section 30B is inserted from above mold section 30A, thereby inserting pins 42.
In each embodiment, the pins 42 can be made shorter, so that their free, sharp ends 42A extend inside the formed mold cavity 47. A closed mold cavity 47 is formed surrounding the strip 12A. In each embodiment, at least one pin 42 can be retractably movable in the longitudinal direction L pin, for example, to remove the product 1 with the strip 12A during demolding or to allow the pin 42 to penetrate the strip _12A before or during closure of the mold 30.

During molding, a mass such as a batter, suspension or liquid is introduced through at least one inlet opening or injection point 5, preferably spaced apart from at least one flexible sheet element 12.
1 into the mold cavity 47. Such at least one introduction point is:
For example, it may be provided between two product-forming parts of a double mould as shown in figures 6, 7 and 8. The mass is introduced such that it passes over and/or under and/or along at least a portion of said at least one flexible sheet element 12 to form at least one bridge portion 13. In each alternative embodiment, the mass is introduced into the mould 30 before or during closing, and the mass is forced to fill the mould cavity 47 by closing the mould 30. In such an embodiment, after supplying the mass to the mould 30 during closing, for example, the at least one flexible sheet element 12, i.e. the at least one flexible sheet element 12, may be supplied.

Instead of or in addition to one or more pins 42 for holding the strip 12A and/or each of the other flexible sheet elements 12, other holding arrangements can be provided, such as clamps for example for fixing at least one flexible sheet element 12 in a fixed position, for example clamps for fixing both ends of the strip 12A during molding, which ends can be released after demolding and/or separated during demolding. The holding means can also include vacuum cups and/or strips for temporarily holding the flexible sheet element 12 in a fixed position. Similarly, other transfer means can be provided for placing the strip in the mold. For example, the strip can be drawn directly into the mold from a roll. In each embodiment, the respective flexible sheet element 12 is provided on a continuous support from which one or more flexible sheet elements 12 can be removed, for example after being transferred into the mold 30 or after demolding the product to which the one or more flexible sheet elements 12 are connected during molding.

The present invention is in no way limited to the embodiments disclosed herein, which are for illustrative purposes only, and many variations of the invention, including all combinations of the features disclosed herein, are encompassed by the invention as defined by the claims.

For example, materials including other materials besides starch, such as, but not limited to, tapioca, may be used. In various embodiments, product 1 according to the present disclosure may have multiple hinge portions, some or all of which are connected by the hinge structures disclosed herein.
The product according to the present disclosure may be a product different from that for packaging. Each part of the product may be made of different materials. In each embodiment, the flexible sheet element forming part of the hinge structure may extend further into one or more parts, such as both product forming parts, for example to form a surface area thereof. In each illustrated embodiment, at least one flexible sheet element is shown on the outer surface area of the product. However, such a flexible sheet element may also be provided on the inner surface area of the product. In each embodiment, each bridge portion may be provided on both sides of the flexible sheet element.

These and other such embodiments are also contemplated as falling within the scope of the present disclosure, which is defined primarily by the claims.

Claims (19)

1. A product manufactured using a mass comprising a natural polymer, the product comprising at least a first product portion and a second product portion connected by a hinge structure;
the hinge structure includes at least one flexible sheet element and a bridge portion made of a mass including the natural polymer;
A product, wherein the hinge structure is designed such that prior to an initial hinge connection, the at least one bridge portion forms a stronger connection between the first product portion and the second product portion than the flexible sheet element, and upon hinge connection, the bridge portion is severed, such that the first and second product portions are connected substantially only by the at least one flexible sheet element. The article of manufacture of claim 1 , wherein said at least one flexible sheet element is at least partially covered on at least one surface by said mass to form said bridge portion. the at least one flexible sheet element is formed by or comprises a flexible sheet element having a longitudinal direction;
3. A product according to claim 1 or 2, wherein at least one face of said flexible sheet element is at least partially covered by said bridge portion. At least two sheet elements are provided,
3. A product according to claim 1 or 2, wherein the bridge portion is at least partially disposed between the sheet elements, and/or at least two bridge portions are provided, with at least one sheet element extending between the bridge portions. each of the first and second product portions are or include a shell shape and are hingeably connected to one another by the hinge structure such that the first product portion can be hinged to the second product portion to enclose a space defined by each of the shell-shaped portions;
5. The product of claim 1, wherein the at least one flexible sheet element faces the space when the first product part is hinged to the second product part. 1. A method of making a product comprising: introducing a mass comprising at least a natural polymer such as starch into a mould; heating said mass in said mould such that said mass comprises at least cross-links of said natural polymer; and said mould comprises at least two product part forming portions connected by bridges;
at least one flexible sheet element is disposed in and/or on said bridge portion, preferably prior to introducing said mass into said mould, said at least one flexible sheet element extending at least partially into each of said product part forming portions on either side of said bridge portion and connected to said mass introduced into said mould;
during introduction of said mass into said mould, at least a portion of said mass flows over said bridge portion, over and/or along said at least one flexible sheet element to form at least one bridge portion in said formed product and to connect said formed product portions within said product portion forming portions;
Preferably, said mass covers at least a portion of at least one surface of said flexible sheet element. The method of claim 6, wherein a paper-based material is used as the flexible sheet element. the at least one flexible sheet element is held at or near the bridge portion;
8. The method according to claim 6 or 7, in particular pinning on at least one and preferably a series of pins in and/or on said bridge portion to hold said at least one flexible sheet element in a fixed position during introduction of said mass into said mould. 9. The method according to claim 8, wherein the at least one pin is located at or near a side of the bridge spaced from the introduction point of the mass in the mould, in particular in one of the product part forming portions of the mould. the mass is introduced into the mould by a closing member during and/or after closing of the mould,
10. A method according to any one of claims 6 to 9, wherein the mass is injected into the mould, preferably under pressure. 11. A method according to any one of claims 6 to 10, wherein the bridge portion and the at least one flexible sheet element are dimensioned such that during introduction of the mass into the mould, the mass can flow over the at least one flexible sheet element from one of the product portion forming parts of the mould to the other. 12. A method according to any one of claims 6 to 11, wherein the at least one flexible sheet element is supplied from a supply, such as a roll, and a predetermined length of sheet material is placed in and/or on the bridge portion, and the flexible sheet element is preferably cut to a predetermined length and/or shape before, during and/or by closing the mould. each of the product portion forming sections of the mold is designed to form a shell portion having a first wall portion connected to the bridge portion;
the at least one flexible sheet element is disposed in and/or on the bridge portion and has a longitudinal direction;
13. A method according to any one of claims 6 to 12, wherein both sides of the at least one flexible sheet element are designed to be folded over respective walls of respective product portion forming portions of the associated mould to form respective surface portions of the associated product portions formed therein. 14. The method according to any one of claims 6 to 13, wherein the at least one flexible sheet element is covered on at least one face of the flexible sheet element by a layer of the mass during the introduction of the mass. the at least one flexible sheet element forms a hinge between the at least two product portions such that the at least two product portions can be folded relative to one another;
15. The method of claim 14, wherein preferably when the product portions are folded relative to one another, the mass covers at least an outwardly or inwardly facing surface of the flexible sheet element. 16. The method according to claim 14 or 15, wherein the at least one layer covering the at least one flexible sheet element is designed to be cut, in particular to break, when the flexible sheet element is folded in a direction substantially perpendicular to the longitudinal direction of the flexible sheet element. 1. An apparatus for forming a product from a mass including at least a natural polymer such as starch, comprising:
The apparatus includes a mold, the mold including at least two product portion forming portions connected by a bridge portion;
The apparatus preferably comprises a system for placing at least one flexible sheet element in and/or on the bridge portion before introducing the mass into the mould, the at least one flexible sheet element extending at least partially into each of the product part forming portions on either side of the bridge portion and connected to the mass introduced into the mould,
Preferably, such that the mass covers at least a portion of at least one surface of the flexible sheet element and connects the product portions formed within the product portion forming portions.
Device. the sheet system comprises at least one roll for supplying a flexible sheet material and at least one sheet transport unit for transporting the flexible sheet elements supplied by said roll to the mould, in particular into and/or onto the bridge portion,
20. The apparatus of claim 17. 19. Apparatus according to claim 17 or 18, wherein the mould comprises at least a retainer, in particular at least one pin, and more preferably a series of pins, in and/or on the bridge portion, the at least one pin and the series of pins being arranged such that the at least one flexible sheet element is pinnable on the at least one pin, preferably on the series of pins.