A COMPRESSION MOULDING METHOD AND APPARATUS

A method for forming an object comprises the steps of:          providing a mould comprising a first and a second mould part opposite to each other, a part selected from between the first mould part and the second mould part comprising a plurality of sectors for shaping a lateral portion of the object, the sectors delimiting a variable-volume forming region of the mould;     positioning a dosed amount of mouldable material between the first and second mould parts while the mould is in an open position;     displacing the first mould part and the second mould part towards each other in a moulding direction, to define between the first mould part and the second mould part a closed forming chamber bringing into contact respective abutment surfaces of the first mould part and the second mould part, the abutment surfaces extending transversely to the moulding direction.

The invention relates to a method and apparatus for producing objects by compression moulding a mouldable material.

The mouldable material which can be manipulated in the method and apparatus according to the invention is, for example, a synthetic polymeric material.

Compression moulding apparatuses for producing objects in polymeric material are known. The known apparatuses comprise an extruder from which a continuous extrudate of polymeric material outflows and one or more cutting elements for cutting the continuous extrudate in order to separate consecutive doses of polymeric material from the latter. The known apparatuses further comprise one or more moulds for receiving corresponding doses of polymeric material and making an object from each dose.

The doses used in the known apparatuses usually have a simple shape, for example spherical or cylindrical, for reasons related to the production methods thereof. The shape of the doses is often very different from the objects to be produced. This may in some cases create inconveniences due to the difficulties in correctly inserting the dose into the mould.

In particular, cases may occur in which the mould has a forming cavity having a small transverse dimension with respect to the dose dimensions, because the corresponding dimension of the object to be produced is small. It may even occur that the dose cannot be introduced into the forming cavity, because a transverse dimension of the forming cavity is smaller than the corresponding transverse dimension of the dose.

If this occurs, the object cannot be produced by compression moulding, unless doses having a relatively complex shape, closer to the shape of the forming cavity, are used, which is not always possible and in any case requires complicated devices for producing the dose.

US 2006/0034973 discloses a mould for producing containers such as crates, by moulding a plastic material. The plastic material is injected into a cavity of the mould, while the mould is in a closed position. A portion of the lateral wall of the mould cavity is subsequently moved to reduce the volume of the cavity and form the container.

U.S. Pat. No. 5,378,416 discloses a method for making a mould from a powder, in which the mould has an undercut portion. A mould is used which comprises two movable plated-like elements moving away from each other to disengage from the undercut portion of the object and allow the object to be extracted from the mould. The plate-like elements are therefore movable to increase the volume of a forming chamber from which the moulded object must be extracted.

FR 1549502 discloses a device for compacting optical fibres, comprising six sectors arranged around an axis and a steel ring which acts on the sectors to bring them closer to the axis, reducing the distance between pairs of facing sectors. The device comprises a housing and a cover which can be removed to introduce the optical fibres between the sectors and subsequently reapplied. In FR 1549502, it is not possible to define a moulding direction. Furthermore, the device disclosed in FR 1549502 does not apply any axial compression action on the optical fibres, as the distance between two graphite blocks, which are arranged respectively above and below the optical fibres, is constant.

An object of the invention is to improve the compression moulding apparatuses and methods for producing objects in mouldable material, for example in synthetic polymeric material.

A further object is to improve the manners of introducing a dosed amount of mouldable material into a mould to be used to produce an object.

Another object is to make it possible, by compression moulding of a dosed amount of mouldable material, to also produce objects having a small transverse dimension with respect to a dimension of the dosed amount of mouldable material.

In a first aspect of the invention, a method is provided for forming an object, comprising the steps of:providing a mould comprising a first mould part and a second mould part opposite to each other, one part selected from between the first mould part and the second mould part comprising a plurality of sectors for shaping at least a lateral portion of the object, the sectors of said plurality delimiting a variable-volume forming region of the mould;positioning a dosed amount of mouldable material between the first mould part and the second mould part;displacing the first mould part and the second mould part towards each other in a moulding direction, to define between the first mould part and the second mould part a closed forming chamber, by bringing into contact respective abutment surfaces of the first mould part and the second mould part, the abutment surfaces extending transversely to the moulding direction,
the method further comprising the step of moving the sectors of said plurality transversely to the moulding direction to reduce volume of the variable-volume forming region.

Owing to the first aspect of the invention, a variable-volume forming region may be made available in the mould. A dosed amount of mouldable material having a relatively large size and a shape completely different from the object to be obtained can be introduced in the variable-volume forming chamber. This allows to produce, with compression moulding technology, a multiplicity of objects of different shapes and sizes starting from dosed amounts having a simple geometry, which are therefore easy to obtain and manipulate.

In an embodiment, the dosed amount of mouldable material is positioned between the first mould part and the second mould part while the mould is in an open position, i.e., while the first mould part and the second mould part are in a position spaced apart from each other.

In an embodiment, the mould comprises a forming component which penetrates the variable-volume forming region, compressing the mouldable material in the moulding direction.

The forming component allows to progressively reduce a size of the forming chamber along the moulding direction. In other words, the forming component allows to progressively decrease a thickness of the object which is about to be formed, said thickness being measured in a direction parallel to the moulding direction.

It is thus possible to compress the mouldable material both parallel to the moulding direction and transversely to the moulding direction.

In one version, the step of moving the sectors of said plurality transversely to the moulding direction starts before the closed forming chamber has been defined, i.e., before the respective abutment surfaces of the first mould part and the second mould part have been brought into mutual contact.

This allows to start reducing the volume of the variable-volume forming region immediately after having introduced the dosed amount of mouldable material into the mould, without waiting for the forming chamber to be closed.

In particular, the step of moving the sectors of said plurality can also start before the first mould part and the second mould part begin to be displaced towards each other to define the closed forming chamber.

In an embodiment, the sectors of said plurality are movable between a first position and a second position. In the first position, the sectors of said plurality define an enlarged configuration of the variable-volume forming region. In the second position, the sectors of said plurality define a final configuration of the variable-volume forming region.

In an embodiment, the dosed amount is deposited on a part selected from between the first mould part and the second mould part while the dosed amount has, transversely (more specifically, perpendicular) to the moulding direction, smaller dimensions than the corresponding dimensions of the variable-volume forming region in the enlarged configuration, transversely (more specifically, perpendicular) to the moulding direction.

This prevents the dosed amount from prematurely touching the sectors, which could cause undesired deformations of the dosed amount and/or compromise the correct positioning of the dosed amount in the mould.

In an embodiment, the second position is reached before the closed forming chamber has been defined.

In this case, the first mould part and the second mould part are brought into contact only after having reached the final configuration of the variable-volume forming region.

In an embodiment, the sectors of said plurality (which are included in a mould part selected from between the first mould part and the second mould part) face the other mould part selected from between the second mould part and the first mould part, so as to be in contact with the other mould part after the closed forming chamber has been defined.

By bringing the sectors to the second position, corresponding to the final configuration of the variable-volume forming region, before defining the closed forming chamber, it is possible to prevent the sectors from sliding in contact with the mould part facing them while they are being brought to the second position. This thereby reduces the friction which the sectors must overcome to move from the first position to the second position.

In an embodiment, the mould part facing the sectors of said plurality can comprise a blocking portion, intended to engage with an edge zone of the dosed amount to press the edge zone against a forming element of the mould part to which the sectors are associated, so as to block the dosed amount in contact with the forming element while the dosed amount is being shaped.

The blocking portion avoids undesired displacements of the dosed amount during the forming.

In an alternative embodiment, it is possible that the step of moving the sectors of said plurality transversely to the moulding direction starts before the closed forming chamber has been defined, but that the second position of the sectors is reached after the forming chamber has been closed.

In another alternative embodiment, the step of moving the sectors of said plurality transversely to the moulding direction starts after the closed forming chamber has been defined.

This prevents the mouldable material from outflowing the mould in an undesirable manner due to the movement of the sectors.

In an embodiment, the first mould part is a female mould part, while the second mould part is a male mould part.

The first mould part can be arranged below the second mould part.

Alternatively, the first mould part can be arranged above the second mould part.

It may therefore occur that the female mould part is arranged below the male mould part or, alternatively, that the female mould part is arranged above the male mould part.

The step of positioning a dosed amount of mouldable material between the first mould part and the second mould part can comprise depositing the dosed amount on a mould part, selected from between the first mould part and the second mould part, which is below the other mould part, selected from between the second mould part and the first mould part.

The sectors of said plurality can be included in the first mould part or alternatively in the second mould part.

It is therefore possible that the sectors of said plurality are associated with the female mould part or with the male mould part.

In an embodiment, the step of displacing the first mould part and the second mould part towards each other in a moulding direction occurs by means of a driving device which moves at least one mould part selected from between the first mould part and the second mould part towards the other mould part selected from between the second mould part and the first mould part.

In an embodiment, the sectors of said plurality are associated with the mould part moved by the driving device.

This embodiment allows to exploit the movement generated by the driving device also to move the sectors of said plurality transversely to the moulding direction. To this end, the sectors of said plurality can be moved transversely to the moulding direction by virtue of the interaction with mechanical control devices associated with the other mould part, i.e., the mould part opposite to that moved by the driving device.

In a second aspect of the invention, an apparatus for forming an object is provided, comprising at least one mould which includes a first mould part and a second mould part opposite to each other, a part selected from between the first mould part and the second mould part comprising a plurality of sectors for at least partially forming a lateral surface of the object, the sectors of said plurality delimiting a variable-volume forming region of the mould, the apparatus further comprising a driving device for approaching the first mould part and the second mould part with respect to each other along a moulding direction, so as to bring the first mould part and the second mould part into mutual contact along respective abutment surfaces arranged transversely to the moulding direction, defining between the first mould part and the second mould part a closed forming chamber, and wherein the apparatus further comprises pushing means for moving the sectors transversely to the moulding direction to reduce the volume of the variable-volume forming region.

The apparatus provided by the second aspect of the invention allows to obtain the advantages described above with reference to the method according to the first aspect of the invention.

In a third aspect of the invention, a method is provided for forming an object, comprising the steps of:providing a mould comprising a first mould part and a second mould part opposite to each other, one part selected from between the first mould part and the second mould part comprising a plurality of sectors for shaping at least a lateral portion of the object;positioning a dosed amount of mouldable material between the first mould part and the second mould part;displacing the first mould part and the second mould part towards each other in a moulding direction, until the first mould part and the second mould part are brought into contact, thereby defining a closed forming chamber therebetween,reducing volume of the closed forming chamber in order to form the object,
wherein the step of reducing volume of the closed forming chamber comprises moving the sectors of said plurality transversely to the moulding direction after the closed forming chamber has been defined.

In the method according to the third aspect of the invention, before the forming chamber is closed, the sectors can be positioned at a relatively large mutual distance. This also makes it possible to accommodate in the mould dosed amounts of mouldable material having large dimensions with respect to the size of the formed object. It is thus possible to produce, by compression moulding, objects which cannot be obtained with traditional compression moulding machines.

Owing to the sectors which can be displaced transversely to the moulding direction to reduce the volume of the closed forming chamber, the forming chamber can initially have a very different shape than the shape of the finished object. This makes it possible to use dosed amounts of simple shape, which are easy to obtain, as well as to produce objects having a rather complicated geometry.

By providing a forming chamber larger than the object to be produced, the risks that the mouldable material may undesirably interact with the mould are reduced, for example by prematurely adhering to a lateral surface of the forming chamber, which could affect the quality of the object obtained. It is therefore possible to significantly improve the introduction of the dosed amount into the mould.

In an embodiment, when the first mould part and the second mould part are in contact, an abutment element included in the second mould part is abutted against an abutment surface of the sectors, which are included in the first mould part.

In an embodiment, the abutment element is a tubular element surrounding a forming component included in the second mould part.

In an embodiment, after the forming chamber has been closed, it is envisaged to mutually move the forming component and the tubular element to make the forming component penetrate into the first mould part.

In this manner it is possible to shape the mouldable material received in the first mould part.

In an embodiment, the sectors are included in the first mould part and the first mould part further comprises an end-forming element, which defines a forming cavity together with the sectors.

In this manner, it is possible to shape the outer surface of the object which is to be produced in the first mould part.

In particular, the forming cavity may have a lateral surface and a transverse surface arranged at one end of the lateral surface to close the lateral surface at that end.

The lateral surface may be defined entirely by the sectors, in which case the end-forming element defines only the transverse surface of the forming cavity.

In an alternative embodiment, the lateral surface is partly defined by the sectors and partly defined by the end-forming element.

In this case the end-forming element is provided with a recess in which a lateral wall of the object may be partly formed.

The end-forming element also defines the transverse surface of the forming cavity.

This allows to obtain objects having a significant dimension in the moulding direction, as occurs for example in the case of preforms for containers.

In an embodiment, the object to be produced has a hole.

The first mould part has a protruding element projecting from the end-forming element to form the interior of the hole.

In an embodiment, the positioning step comprises arranging the dosed amount in a non-centred position with respect to the sectors, at a side of the protruding element.

When the sectors are moved transversely to the moulding direction to reduce the volume of the closed forming chamber, the dosed amount is flattened around the protruding element, which allows the hole to be formed in the object produced.

This allows to obtain perforated objects without starting from dosed amounts of mouldable material having an annular shape, which are quite difficult to produce.

In a fourth aspect of the invention, an apparatus for forming an object is provided, comprising a mould which includes a first mould part and a second mould part opposite to each other, a part selected from between the first mould part and the second mould part comprising a plurality of sectors for at least partially forming a lateral surface of the object, the apparatus further comprising a driving device for bringing the first mould part and the second mould part into mutual contact, thereby defining between the first mould part and the second mould part a closed forming chamber, and wherein the apparatus further comprises pushing means for moving the sectors transversely to the moulding direction after the forming chamber has been closed, so as to reduce the volume of the closed forming chamber.

As already described with reference to the third aspect of the invention, the apparatus provided by the fourth aspect of the invention also allows to improve the positioning of the dosed amount between the first mould part and the second mould part, as well as to expand the range of objects which can be produced.

In a fifth aspect of the invention, a method is provided for forming an object, comprising the steps of:providing a mould comprising a first mould part and a second mould part opposite to each other;positioning a dosed amount of mouldable material between the first mould part and the second mould part;displacing the first mould part and the second mould part towards each other in a moulding direction, in order to form an object from the dosed amount by means of compression moulding,
wherein an edge zone of the dosed amount is blocked between the first mould part and the second mould part before starting to deform a central zone of the dosed amount.

This makes it possible to avoid unwanted deformations of the dosed amount during the moulding. For example, it is possible to prevent the dosed amount from shrinking or being arranged non-centred in the mould while being deformed between the first mould part and the second mould part.

In a sixth aspect of the invention, an apparatus is provided for forming an object from a dosed amount of mouldable material, comprising at least one mould which includes a first mould part and a second mould part opposite to each other, a driving device for displacing the first mould part and the second mould part towards each other in a moulding direction, so as to form an object from the dosed amount by compression moulding, wherein a mould part selected from between the first mould part and the second mould part comprises a blocking portion, intended to engage with an edge zone of the dosed amount to press the edge zone against the other mould part selected from between the second mould part and the first mould part, so as to block the dosed amount in contact with the other mould part while the dosed amount is being shaped.

The blocking portion avoids undesired displacements of the dosed amount during the forming.

FIGS.1to7schematically show a mould1of a moulding apparatus for producing an object by compression moulding a mouldable material.

In the example shown, the mouldable material is a synthetic thermoplastic material, which has been previously extruded in an extrusion device not shown. The extruded material has then been cut to separate doses or dosed amounts100therefrom of mouldable material having a predetermined mass. Each dosed amount100is intended to originate an object.

In the example shown, the dosed amount100has a substantially spherical shape, but other shapes of the dosed amount100, for example cylindrical or prismatic, are also possible.

The moulding apparatus may comprise a transport device not shown for transporting each dosed amount100to a mould1, after the dosed amounts100have been separated from the material exiting the extruder device.

The moulding apparatus may comprise a plurality of moulds1, for example mounted in a peripheral region of a carousel rotatable about a rotational axis.

In the example shown, the mould1is intended to form a preform for a container. The preform is intended to be blow moulded or stretch-blow moulded to obtain a container. The preform comprises a hollow body, having a lateral wall which can be cylindrical or troncoconical. The lateral wall is closed by a transverse wall which may be dome-shaped. The preform further comprises a neck, which may be provided, externally, with fixing means for removably fixing a cap to the neck of the container obtained from the preform. The fixing means may comprise for example one or more threads.

The mould1comprises a first mould part2and a second mould part3, facing each other. A driving device not shown is arranged to move the first mould part2and the second mould part3with respect to each other along a moulding direction D, to mutually approach or alternatively mutually distance the first mould part2and the second mould part3. The driving device may be hydraulic, mechanical or other. One example of a hydraulic-type driving device is a hydraulic actuator. One example of a mechanical-type driving device is a cam device.

The driving device may be associated with the first mould part2, to bring the first mould part2closer to, or alternatively move the first mould part2away from, the second mould part3, which remains fixed along the moulding direction D. Alternatively, the driving device may be associated with the second mould part3, while the first mould part2remains fixed along the moulding direction D. A driving device may also be associated with both the first mould part2and the second mould part3, which in this manner are both movable along the moulding direction D.

Furthermore, the moulding direction D, which in the example shown is vertical, may also be non-vertical, for example horizontal or oblique.

In the example shown, the first mould part2is a female mould part, while the second mould part3is a male mould part.

In the example shown, the first mould part2is arranged below the second mould part3, but this condition is not necessary and other mutual arrangements of the first mould part2and the second mould part3are possible.

The first mould part2has a forming cavity24, into which an outer surface of the object may be shaped. The forming cavity24may have a Y axis.

In the example shown, the first mould part2comprises a plurality of sectors8and an end-forming element14, which interact to define the forming cavity24.

In particular, the sectors8are configured to define a variable-volume forming region4of the forming cavity24, adjacent to the second mould part3. The end-forming element14is arranged to form at least one end wall of the object, which extends transversely to the moulding direction D.

In the example shown, a recess70is provided in the end-forming element14which is included in the forming cavity24. The recess70defines a portion of the forming cavity24with constant volume.

The sectors8are interposed between the end-forming element14and the second mould part3.

The sectors8and the end-forming element14are arranged to shape an outer surface of the object to be produced. More specifically, if the object to be produced is a preform, the sectors8are intended to form at least the preform neck from the outside, while the end-forming element14is arranged to shape the end wall of the preform from the outside, in addition to the hollow body interposed between the neck and the end wall.

The variable-volume forming region4is delimited by a lateral surface5, which surrounds a central zone6. The lateral surface5is intended to externally shape at least the preform neck.

The sectors8are suitable for defining the lateral surface5of the variable-volume forming region4.

In the example shown, four sectors8are provided, namely a first sector8a, a second sector8b, a third sector8cand a fourth sector8d.

Each sector8is in contact with two adjacent sectors8. For example, in the version shown, the first sector8ais in contact with the second sector8band the fourth sector8d, which are adjacent to the first sector8a.

In an alternative embodiment not shown, it is also possible to provide a number of sectors8other than four.

The sectors8may have the same shape.

Each sector8comprises a body9, which may have a substantially parallelepiped shape. A forming appendage10projects from the body9, protruding from the part of the body9turned to the central zone6.

The body9is delimited by a forming surface11, facing the forming region4and intended to define, together with the forming surfaces11of all the sectors8, the lateral surface5of the variable-volume forming region4.

In the example shown, the forming surface11delimits the forming appendage10of the corresponding sector8.

The forming surface11may be curved.

In the example shown, each forming surface11has the shape of a cylinder portion, more specifically a quarter of a cylinder, having depressed parts and/or raised parts to originate threads or other fixing means on the preform neck.

Each sector8is further delimited by a sliding surface12, arranged in a position adjacent to the forming surface11. An adjacent sector8is sliding along the sliding surface12of a sector8, as will be better described below. The sliding surface12is shaped as a continuation of the forming surface11. The sliding surface12may be seamlessly contiguous with the forming surface11. The sliding surface12may be tangent to the forming surface11. In the example shown, each sliding surface12has a substantially flat shape.

Each sector8also has a contact surface13arranged on the opposite side of the forming surface11with respect to the sliding surface12, i.e., on the part of the forming appendage10facing away from the forming cavity24. The contact surface13of a sector8is intended to slide along the sliding surface12of an adjacent sector8. In the example shown, the contact surface13has a substantially flat shape.

The moulding apparatus further comprises a plurality of pushing devices, not shown, arranged to apply a force on corresponding sectors8so as to push each sector8towards the central zone6of the variable-volume forming region4.

Each pushing device may comprise an actuator, for example hydraulic, or electric, or pneumatic. Alternatively, each pushing device may comprise a mechanical actuator, for example of the cam type.

The pushing devices allow the sectors8to be moved between a first position P1, shown inFIGS.1and2, and a second position P2, shown inFIGS.6and7. In the first position P1, the sectors8define an enlarged configuration C1of the variable-volume forming region4. In the second position P2, the sectors8define a final configuration C2of the variable-volume forming region4.

In the final configuration C2, the variable-volume forming region4has a shape corresponding to the outer shape of the preform neck. In the enlarged configuration C1, the variable-volume forming region4instead has larger dimensions than the dimensions of the preform neck, i.e., larger dimensions with respect to the dimensions which the variable-volume forming region4has in the final configuration C2. To switch from the enlarged configuration C1to the final configuration C2, the volume of the variable-volume forming region4decreases.

It is possible to provide a number of pushing devices equal to the number of sectors8, i.e., a pushing device associated with each sector8, so that each sector8is moved by the corresponding pushing device.

For example, as shown inFIG.4, a first pushing device, not shown, may be configured to apply a first force F1to the first sector8a, directed along a first direction D1. The first force F1is such as to move the first sector8atowards the central zone6of the variable-volume forming region4, in particular by reducing the distance between the sliding surface12of the first sector8aand the Y axis.

As the first sector8amoves towards the moulding axis Y, the contact surface13of the first sector8aslides along the sliding surface12of the second sector8b. The first force F1, as well as the corresponding first direction D1, is in fact directed parallel to the contact surface13of the first sector8aand the sliding surface12of the second sector8b.

Furthermore, a portion of the sliding surface12of the first sector8awhich is in contact with the fourth sector8dpushes on the fourth sector8d(in particular on the contact surface13thereof) by moving the forming appendage10of the fourth sector8dtowards the moulding axis Y, i.e., towards the central zone6of the variable-volume forming region4. This occurs because the sliding surface12of the first sector8aand the contact surface13of the fourth sector8dare arranged transversely, in particular perpendicular, to the first direction D1of the first force F1.

At the same time, the second pushing device acts on the second sector8b, applying a second force F2on the latter, directed along a second direction D2, which is arranged transversely to the first direction D1.

In the example shown, the second direction D2is perpendicular to the first direction D1.

The second sector8bis thus pushed towards the central zone6of the variable-volume forming region4, i.e., towards the Y axis. While this occurs, the contact surface13of the second sector8bslides along the sliding surface12of the third sector8c.

The second sector8bis in contact with the first sector8abecause the contact surface13of the first sector8ais in contact with the sliding surface12of the second sector8b. These two surfaces are arranged transversely, in particular perpendicular, to the second direction D2. Under the action of the second pushing device, the second sector8btherefore transmits the second force F2to the first sector8a.

A resulting force is thus applied on the first sector8a, given by the combination of the first force F1and the second force F2, which pushes the forming surface11(in particular the forming appendage10) of the first sector8atowards the Y axis, along a trajectory which is arranged obliquely with respect to the first direction D1and the second direction D2. For example, the forming surface11of the first sector8amay move towards the Y axis along a direction inclined by 45° with respect to the first direction D1and the second direction D2.

The same situation occurs with reference to the other pairs of sectors8. For example, a third force F3directed along a third direction D3is applied to the third sector8cthanks to the third pushing device. The third direction D3may be the same as and opposite to the first direction D1.

The third force F3pushes the third sector8ctowards the central zone6of the variable-volume forming region4, while the contact surface13of the third sector8cslides along the sliding surface12of the fourth sector8d. At the same time, the third force F3is transmitted on the second sector8b, which is in contact with the third sector8c, because the sliding surface12of the third sector8ctouches the contact surface13of the second sector8b. A resulting force given by the combination of the second force F2and the third force F3is applied to the second sector8b.

The fourth pushing device exerts a fourth force F4on the fourth sector8d, directed along a fourth direction D4which, in the example shown, is the same as and opposite to the second direction D2. The fourth direction D4is thus arranged transversely, in particular perpendicular, to the first direction D1and the third direction D3.

The fourth sector8dthus moves towards the Y axis, sliding along the first sector8aalong a direction parallel to the fourth direction D4. At the same time, the fourth sector8dtransmits the fourth force F4to the third sector8c. A resulting force, given by the combination of the third force F3and the fourth force F4, directed along a direction inclined with respect to the third direction D3and the fourth direction D4, then acts on the latter.

The first force F1from the first sector8ais also transmitted on the fourth sector8d, so that the forming appendage10of the fourth sector8dmoves towards the Y axis under the combined action of the first force F1and the fourth force F4.

In general, a force directed towards the Y axis is applied to each of the sectors8, which pushes the forming appendage10of the corresponding sector8towards the central zone6of the variable-volume forming region4. At the same time, the contact surface13of the considered sector8, which can be parallel to the force applied on that sector, slides along the sliding surface12of an adjacent sector8. The sliding surface12of the sector8considered, which is arranged transversely (for example perpendicular) to the contact surface13of a further adjacent sector8, transmits to the further adjacent sector8the force applied on the sector8considered, so as to push the forming appendage10of the further adjacent sector towards the Y axis. Two forces are therefore exerted on each sector8, one of which is due to the pushing device associated with the sector8considered, while the other is applied by a sector8adjacent to the one considered. The result of these two forces pushes the forming surface11of the sector8considered towards the Y axis, along a trajectory which can be radial with respect to the Y axis. In this manner, the sectors8allow to reduce the volume of the variable-volume forming region4in which the mouldable material has already been positioned.

In the example described above, a pushing device is provided for each sector8. In an alternative version not shown, the number of pushing devices may be different, in particular smaller, than the number of sectors8.

For example, in an embodiment not shown, only two pushing devices may be provided, acting on the first sector8aand the second sector8brespectively, while the third sector8cand the fourth sector8dare arranged in a fixed position.

The sectors8are slidable in contact with the end-forming element14to move from the first position P1to the second position P2.

The second mould part3comprises a male forming component15, shaped like a punch, which extends along the Y axis and is arranged to penetrate the variable-volume forming region4so as to shape the object to be produced from the inside. In other words, the male forming component15allows the mouldable material to be compressed along a direction parallel to the Y axis.

An abutment element16, with respect to which the male forming component may slide, is arranged outside the male forming component15. The abutment element16is arranged to abut against the first mould part2, for the reasons which will be set out below. The abutment element16may be shaped as a tubular element, i.e., having a hole within which the male forming component15is housed.

In an alternative embodiment not shown, the male forming component15is arranged inside the abutment element16, with one or more components interposing between the male forming component15and the abutment element16.

The abutment element16is delimited by a front surface71, which extends transversely, in particular perpendicular, to the Y axis. The front surface71faces the sectors8, more particularly an abutment surface72which delimits the sectors8.

During operation, the mould1is initially in an open position, i.e. the first mould part2and the second mould part3are initially in a spaced position, shown inFIG.1, in which the abutment element16is detached from the first mould part2. In particular, the front surface71of the tubular element16is not in contact with the abutment surface72of the sectors8. The forming cavity24is open at the top and a transport device not shown may be introduced between the first mould part2and the second mould part3to deposit a dosed amount100of mouldable material in the forming cavity24. The male forming component15is in a retracted position with respect to the abutment element16and does not protrude from the abutment element16.

The sectors8are arranged in the first position P1, in which they define the enlarged configuration C1of the variable-volume forming region4. The sectors8therefore delimit a variable-volume forming region4having a relatively large volume, which is able to receive a dosed amount100of mouldable material having a significant dimension, measured transversely to the moulding direction D. In particular, the dosed amount100may have a transverse dimension (for example a diameter, in the case of a spherical dosed amount100) greater than the outer diameter of the preform neck to be formed by the dosed amount100.

In the example shown, the dosed amount100is received between the sectors8and initially rests on an upper zone of the end-forming element14. The dosed amount100is therefore initially spaced from a bottom of the recess70.

Furthermore, the dosed amount100has a transverse dimension (e.g., a diameter, in the case of a spherical dosed amount100), smaller than the corresponding transverse dimension of the variable-volume forming region4, when the latter is in the enlarged configuration C1. Accordingly, when the dosed amount100is deposited in the first mould part2, the dosed amount100is spaced from the sectors, in particular from the lateral surface5of the variable-volume forming region4.

The first mould part2and the second mould part3are brought closer together until the abutment element16abuts against the sectors8, as shown inFIG.3. In the example shown, the driving device not shown acting on the first mould part2displaces the first mould part2towards the second mould part3, bringing the abutment surface72of the sectors8into contact with the abutment element16, in particular with the front surface71of the latter. The front surface71thus acts as a further abutment surface against which the abutment surface72contacts.

When the sectors8and the second mould part3come into mutual contact, i.e., when the respective abutment surfaces71,72of the first mould part2and the second mould part3touch, a closed forming chamber17is defined between the first mould part2and the second mould part3, having a much greater volume than the final volume of the object to be produced, i.e., the preform, as shown inFIG.3. More specifically, the forming chamber17is defined between the end-forming element14, the sectors8, the abutment element16and the male forming component15.

The male forming component15is still in the retracted position, where it does not protrude from the abutment element16.

The sectors8are still in the first position P1, as shown inFIG.4. Consequently, the dosed amount100has not yet undergone significant deformation.

The driving device continues to push the first mould part2towards the male forming component15. In this way, the abutment element16, which is now in contact with the first mould part2, is also retracted, for example by compressing one or more springs not shown.

The male forming component15may be arranged in a fixed position in the moulding direction D. Accordingly, as the abutment element16continues to be displaced backwards (i.e., upwards inFIG.5) from the first mould part2, the male forming component15begins to protrude from the abutment element16and penetrate the forming cavity24. Initially, the male forming component15penetrates the variable-volume forming region4, after which it also enters the recess70, as shown inFIG.5. The mouldable material is thus gradually compressed along the moulding direction D, i.e., parallel to the Y axis.

At the same time the sectors8, which were initially in the first position P1, begin to approach each other, according to the methods described above, as shown inFIG.5. In particular, each sector8, under the action of the force applied thereto by the corresponding pushing device and that applied thereto by an adjacent sector8, moves in motion such that the corresponding forming surface11approaches the Y axis, displacing itself for example along a trajectory, which can be linear, for example inclined by 45° with respect to the directions of the two forces applied on the sector8considered.

The volume of the forming chamber17gradually decreases and the mouldable material, which is not shown inFIGS.5to7, is gradually shaped between the first mould part2and the second mould part3.

The first mould part2continues to be pushed towards the male forming component15, and the sectors8continue to be moved towards the Y axis, until the condition shown inFIGS.6and7is reached. In this condition, the sectors8have reached the second position P2, and the male forming component15is at a distance, from a bottom region of the recess70, which is substantially equal to the thickness of the end wall of the preform.

The preform is thus obtained from the dosed amount100. The latter remains in the mould1, and is cooled thanks to cooling means not shown, for a sufficient time to reach a degree of hardening which allows it to be handled without damage. Subsequently, with a sequence of steps opposite to that described above, the mould1is opened, the preform is extracted and a new forming cycle may be started.

As is clear from the comparison betweenFIGS.4and7, not only the volume, but also the shape of the variable-volume forming region4changes from the enlarged configuration C1to the final configuration C2.

More specifically, in the example shown, in the enlarged configuration C1the lateral surface5of the variable-volume forming region4is defined by a plurality of curved portions, corresponding to the forming surfaces11, between which respective flat portions, corresponding to the sliding surfaces12, are interposed.

In the final configuration C2, each forming surface11is contiguous with the forming surface11of an adjacent sector8, and the sliding surfaces12are no longer facing the forming region4, as each sliding surface12is covered, or hidden, by the forming appendage10of an adjacent sector.

The mould1allows to obtain objects of good quality, having a curved lateral wall, for example circular.

FIGS.8to15show a mould301according to an alternative version, which allows to obtain objects having a non-circular shape in plan view, for example a polygonal shape. In the example shown, in particular, the mould301allows to produce a spoon, shaped like a scoop, in particular for ice cream, yoghurt or other creamy products. However, a mould similar to the mould301may also be used to produce objects other than spoons.

The parts of the mould301similar to the parts of the mould1described above will be indicated with the same reference numerals already used forFIGS.1to7and will not be further described in detail.

The mould301is also particularly suitable for producing objects in synthetic polymeric material from a dosed amount100of synthetic polymeric material. The dosed amount100was separated from a continuous extrudate outflowing from an extrusion device and subsequently transported towards the mould301via a transport device not shown.

In the example shown, the dosed amount100has a substantially spherical shape, but other shapes are possible for the dosed amount100.

The dosed amount100has a relatively large dimension with respect to the dimensions of the object to be obtained. In the example shown, the dosed amount100has a diameter greater than a transverse dimension W of the object to be formed, shown inFIG.15.

The mould301also comprises a first mould part302and a second mould part303, movable with respect to one another along a moulding direction D, which in the example shown is vertical. The first mould part302and the second mould part303are similar to the first mould part2and the second mould part3described above.

In particular, in the example shown, the first mould part302is a female mould part and is arranged below the second mould part303.

The first mould part302comprises a plurality of sectors308, adapted to define the lateral surface5which delimits the variable-volume forming region4.

In the example shown, the sectors308have different shapes from each other.

In particular, in the example shown there are four sectors308, but the number of sectors308may be different from four.

In the example shown, a first sector308a, a second sector308b, a third sector308cand a fourth sector308dmay be identified, as shown inFIG.11.

Each sector308is delimited by a forming surface311facing the variable-volume forming region4.

In the example shown, the first sector308aand the third sector308chave respective, substantially flat forming surfaces311. The second sector308band the fourth sector308d, on the other hand, have forming surfaces311which are not flat, but have, for example, a step56, to define an enlarged portion of the spoon to be formed. The enlarged portion is a withdrawal portion for withdrawing a substance, for example food, from a container.

Each sector308also has a sliding surface312, arranged adjacent to the forming surface311of that sector. The sliding surface312may be a continuation of the forming surface311. The sliding surface312faces the variable-volume forming region4.

Each sector also has a contact surface313, adapted to slide along the sliding surface312of an adjacent sector.

The sliding surface312and the contact surface313may both be flat. The contact surface313of a sector308is arranged transversely, in particular perpendicular, to the sliding surface312of the same sector308. The forming surface311is interposed between the contact surface313and the sliding surface312of a sector308. In this manner, an end zone of the forming surface311is adjacent to the sliding surface312, while a further end zone of the forming surface311, opposite the above-mentioned end zone, is adjacent to the contact surface313.

A plurality of pushing devices not shown is further provided for applying respective forces to the sectors308directed towards a central zone6of the variable-volume forming region4.

In particular, the pushing devices are configured to apply on the first sector308a, on the second sector308b, on the third sector308cand on the fourth sector308drespectively a first force F1, a second force F2, a third force F3and a fourth force F4, as already described above with reference toFIGS.1to7.

Each sector308is displaceable towards the central zone6of the variable-volume forming region4due to the resulting force of two distinct forces. One of these forces is applied to the sector308by the corresponding pushing device, while the other force, which is directed transversely (in particular perpendicular) to the previous one, is transmitted to the sector308by the adjacent sector.

Under the action of the force applied by the respective pushing device to each sector308, the latter moves towards the central zone6so that the contact surface313of the sector308considered slides along the sliding surface312of an adjacent sector. At the same time, the adjacent sector308transmits to the sector308considered a force as a result of which the sliding surface312of the sector308considered flows along the contact surface313of a further sector308adjacent to the sector308considered.

The first mould part302further comprises an end-forming element314, in contact with which the sectors308may slide. The end-forming element314delimits the variable-volume forming region4transversely to the moulding direction D, from the side opposite the second mould part303.

The end-forming element314defines, together with the sectors308, the forming cavity24, which in the example shown is open upwards.

In the example shown, the end-forming element314is of the slab type.

Unlike what occurred in the mould1shown inFIGS.1to7, the end-forming element314is not provided with any recess in which the mouldable material can be shaped.

Thus, in the mould301ofFIGS.8to15, the forming cavity24has a lateral surface, which extends around the Y axis and is defined by the sectors308. The forming cavity24further has a transverse surface defined by the end-forming element314. The transverse surface of the forming cavity24may be flat.

The second mould part303comprises a forming component315adapted to penetrate the forming cavity24to shape the desired object by applying a compression action to the mouldable material in a direction parallel to the Y axis, i.e., along the moulding direction D.

The forming component315is arranged inside an abutment element316which, in the example shown, is provided with a central hole in which the forming component315is housed. The abutment element316is adapted to abut against the sectors308to close a forming chamber17defined between the first mould part302and the second mould part303.

The forming component315is slidably movable, along the moulding direction D, with respect to the abutment element316.

During operation, the mould301is initially in an open position, i.e., the first mould part302and the second mould part303are initially in a spaced position, as shown inFIG.8. The front surface71of the abutment element316is spaced from the abutment surface72of the sectors308. A transport device not shown may therefore deposit a dosed amount100of mouldable material in the forming cavity24.

The sectors308are in the first position P1, as shown inFIG.9. A variable-volume forming region4is therefore defined between the sectors308, having dimensions larger than the size of the dosed amount100, so that the dosed amount100may be received in the variable-volume forming region4without interfering with the sectors308.

A driving device moves the first mould part302and the second mould part303towards each other in the moulding direction D, so that the first mould part302and the second mould part303come into contact to define the closed forming chamber17therebetween. In particular, the first mould part302and the second mould part303come into contact with each other when the abutment surface72touches the front surface71, which can be considered as a further abutment surface.

In the example shown, the driving device is associated with the first mould part302and pushes the latter towards the second mould part303. When the abutment surface72of the sectors308is in contact with the front surface71of the abutment element316, a closed forming chamber17is defined between the end-forming element314, the sectors308, the abutment element316and the forming component315. The latter is still in a retracted position in which it does not protrude from the abutment element316towards the end-forming element314, as shown inFIG.10.

The sectors308are still in the first position P1and have not yet begun to significantly interact with the dosed amount100, as shown inFIG.11.

The pushing devices not shown now act on the sectors308to bring the sectors308into the second position P2, as shown inFIGS.12and13. This causes a progressive decrease in the volume of the variable-volume forming region4and thus of the closed forming chamber17.

While the sectors308are brought to the second position P2, the driving device continues to move the first mould part302towards the second mould part303. The sectors308, pushed towards the second mould part303by the driving device, cause the abutment element316to retract with respect to the forming component315. The forming component315thus begins to protrude from the abutment element316and can penetrate the forming cavity24to push the mouldable material towards the end-forming element314, in the moulding direction D. The mouldable material is progressively forced to fill the entire closed forming chamber17to originate the desired object. It is noted that the forming component315may penetrate the forming cavity24by sliding in contact with the sectors308to form a flat object, i.e., without the mouldable material interposing between the forming component315and the sectors308.

The driving device continues to push the first mould part302towards the second mould part303, while the forming component315increasingly protrudes from the abutment element316. In this manner, the forming component315continues to approach the end-forming element314until it reaches a distance, from the end-forming element314, equal to the thickness of the object to be obtained, as shown inFIG.14. The mould301remains in this condition for a sufficient time for the object to become sufficiently rigid in order to be handled without damage, after which the first mould part302and the second mould part303move away from each other and the object is removed to allow a new dosed amount100to be introduced into the variable-volume forming region4.

This allows to obtain, by compression moulding, also objects having a relatively small dimension transversely to the moulding direction D, which however require relatively large dosed amounts, i.e., having an initial transverse dimension greater than the corresponding dimension of the finished object.

FIGS.16to23show a mould101according to an alternative version, which allows to obtain perforated objects, in particular objects having a through hole.

The mould101comprises a first mould part102and a second mould part103, facing each other and movable with respect to one another in a moulding direction D, similarly to what is described for the first mould part2and the second mould part3shown inFIGS.1to7.

The first mould part102comprises a plurality of sectors108, adapted to define the lateral wall5of the variable-volume forming region4. In the example shown, there are four sectors108, having the same shape as each other.

The sectors108are functionally similar to the sectors8described with reference toFIGS.1to7, although the shape thereof is different from that of the sectors8, as it is specific to the particular object to be produced.

In particular, each sector108comprises a forming surface111, which in the example shown has the shape of a cylinder portion. The forming surfaces111are intended to cooperate with each other to shape a lateral wall of the object from the outside. Each sector108further has a sliding surface112, which may be flat. The sliding surface112of a sector108is adjacent to the forming surface111.

When the sectors108are in the first position P1, to define an enlarged configuration C1of the forming cavity24, the forming surface111and the sliding surface112of each sector108delimit the lateral surface5of the variable-volume forming region4.

Each sector108also has a contact surface113, which is intended to slide along the sliding surface112of an adjacent sector108, when the sectors108move to reduce the volume of the variable-volume forming region4, as already described with reference toFIGS.1to7.

The contact surface113, which may be flat, does not face the variable-volume forming region4, as it faces the sliding surface112of an adjacent sector108.

The sectors108are movable between the first position P1, shown inFIGS.17and19, and the second position P2, shown inFIGS.21and23, by means of pushing devices not shown, as previously described with reference toFIGS.1to7.

The first mould part102further comprises an end-forming element114, which delimits the variable-volume forming region4transversely to the moulding direction D, from the side opposite to the second mould part103. The sectors108are arranged in contact with the end-forming element114and are slidable relative to the latter.

A core73projects from the end-forming element114, protruding towards the second mould part103. The core73is intended to shape the interior of the hole of the object to be produced. In the example shown, the core73has a cylindrical shape.

The core73may have a dimension, along the moulding direction D, greater than the corresponding dimension of the sectors108. In this case, the core73protrudes towards the second mould part103with respect to the sectors108.

A forming cavity24having an annular shape is defined between the core73and the sectors108. The forming cavity24is open at the top.

The second mould part103comprises an abutment element116, adapted to abut against the sectors108to close the forming chamber24. A forming component115is housed inside the abutment element116, adapted to form an edge zone of the object, opposite to that which will be formed in contact with the end-forming element114.

The forming component115has a guide hole74, arranged to receive a portion of the core73associated with the end-forming element114. The guide hole74may in particular engage in a shaped coupling with the core73.

A through hole75may be provided in the forming component115. The through hole75may extend between the guide hole74and a surface of the forming component115farther from the forming cavity24. The through hole may for example serve as a vent hole for the outflow of air present between the core73and the forming component115.

The forming component115is slidable with respect to the abutment element116parallel to the moulding direction D.

During operation, the mould101is initially open. The first mould part102and the second mould part103are located in a spaced position, shown inFIG.16. In this position, a transport device not shown may be inserted between the first mould part102and the second mould part103, which transports a dosed amount100separated from the continuous extrudate exiting the extrusion device and depositing it in the forming cavity24.

The sectors108are in the first position P1, as shown inFIG.17. The volume of the variable-volume forming region4is therefore maximum, so that the variable-volume forming region4can easily accommodate the dosed amount100.

In particular, the distance between the core73and the lateral surface5of the variable-volume forming region4is, at least at some points, greater than the transverse dimension of the dosed amount100. In the example shown, the variable-volume forming region4has, in plan, approximately the shape of a quadrilateral (in particular a square) with rounded vertices. Each side of the quadrilateral is defined by the sliding surface112and the forming surface111of a sector108. The rounded vertices of the quadrilateral correspond to the forming surfaces111which are arranged near the vertices of the quadrilateral.

The distance between the vertex zones of the quadrilateral and the core73is greater than the transverse dimension of the dosed amount100. As shown inFIG.17, a dosed amount100of mouldable material may then be positioned in a non-centred position in the variable-volume forming region4, close to an edge zone of the variable-volume forming region4.

In the example shown, the distance between the lateral surface5of the variable-volume forming region4and the core73is in fact greater than a transverse dimension of the dosed amount100, in particular of the diameter of the latter, at least along a diagonal of the quadrilateral defined, in plan, by the lateral surface5.

After the dosed amount100has been received in the variable-volume forming region4, the first mould part102and the second mould part103are moved towards each other until they come into contact with each other. In particular, in the example shown, a driving device moves the first mould part102towards the second mould part103in the moulding direction D, as shown inFIG.16. The sectors108are thus brought into contact with the abutment element116, as shown inFIG.18. The forming component115is housed inside the abutment element116and, in the example shown, does not yet protrude, in this step, from the abutment element116towards the first mould part102.

The core73has already partially penetrated the guide hole74, engaging in a shaped coupling with the latter. This allows the first mould part102to be kept more effectively guided than the second mould part103.

The sectors108are still in the first position P1, as shown inFIG.19.

When the first mould part102and the second mould part103come into contact with each other, a closed forming chamber17is defined between the first mould part102and the second mould part103, shown inFIG.18. The forming chamber17is defined, at an end thereof (which in the example shown is a lower end) by the end-forming element114. The forming chamber17is further defined, at the opposite end thereof, by the abutment element116and the forming component115. Finally, the forming chamber17is defined laterally, by the sectors108(outside) and the core73(inside). Subsequently, the sectors108are moved transversely to the moulding direction D, for example according to the methods previously described with reference toFIGS.1to7, and approach the core73. The dosed amount100thus begins to be deformed between the sectors108and the core73to fill the forming chamber17.

As the sectors108approach the core73, the volume of the variable-volume forming region4decreases, as does the volume of the closed forming chamber17.

Furthermore, the first mould part102and the second mould part103continue to be moved towards each other. More in detail, the driving device continues to move the first mould part102towards the second mould part103. The abutment element116, which is abutted against the sectors108, is thus moved in the moulding direction D along with the first mould part102(upwards in the example shown). The forming component115instead remains in a fixed position along the moulding direction D. Thus, the core73penetrates deeper into the guide hole74of the forming component115. The latter begins to enter the forming cavity24, i.e., to be interposed between the sectors108and the core73, to shape an end zone of the object opposite the further end zone which is shaped by the portion of the end-forming element114from which the core73protrudes.

This step is shown inFIGS.20and21.

In one version, the sectors108are first brought to the second position P2, after which the forming component115begins to protrude from the abutment element116to be interposed between the sectors108and the core73. However, this condition is not mandatory, and the forming component115could begin to be interposed between the sectors108and the core73even before the sectors108have reached the second position P2.

The driving device continues to move the first mould part102, which pushes the abutment element116, towards the forming component115. The latter thus penetrates further into the variable-volume forming region4, until it reaches a final forming position in which the forming chamber17has a shape corresponding to the object to be produced, shown inFIG.22. During this step, the volume of the forming chamber17, which was previously closed, is further reduced. In particular, while the volume of the forming chamber17is reduced, the forming component115compresses the mouldable material in the moulding direction D, while the sectors108compress the mouldable material transversely to the moulding direction D.

The mould101remains in the position shown inFIGS.22and23for sufficient time to consolidate the object. Subsequently, the mould101is returned to the open position and the formed object is extracted from the mould101to allow a new object to be formed.

A tubular object, provided with a through hole originating from the core73, was thus obtained.

This was made not from a dosed amount of mouldable material having an annular shape, which is rather complicated to produce and manipulate, but from a dosed amount of mouldable material having a full shape, in particular spherical or cylindrical, which may be produced and transported relatively easily.

In an alternative version not shown, the mould101may be used to produce not only perforated objects, but also hollow objects having a non-through indentation, such as container preforms or heads for crushable tube containers, having a closed end. In this case, the first mould part102comprises the core73which, however, in the final forming position, is not in contact with the second mould part103, so as to form a closed end of the object.

FIGS.24to26show a mould201according to an alternative version. The mould201comprises a first mould part202and a second mould part203, which can be moved towards each other or alternatively moved away from each other along a moulding direction D. This may occur thanks to a driving device not shown, similar to that described above with reference to the versions already described. In the example shown, the driving device is connected to the second mould part203, which is thus movable along the moulding direction D, while the first mould part202remains fixed in that direction.

The first mould part202is a female mould part, while the second mould part203is a male mould part. Unlike what occurred in the versions described with reference toFIGS.1to23, the first mould part202is positioned above the second mould part203.

The mould201is adapted to form a concave object, for example a container such as a capsule for coffee or for other substances, starting from a dosed amount100of mouldable material, which in the example shown is spherical in shape. However, other forms are possible for the dosed amount100.

The dose100may be cut from a continuous extrudate outflowing from an extrusion device not shown and transported to the mould201by a transport device not shown.

The first mould part202comprises a plurality of sectors208, adapted to define the lateral surface5of the variable-volume forming region4. The sectors208may have a shape similar to the sectors8shown inFIGS.1to17. The sectors208may be movable between a first position P1, shown inFIG.24, and a second position P2, shown inFIG.26, by respective pushing devices, similarly to what is described with reference to the preceding Figures.

The first mould part202further comprises an end-forming element214, which delimits the variable-volume forming region4transversely to the moulding direction D, from the side opposite to the second mould part203. The forming cavity24is defined between the sectors208and the end-forming element214, which in the example shown faces downwards.

The second mould part203comprises a male forming component215, delimited at the upper end thereof by a support surface76on which a dosed amount100of mouldable material may be rested.

The second mould part203further comprises an abutment element216, surrounding the male forming component215. The abutment element216may have a tubular shape. The abutment element216is adapted to abut against the sectors208to close a forming chamber17defined between the first mould part202and the second mould part203. In particular, the abutment element216is delimited, transversely to the moulding direction D, by the front surface71, adapted to abut against the abutment surface72of the sectors208.

The front surface71and the abutment surface72extend transversely, in particular perpendicular, to the moulding direction D. In the shown example, the front surface71and the abutment surface72are substantially flat.

During operation, the mould201is initially in an open position, i.e. the first mould part202and the second mould part203are initially in the spaced position shown inFIG.24, in which between the first mould part202and the second mould part203it is possible to introduce a transport device transporting a dosed amount100of mouldable material. The sectors208are located in the first position P1, where the volume of the variable-volume forming region4is maximum.

The transport device deposits a dosed amount100into the mould201, in particular by positioning the dosed amount100on the support surface76of the male forming component215. The latter protrudes from the abutment element216towards the first mould part202.

Subsequently, the driving device begins to move the second mould part203towards the first mould part202. The male forming component215approaches the forming cavity24and, at a certain point, begins to penetrate into the latter, to compress the mouldable material in the moulding direction D. The abutment element216then abuts against the sectors208. When this occurs, a forming chamber17is defined between the first mould part202and the second mould part203which is closed, as shown inFIG.25. The forming chamber17is in particular delimited by the end-forming element214, the sectors208, the male forming element215and the abutment element216. The sectors208are still in the first position P1.

After the forming chamber17has been closed, the abutment element216remains in a fixed position along the moulding direction D, as it abuts against the sectors208, which in turn are in contact with the end-forming element214.

The sectors208are moved transversely to the moulding direction D, so as to approach the male forming component215and reach the second position P2, shown inFIG.26. In this manner the volume of the variable-volume forming region4is progressively reduced.

The driving device further moves the male forming element215towards the end-forming element214, until the male forming element215reaches a distance, from the end-forming element214, equal to the thickness of a transverse wall of the object to be produced. At this point, the mould201is in a final forming position. The first mould part202and the second mould part203remain in this position for a sufficient time for the formed object to be adequately cooled, after which the mould201opens and the object may be removed.

FIGS.27to30show a mould401completely analogous to the mould1shown inFIGS.1to7, used to produce an object, particularly a preform, by compression moulding, starting from a dosed amount400of mouldable material having a geometry different from the geometries of the dosed amounts100shown so far.

More specifically, the dosed amount400has a flat geometry, with a plan shape that may be square, rectangular, cylindrical, or polygonal. The height of the dosed amount400, i.e., its dimension along the moulding direction D, may be smaller than the dimensions of the dosed amount400transversely to the moulding direction D.

The dose400may be formed from a single material or, as in the shown example, have a multilayer structure.

In particular, the dosed amount400may comprise an intermediate layer77interposed between two outer layers78. The intermediate layer77may comprise a material having barrier properties, for example to oxygen, and/or gases, and/or light, and/or flavourings. Alternatively, the intermediate layer77may be at least in part made of a recycled polymeric material.

The outer layers78may be formed by a material having the purpose of conferring the desired mechanical and aesthetic properties to the object. Between the outer layers78and the intermediate layer77, one or more layers of compatibilizing material may be interposed, adapted to improve the adhesion between the intermediate layer77and the outer layers78.

The mould401is initially in an open position, as shown inFIG.27, in which the first mould part2is spaced from the second mould part3. The sectors8are in the first position P1, corresponding to the enlarged configuration C1of the variable-volume forming region4. The dosed amount400is now inserted into the mould401, in particular by delivering it to the first mould part2so that the dosed amount400is supported on a support surface79of the end-forming element14, in a position spaced from the bottom of the recess70. More specifically, the support surface79has an annular shape and an edge area of the dosed amount400can be supported thereon. The support surface79is surrounded by the sectors8. In the shown example, the support surface79has an area which decreases when the sectors8pass from the first position P1to the second position P2. In the second position P2, the support surface79is intended to form an inner surface of a ring which projects radially from the neck of the preform.

The dosed amount400is thus surrounded by the sectors8which, being still arranged in the first position P1, delimit a relatively wide variable-volume forming region4, in which the dosed amount400may be placed without the latter touching the sectors8. More specifically, despite having greater transverse dimensions than the transverse dimension of the recess70, the dosed amount400is introduced into the mould without being substantially deformed, since the sectors8, in the first position P1, delimit a variable-volume forming region4whose transverse dimensions are greater than those of the dosed amount400.

The dosed amount400is introduced into the first mould part2, for example by supporting it on the shoulder79, with an orientation in which the intermediate layer77is arranged transversely, in particular perpendicular, to the moulding direction D.

The first mould part2and the second mould part3are now moved towards each other to define, between the first mould part2and the second mould part3, a closed forming chamber17, shown inFIG.28. The closed forming chamber17is defined when the sectors8abut against the abutment element16. In particular, the abutment surface72of the sectors8abuts against the further abutment surface or front surface71of the abutment element16.

At this point, as shown inFIG.29, the sectors8are moved to the second position P2, by applying to the sectors8respective forces Fi directed transversely, in particular perpendicular, to the moulding direction D. The forces Fi can be applied as described with reference toFIGS.1to7. It is also possible to use sectors8having a different geometry from those shown inFIGS.1to7, and which pass from the first position P1to the second position P2along different trajectories.

In any case, the forces Fi move the sectors8along respective directions arranged transversely to the moulding direction D. In the shown example, the sectors8are moved perpendicular to the moulding direction D with respect to the end-forming element14.

In the second position P2, the sectors8delimit the lateral surface5of the variable-volume forming region4, the lateral surface5having the shape of a portion of the outer surface of the object to be obtained, specifically of the neck of the preform.

As the sectors8pass from the first position P1to the second position P2, the first mould part2and the second mould part3continue to move towards each other. In particular, the first mould part2moves in the moulding direction D towards the male forming component15. The abutment element16, which is in contact with the sectors8, is also moved in the moulding direction D with respect to the male forming component15. The male forming component15thus penetrates between the sectors8and subsequently into the recess70, internally shaping the object.

FIG.29shows a situation in which the dosed amount400, deformed by the male forming component, has reached the bottom of the recess70and is gradually originating the preform. During the deformation of the dosed amount400, the intermediate layer77is also deformed and distributed substantially throughout the body of the moulded object. In this way, the properties conferred by the intermediate layer77are substantially uniform throughout the object.

The male forming component15continues to penetrate the recess70, as a result of the upwards movement (i.e., towards the male forming component50) of the first mould part2and the abutment element16, until the preform has reached its definitive shape, as shown inFIG.30. When this occurs, a maximum compressive force is applied to the first mould part2to keep the mould401in a forming position and obtain the desired object.

After the preform has cooled sufficiently within the mould401, the mould is returned to the open position and the preform is extracted from the mould to be further processed.

In the examples described so far, the sectors were moved transversely to the moulding direction D, to be brought into the second position P2, only after the closed forming chamber17had been defined, i.e., after the first mould part and the second mould part had come into mutual contact.

However, this condition is not necessary and it is possible to start moving the sectors to reduce the volume of the variable-volume forming region4even when the first mould part and the second mould part are still spaced apart from each other.

An example of the above is depicted inFIGS.31to34, showing a mould501according to an alternative version, where the sectors reach the second position P2before closing the mould.

In the shown example, the mould501is configured to produce capsules for coffee or for other substances intended for the preparation of beverages or foods by passing an extraction fluid through the capsule. It is understood that a mould similar to that ofFIGS.31to34could however be used to produce other objects, especially concave objects such as caps, containers, preforms for containers and the like.

The mould501also comprises a first mould part502and a second mould part503, movable with respect to one another along a moulding direction D, which in the example shown is vertical.

In the shown example, the first mould part502is arranged below the second mould part503, but this condition is not necessary.

The first mould part502is a female mould part, while the second mould part503is a male mould part.

The first mould part502may comprise an end-forming element514in which a recess570is formed. The recess570is arranged to form from the outside a bottom wall, for example substantially flat, and a lateral wall, for example truncoconical, of the capsule.

The first mould part502further comprises a plurality of sectors508, for example analogous to the sectors8described above. In more detail, the sectors508are slidable in contact with an upper surface of the end-forming element514, transversely (in particular perpendicular) to the moulding direction D.

The end-forming element514is delimited, in its own upper portion, by a support surface579adapted to supportingly receive a dosed amount500of mouldable material. The support surface579may be flat and may be arranged transversely, in particular perpendicular, to the moulding direction D.

The support surface579surrounds the recess570and is interposed between the sectors508. The support surface579has an annular shape.

The sectors508are movable between the first position P1and the second position P2, for example in manners similar to those described for the previous versions, thanks to pushing means not shown.

When the sectors508move from the first position P1to the second position P2, the volume of the variable-volume forming region4, defined between the sectors508, decreases. At the same time, the area of the support surface579is reduced. In the second position P2, the support surface579is configured to form a lower surface of a capsule flange. The flange projects outwards from an upper region of a capsule body.

The sectors508are configured to form a lateral surface of the flange, i.e., a flange surface which extends about an axis of the capsule and may be parallel to such an axis.

The second mould part503comprises a male forming component515adapted to penetrate the recess570to shape the bottom wall and the lateral wall of the capsule from the inside. The male forming component515allows the mouldable material to be compressed in a direction parallel to the moulding direction D.

The second mould part503further comprises an abutment element516adapted to come into contact with the first mould part502, specifically with the sectors508, to close the mould501, i.e., to define within the mould501a closed forming chamber17.

More specifically, each sector508is delimited by an abutment surface572arranged in a position facing the abutment element516.

The abutment surface572is adapted to abut against a further abutment surface571(or front surface), which delimits the abutment element516in a position facing the first mould part502.

The abutment surface572and the further abutment surface571extend transversely, in particular perpendicular, to the moulding direction D.

The abutment element516surrounds the male forming component515. In a version not shown, additional components may be present between the abutment element516and the male forming component515.

The abutment element516comprises a blocking portion580which protrudes from the further abutment surface571towards the first mould part502. The blocking portion580has an annular geometry and may be for example shaped like a circular crown.

The blocking portion580may be delimited by a blocking surface581, for example flat, which extends transversely, in particular perpendicular, to the moulding direction D.

The blocking portion580is adapted to contact the dosed amount500to push it against the end-forming element514, in particular against the support surface579. In more detail, the blocking portion580is intended to block an edge zone of the dosed amount500against the end-forming element514, so that the dosed amount500remains in a centred position with respect to the recess570even when the male forming component515deforms the dosed amount500.

During operation, the mould501is initially in an open position, shown inFIG.31. The first mould part502is spaced from the second mould part503, so that the dosed amount500of polymeric material can be inserted into the mould501. The dosed amount500may for example be released into the mould501by a transport element not shown, temporarily interposed between the first mould part502and the second mould part503.

In the shown example, the dosed amount500has a multilayer structure and comprises an intermediate layer interposed between at least two outer layers of polymeric material, as already described with reference to the dosed amount400shown inFIGS.27and28.

The dosed amount500is supported on the support surface579, so that only the edge zone thereof is in contact with the first mould part502, while a central area of the dosed amount500is initially spaced from the bottom of the recess570and does not touch the first mould part502.

When the dosed amount is placed on the support area579, the intermediate layer is arranged transversely, in particular perpendicular, to the moulding direction D.

In a version not shown, the mould501may also be used in combination with doses having a monolayer structure, i.e., formed from a single synthetic polymeric material.

The sectors508are arranged in the first position P1corresponding to the enlarged configuration C1of the variable-volume forming region4. In the first position P1, the variable-volume forming region4has greater transverse dimensions (i.e., measured transversely to the moulding direction D) than the transverse dimensions of the dosed amount500. Consequently, the dosed amount500is not prematurely deformed by the sectors508when it is introduced into the mould501by supporting it on the support surface579.

Subsequently, the pushing means apply on the sectors508respective forces Fi to bring the sectors508closer to a central zone of the variable-volume forming region4, until the sectors508reach the second position P2, as shown inFIG.32. The forces Fi can be applied in the manners shown inFIGS.1to7, or in other manners, for example by exerting on each sector508a single force directed towards the central zone of the variable-volume forming region4.

The sectors508thus begin to deform the edge zone of the dosed amount500.

When the sectors508reach the second position P2, the first mould part502is still spaced from the second mould part503. To be precise, the first mould part502and the second mould part503have not yet begun to move towards each other.

Subsequently, the first mould part502and the second mould part503begin to move closer towards each other. In the shown example, this occurs by moving the first mould part502along the moulding direction D and holding the second mould part503in a fixed position along the moulding direction D.

This leads to a situation, shown inFIG.33, in which the abutment surface572of the sectors508is in contact with the further abutment surface571of the abutment element516.

At this point, a closed forming chamber17is defined between the first mould part502and the second mould part503.

The blocking portion580has been inserted between the sectors508so that the blocking surface579acts on the edge zone of the dosed amount500, crushing such an edge zone and pressing it against the end-forming element514.

In practice, the blocking portion580exerts a sort of “stapling” action on the edge zone of the dosed amount500, which thus remains firmly blocked between the blocking portion580and the end-forming element514even when the dosed amount500is deformed by the male forming component515.

The first mould part502, together with the abutment element516against which the first mould part502abuts, continues to move with respect to the male forming component515, in particular by approaching such a component. Since the male forming component515is arranged in a fixed position along the moulding direction D, the male forming component515penetrates the recess570, deforming the dosed amount also in the central zone of the latter, until reaching the end-of-forming position shown inFIG.34. In this position, the capsule has been fully formed and, after having been sufficiently cooled, it can be extracted from the mould501.

By clamping the edge zone of the dosed amount500between the blocking portion580and the first mould part502, it is possible to maintain the dosed amount500in a centred position with respect to the recess570even when a central zone of the dosed amount500is deformed by the male forming component515. Furthermore, if the dosed amount500has a multilayer structure, it is possible to prevent the intermediate layer of the dosed amount, flowing outwards of the dosed amount in the edge zone, from emerging on an outer surface of the formed object and being visible on such an object.

It is noted that the blocking portion580which blocks the edge zone of the dosed amount500against the first mould part503can also be used in moulds in which the sectors508are absent, i.e., in moulds in which in the first mould part503a forming cavity is made having fixed dimensions transversely to the moulding direction D.

It is noted that, not only in the mould version described with reference toFIGS.31to35, but also in moulds of the type shown inFIGS.1to30, it is possible to start moving the sectors transversely to the moulding direction D to bring the sectors into the second position P2even before the forming chamber has been closed, i.e., even before the closed forming chamber17has been defined between the first mould part and the second mould part. If the sectors are moved before closing the forming chamber, the second position P2can be reached before or after the closed forming chamber17has been defined.

In all the mould versions referred to, the sectors may be moved between the first position and the second position due to the interaction between the mould part in which they are included and the other mould part. For example, each sector could be provided with a roller or a set of levers which interact with the mould part opposite to that in which the sector is included in order to displace the sector from the first position to the second position. The sectors associated with a mould part could therefore be moved between the first position and the second position on the other mould part. In one version, the sectors could be moved from the first position to the second position also in a non-axially symmetrical way, for example following trajectories not oriented at 45° with respect to the directions of the forces applied, or having different lengths from each other.

The sectors could further be moved between the first position and the second position also with different movement methods than those described thus far, for example due to the effect of simple actuators which move the corresponding sector in the direction of the applied force.

In the above description, reference has always been made to sectors included in the female mould part. In an alternative version not shown, the sectors delimiting the variable-volume forming region could be included in the male mould part.

In the foregoing description, reference was always made to a dosed amount of mouldable material, in particular synthetic polymeric material, obtained by cutting a continuous extrudate outflowing from an extrusion device. However, it is also possible to use a dosed amount of synthetic polymeric material obtained in other ways, for example by cutting a sheet or film of synthetic polymeric material.

Alternatively, the mouldable material forming the dosed amount may be a material at least a part of which is derived from natural fibres, for example cellulose, in the form of powder, granules, or supplemented with particular liquid substances, for example to obtain a sort of paste, or in the form of wadding, or preform, or other element cut from a film.

In this case, the starting material has a relatively low density and needs to be pressed with a high degree of compaction to provide a finished object of good quality. This means that the initial volume of the material at least a part of which is derived from natural fibres is much greater than the volume of the finished object. Accordingly, it is useful to have a mould comprising the sectors described above, movable between a first position in which the variable-volume forming region is relatively large, and therefore can house a low-density material which occupies a lot of space, and a second position in which the material has been compacted and has reached the shape and size of the finished object.

In conclusion,

The dosed amount can be pre-packaged, i.e., prepared separately from the mould (for example by cutting, pressing or other) and inserted into the open mould.

The method and apparatus described herein make it possible to obtain an object of good quality starting from a dosed amount having a dimension, in particular measured transversely to the moulding direction D, greater than a corresponding transverse dimension of the moulded object.

In summary, in a first version of a first aspect of the invention, a method for forming an object is provided, comprising the steps of:providing a mould (1;101;201;301;401;501) comprising a first mould part (2;102;202;302;502) and a second mould part (3;103;203;303;503) opposite to each other, a part selected from between the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) comprising a plurality of sectors (8;108;208;308;508) for shaping at least a lateral portion of the object, the sectors (8;108;208;308;508) of said plurality delimiting a variable-volume forming region (4) of the mould;positioning a dosed amount (100;400;500) of mouldable material between the first mould part (2;102;202;302;502) and the 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 moulding direction (D), to define between the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) a closed forming chamber (17),
the method further comprising the step of moving the sectors (8;108;208;308;508) transversely to the moulding direction (D) to reduce the volume of the variable-volume forming region (4).

The dosed amount (100;400;500) of mouldable material may be positioned between the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) while the mould is in an open position.

The closed forming chamber (17) can be defined by bringing into contact respective abutment surfaces (71,72;571,572) of the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503), the abutment surfaces (71,72;571,572) extending transversely to the moulding direction (D).

In a second version, a method according to the first version is provided, wherein the sectors (8;108;208;308;508) are movable transversely to the moulding direction (D) between an enlarged configuration (C1) and a final configuration (C2), the dosed amount (100;400;500) being released between the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) while the dosed amount (100;400;500) has transverse dimensions, measured perpendicular to the moulding direction (D), which are smaller than the transverse dimensions of the variable-volume forming region (4) in the enlarged configuration (C1).

In a third version, a method according to the first or second version is provided, wherein the step of moving the sectors (8;108;208;308;508) transversely to the moulding direction (D) starts before the closed forming chamber (7) has been defined.

In a fourth version, a method is provided according to one of the versions from the first to the third, wherein the step of moving the sectors (8;108;208;308;508) transversely to the moulding direction (D) starts after the closed forming chamber (7) has been defined.

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

In a sixth version, a method is provided according to one of the versions from the first to the fifth, wherein the step of displacing the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) towards each other in the moulding direction (D) occurs by means of a driving device which moves at least one mould part selected from between the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) towards the other mould part selected from between the second mould part (3;103;203;303;503) and the first mould part (2;102;202;302;502), the sectors (8;108;208;308;508) being included in the mould part moved by the driving device.

In a seventh version, a method is provided according to one of the versions from the first to the sixth, wherein the closed forming chamber (17) is defined by bringing into mutual contact the sectors (8;108;208;308;508) and an abutment element (16;116;216;316;516) of the mould part opposite to the sectors and selected from between the second mould part (3;103;203;303;503) and the first mould part (2;102;202;302;502) the mould part facing the sectors (8;108;208;308;508), further comprising a forming component (15;115;215;315;515) at least partially surrounded by the abutment element (16;116;216;316;516).

In an eighth version, a method according to the seventh version is provided, wherein said respective abutment surfaces (71,72;571,572) comprise an abutment surface (72;572) and a further abutment surface (71;571) of the abutment element (16;116;216;316;516), said abutment surface (72;572) and said further abutment surface (71;571) being brought into mutual contact to close the forming chamber (17).

In a ninth version, a method is provided according to the seventh or the eighth version, wherein after the sectors (8;108;208;308;508) and the abutment element (16;116;216;316;516) have been brought into mutual contact, at least said part selected from between the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) is moved further in the moulding direction (D), so that the forming component (15;115;215;315;515) penetrates between the sectors (8;108;208;308;508) of said plurality to form the object.

In a tenth version, a method is provided according to one of the versions from the seventh to the ninth, wherein the forming component (15;115;215;315;515) is a male forming component (15;215;515), the mouldable material flowing between the sectors (8;108;208;308;508) and the male forming component (15;215;515) to originate a lateral wall of the object.

In an eleventh version, a method according to the tenth version is provided, wherein the male forming component (215) is included in the second mould part (3;103;203;303;503) and is positioned below the first mould part (2;102;302:402;502), and wherein the dosed amount (100) is positioned on a support surface (76) delimiting an upper end of the male forming component (215).

In a twelfth version, a method is provided according to one of the versions from the seventh to the tenth, wherein, in a final forming position, the forming component (315) delimits the closed forming chamber (17) transversely to the moulding direction (D) and is in contact with the sectors (8;108;208;308;508) to prevent the mouldable material from flowing between the forming component (315) and the sectors (8;108;208;308;508).

In a thirteenth version, a method according to one of the previous versions is provided, wherein an edge zone of the dosed amount (500) is blocked between the first mould part (2;102;302:402;502) and the second mould part (3;103;203;303;503) before starting to deform a central zone of the dosed amount (500).

In a fourteenth version, a method according to the thirteenth version is provided, when in the thirteenth version the features of the seventh version are included, wherein the sectors (8;108;208;308;508) are included in the first mould part (2;102;302:402;502), and wherein the edge zone of the dosed amount (500) is 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 component (15;115;215;315;515) starts to interact with the central zone of the dosed amount (500).

In a fifteenth version, a method is provided according to the thirteenth version, when the thirteenth version includes the features of the seventh version, or according to the fourteenth version, wherein the sectors (8;108;208;308;508) are included in the first mould part (2;102;302:402;502), and wherein the edge zone of the dosed amount (500) is blocked between the first mould part (2;102;302:402;502) and the second mould part (3;103;203;303;503), clamping the dosed amount (500) between a blocking portion (580) which projects from the abutment element (16;116;216;316;516) and a support surface (79;579) of the first mould part (2;102;302:402;502), the sectors (8;108;208;308;508) being slidable along the support surface (79;579) to reduce the volume of the variable-volume forming region (4).

In a sixteenth version, a method is provided according to the fifteenth version, wherein the blocking portion (580) interposes between the sectors (8;108;208;308;508) to clamp the dosed amount (500) against the support surface (79;579).

In a seventeenth version, a method is provided according to one of the previous versions, wherein the sectors (8;108;208;308;508) are movable between a first position (P1) in which the volume of the variable-volume forming region (4) is maximum, and a second position (P2), in which the volume of the variable-volume forming region (4) is minimum, and in which the dosed amount (100;400;500) is positioned between the first mould part (2;102;202;302;502) and the second mould part (3;103;203;303;503) while the sectors (8;108;208;308;508) are in the first position (P1).

In an eighteenth version, a method is provided according to one of the previous versions, wherein the first mould part (2;102;202;302;502) comprises the sectors (8;108;208;308;508) and an end-forming element (14;114;214;314;514) delimiting the closed forming chamber (17) transversely to the moulding direction (D) at the opposite side with respect to the second mould part (3;103;203;303;503).

In a nineteenth version, a method is provided according to the eighteenth version, wherein the sectors (8;108;208;308;508) are slidable transversely to the moulding direction (D) in contact with the end-forming element (14;114;214;314;514) to decrease the volume of the closed forming region (4).

In a twentieth version, a method is provided according to the eighteenth or the nineteenth version, wherein the first mould part (2;102;202;302;502) has a forming cavity (24), the forming cavity (24) comprising the variable-volume forming region (4) delimited by the sectors (8;508) and a recess (70) made in the end-forming element (14;514).

In a twenty-first version, a method is provided according to the eighteenth or the nineteenth version, wherein the first mould part (2;102;202;302;502) comprises a protruding core (73) protruding from the end-forming element (14;114;214;314;514) towards the second mould part (3;103;203;303;503), and wherein the dosed amount (100;400;500) is positioned in the first mould part (2;102;202;302;402) in a non-centred position with respect to the sectors (8;108;208;308;508), at a side of the protruding core (73), so that the mouldable material flows between the sectors (8;108;208;308;508) and the protruding core (73) to originate an object having a hole or a hollow.

In a twenty-second version, a method is provided according to the twenty-first version, when the eighteenth version comprises the features of the seventh version, wherein the protruding core (73) protrudes from the sectors (8;108;208;308;508) towards the second mould part (3;103;203;303;503) to engage in a guide hole (74) made in the forming component (115).

In a twenty-third version, a method is provided according to the previous versions, wherein in each sector (8;108;208;308;508) moves transversely to the moulding direction (D) to reduce the volume of the variable-volume forming region (4) under the action of a resulting force given by the combination of a first force (F1) applied to said sector (8;108;208;308;508) by a pushing device and a second force (F2) applied to said sector (8;108;208;308;508) by an adjacent sector (8;108;208;308;508) of said plurality.

In a twenty-fourth version, a method is provided according to one of the previous versions, and further comprising extruding the mouldable material, generating a continuous extrudate of mouldable material, separating a dosed amount (100;400;500) from the continuous extrudate, transporting the dosed amount (100;400;500) into the mould (1;101;201;301;401;501).

In a twenty-fifth version, a method is provided according to the twenty-fourth version, wherein the continuous extrudate comprises at least two layers (78,79) of polymeric material, the dosed amount (400;500) being introduced into the mould (401;501) such that each of said two layers (78,79) extends transversely, preferably substantially perpendicular, to the moulding direction (D).

In a first version of a second aspect of the invention, an apparatus is provided for forming an object, comprising at least one mould (1;101;201;301;401;501) which includes a first mould part (2;102;202;302;402;502) and a second mould part (3;103;203;303;403;503) opposite to each other, a mould part selected from between the first mould part (2;102;202;302;402;502) and the second mould part (3;103;203;303;403;503) comprising a plurality of sectors (8;108;208;308;508) for at least partially forming a lateral surface of the object, the sectors (8;108;208;308;508) delimiting a variable-volume forming region (4) of the mould (1;101;201;301;401;501), the apparatus further comprising a driving device for bringing the first mould part (2;102;202;302;402;502) and the second mould part (3;103;203;303;403;503) closer to each other along a moulding direction (D), so as to bring into mutual contact the first mould part (2;102;202;302;402;502) and the second mould part (3;103;203;303;403;503) along respective abutment surfaces (71,72;571,572) arranged transversely to the moulding direction (D), defining 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), and wherein the apparatus further comprises pushing means for moving the sectors (8;108;208;308;508) transversely to the moulding direction (D) to reduce volume of the variable-volume forming region (4).

In a second version of the second aspect, an apparatus is provided according to the first version of the second aspect, wherein the sectors (8;108;208;308;508) are included in the first mould part (2;102;202;302;402;502) and the second mould part (3;103;203;303;503) comprises an abutment element (16;116;216;316;516) adapted to contact the sectors (8;108;208;308;508) to define the closed forming chamber (17) and a forming component (15;115;215;315;515) at least partially surrounded by the abutment element (16;116;216;316;516), the forming component (15;115;215;315;515) and the abutment element (16;116;216;316;516) being distinct from each other and displaceable with respect to each other.

In a third version of the second aspect, an apparatus is provided according to the second version of the second aspect, wherein the second mould part comprises a blocking portion (280) adapted to be interposed between the sectors (8;108;208;308;508) for blocking an edge zone of the dosed amount (500) before starting to deform a central zone of the dosed amount (500).

In a fourth version of the second aspect, an apparatus is provided according to the third version of the second aspect, wherein the blocking portion (280) projects from the abutment element (16;116;216;316;516) to clamp the dosed amount (500) against a support surface (79;579) of the first mould part (2;102;302:402;502), the sectors (8;108;208;308;508) of said plurality being slidable along the support surface (79;579) to reduce the volume of the variable-volume forming region (4).

In a fifth version of the second aspect, an apparatus is provided according to one of the versions from the first to the fourth of the second aspect, wherein the sectors (8;108;208;308;508) are included in the first mould part (2;102;202;302;402;502) and the first mould part (2;102;202;302;502) further comprises an end-forming element (14;114;214;314;514) delimiting the closed forming chamber (17) transversely to the moulding direction (D) on the opposite side with respect to the second mould part (3;103;203;303;503) and wherein a protruding core (73) projects from the end-forming element (14;114;214;314;514) towards the second mould part (3;103;203;303;503) to originate an object having a hole or a hollow starting from a dosed amount (100;400;500) positioned in the first mould part (2;102;202;302;502) in a non-centred position with respect to the sectors (8;108;208;308;508) of said plurality, at a side of the protruding core (73).

In a first version of a third aspect of the invention, a method is provided for forming an object, comprising the steps of:providing a mould (501) comprising a first mould part (502) and a second mould part (503) opposite to each other;positioning a dosed amount (500) of mouldable material between the first mould part (502) and the second mould part (503);displacing the first mould part (502) and the second mould part (503) towards each other in a moulding direction (D), to form an object from the dosed amount (500) by means of compression moulding,
wherein an edge zone of the dosed amount (500) is blocked between the first mould part (502) and the second mould part (503) before starting to deform a central zone of the dosed amount (500).

In a second version of the third aspect of the invention, a method is provided according to the first version of the third aspect of the invention, wherein the first mould part (502) comprises a forming cavity (24), the edge zone of the dosed amount (500) being blocked between the first mould part (502) and the second mould part (503) while the central zone of the dosed amount is spaced by a bottom of the forming cavity (24).

In a third version of the third aspect of the invention, a method is provided according to the first or second version of the third aspect of the invention, wherein the second mould part (503) comprises an abutment element (516) adapted to contact the first mould part (502) to define a closed forming chamber (17) between the first mould part (502) and the second mould part (503), the second mould part (503) further comprising a forming component (515) at least partially surrounded by the abutment element (516), the forming component (515) and the abutment element (516) being distinct from each other and displaceable with respect to each other, and wherein the dosed amount (500) is blocked between the first mould part (502) and the second mould part (503) by a blocking portion (280) projecting from the abutment element (516) and pushing the dosed amount (500) against the first mould part (502).

In a first version of a fourth aspect of the invention, an apparatus is provided for forming an object from a dosed amount (500) of mouldable material, comprising at least one mould which includes a first mould part (502) and a second mould part (503) opposite to each other, a driving device for displacing the first mould part (502) and the second mould part (503) towards each other in a moulding direction (D), so as to form an object from the dosed amount (500) by means of compression moulding, wherein a mould part selected from between the first mould part (502) and the second mould part (503) comprises a blocking portion (280), intended to engage with an edge zone of the dosed amount (500) to press the edge zone against the other mould part selected from between the second mould part (503) and the first mould part (502), so as to block the dosed amount (500) in contact with the other mould part while the dosed amount (500) is shaped. In a second version of the fourth aspect of the invention, an apparatus is provided according to the first version of the fourth aspect of the invention, wherein the blocking portion (280) is included in the second mould part (503) and the first mould part (502) is a female mould part.

In a third version of the fourth aspect of the invention, an apparatus is provided according to the second version of the fourth aspect of the invention, wherein the second mould part (503) comprises an abutment element (516) adapted to contact the first mould part (502) to define a closed forming chamber (17) between the first mould part (502) and the second mould part (503), the second mould part (503) further comprising a forming component (515) at least partially surrounded by the abutment element (516), the forming component (515) and the abutment element (516) being distinct from each other and displaceable with respect to each other, and in which the blocking portion (280) projects from the abutment element (516) towards the first mould part (502).