Method for manufacturing packaging items or parts thereof

A method for producing multilayer packaging items (50) or parts thereof which items or parts comprise a thermoplastic bulk layer and a functional layer, wherein the thermoplastic bulk layer consists of a thermoplastic polymer bulk material and has for mechanical reasons areas of higher thickness and areas of lower thickness and wherein the functional layer consists of a functional material and for being effectively functional requires a given minimum thickness, the method comprising the steps of:

• producing a multilayer film material (10) containing the functional material in a layer of a uniform thickness,
• providing a mold,
• positioning the film material in the mold,
• injecting the thermoplastic polymer bulk material into the mold to form a blank (30) consisting of a film part (10) of a uniform thickness joined to an injection molded part (21) with areas of lower thickness and areas of higher thickness located such that they anticipate areas of lower wall thickness and areas of higher wall thickness of the item or part, and
• thermoforming the blank,
• wherein for joining the film part and the thermoplastic polymer bulk part in the step of injecting, the film material comprises a surface layer (2) of a material able to form a fusion bond with the thermoplastic polymer bulk material, and
• wherein in the step of thermoforming, the item or part is made from the blank;
• wherein the thickness ratio for the higher to lower thickness areas of the multilayer packaging items or parts thereof is substantially similar to the thickness ratio of corresponding higher and lower thickness areas of the blank.