# US 10,118,332 B2 · Formed thermoplastic article having a peelable surface and smooth edges > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,118,332 B2 - Document ID: US10118332B2 - Status: Granted - Kind: B2 - Application number: 15/787,261 - Filed: 2017-10-18 - Published: 2018-03-01 - Granted: 2018-11-06 - Earliest claimed: 2015-08-31 - Assignees: Converter Manufacturing, LLC - Applicants: Converter Manufacturing, LLC - Inventors: Millard F Wallace - Web page: https://patentgrep.com/patent/US10118332B2 ## CPC - B29C 51/306: {with means for forming a rim (combined with cutting B29C51/325; rim rolling per se B29C53/34)} - B26F 1/40: using a press, e.g. of the ram type (presses in general B30B) - B29C 48/0017: {combined with blow-moulding or thermoforming} - B29C 48/10: flexible, e.g. blown foils - B29C 48/23: with means for avoiding adhesion of the layers, e.g. for forming peelable layers - B29C 48/885: External treatment, e.g. by using air rings for cooling tubular films - B29C 48/912: {of tubular films} - B29C 48/918: {characterized by differential heating or cooling} - B29C 51/082: {by shaping between complementary mould parts} - B29C 51/14: using multilayered preforms or sheets - B29C 51/20: having movable moulds or mould parts - B29C 51/265: {Auxiliary operations during the thermoforming operation (B29C51/42, B29C51/46 take precedence)} - B29C 51/266: {Auxiliary operations after the thermoforming operation (B29C51/42, B29C51/44, B29C51/46 take precedence)} - B29C 51/268: {Cutting, rearranging and joining the cut parts} - B29C 51/42: Heating or cooling - B29C 57/12: Rim rolling - B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12} - B32B 7/06: permitting easy separation - B32B 27/08: of synthetic resin - B65D 1/22: Boxes or like containers with side walls of substantial depth for enclosing contents {(B65D43/162, B65D81/02, B65D81/3813 take precedence)} - B65D 1/265: {Drinking cups (B65D81/3865 takes precedence, holders for plastic cups A47G23/0208)} - B65D 1/34: Trays or like shallow containers {(B65D81/3813 takes precedence)} - B65D 1/40: Details of walls (other container details B65D23/00, B65D25/00) - B65D 1/42: Reinforcing or strengthening parts or members - B65D 1/46: Local reinforcements, e.g. adjacent closures - B65D 21/0212: {Containers presenting local stacking elements protruding from the upper or lower edge of a side wall, e.g. handles, lugs, ribs, grooves (B65D21/0211, B65D21/0215, B65D21/023 take precedence)} - B65D 43/0204: {secured by snapping over beads or projections} - B65D 53/06: Sealings formed by liquid or plastic material - B65D 77/2024: {the cover being welded or adhered to the container} - B29C 51/10: Forming by pressure difference, e.g. vacuum - B29C 53/34: Rim rolling (of tube ends B29C57/12) - B29C 2791/001: Shaping in several steps - B29C 2791/006: Using vacuum - B29C 2791/007: Using fluid under pressure - B29K 2023/086: {EVOH, i.e. ethylene vinyl alcohol copolymer} - B29K 2067/003: {PET, i.e. poylethylene terephthalate} - B29K 2101/12: Thermoplastic materials - B29K 2105/256: {Sheets, plates, blanks or films} - B29K 2995/0067: non-permeable - B29L 2031/565: {for containers} - B29L 2031/712: {Containers; Packaging elements or accessories, Packages (closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418)} - B65D 21/0233: {Nestable containers} - B65D 81/20: under vacuum or superatmospheric pressure, or in a special atmosphere, e.g. of inert gas {(B65D81/28 takes precedence; containers with pressurising means for maintaining ball pressure A63B39/025)} - B65D 2543/00194: square or rectangular - B65D 2543/00296: Plastic - B65D 2543/00351: Dome-like - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B26F: PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING (marking-out, perforating or making buttonholes A41H25/00; shoemaking A43D; surgery A61B; punching metal B21D; drilling metal B23B; cutting of metal by applying heat locally, e.g. flame cutting, B23K; cutting by abrasive fluid jets B24C5/02; details common to machines for severing B26D; drilling wood B27C; drilling stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; of glass C03B; of leather C14B; of textile materials D06H; for light guides G02B6/25; of tickets G07B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract The disclosure relates to forming shaped thermoplastic articles having smooth peripheries. Many thermoplastic articles have sharp edges formed upon molding or cutting the article from a feedstock sheet. Such sharp edges can damage thin plastic films or flesh which they contact, and smoothing the edges is desirable. Described herein are methods of forming a smooth periphery for such sharp-edged articles by rolling over the sharp edge. The smoothing operation is performed by forming a deflectable flange including a bend region separated from the potentially sharp peripheral edge by a spacer, deflecting a portion of the deflectable flange, and softening at least one bent portion of the deflectable flange to yield a smooth periphery upon cooling. A liner sheet may be attached to the feedstock sheet prior to, during, or after forming and can be peelable therefrom. ## Claims ### Claim 1 A shaped article comprising: a) a thermoplastic sheet having a shape which includes a peripheral edge and a body having a concave interior portion, the thermoplastic sheet including a deflectable flange extending peripherally away from the interior portion and including the peripheral edge, the deflectable flange including an extension adjoining the junction between the body and the deflectable flange, a bend region interposed between the extension and the peripheral edge, the bend region forming an angle of not less than 75 nor more than 105 degrees between the extension and a spacer interposed between the bend region and the peripheral edge, and a bent portion between the bend region and the peripheral edge, the bent portion having a smooth periphery and being sufficiently bent that the peripheral edge is displaced from the periphery of the article, whereby the article has a smooth periphery; and b) at least one pliable liner sheet conforming to and being peelably attached to the thermoplastic sheet, the liner sheet being detached from the thermoplastic sheet at least a portion of the peripheral edge. ### Claim 2 (depends on 1) The shaped article of claim 1, wherein at least one liner sheet is peelable attached to each of the interior portion, the extension, and the bent portion of the thermoplastic sheet. ### Claim 3 (depends on 1) The shaped article of claim 1, wherein each of the peripheral edge, the bent portion, and the extension completely surrounds the interior portion, and wherein each of the interior portion, the extension, and the bent portion of the thermoplastic sheet has a liner sheet peelably attached thereto. ### Claim 4 (depends on 3) The shaped article of claim 3, wherein the same liner sheet is peelably attached to each of the interior portion, the extension, and the bent portion of the thermoplastic sheet. ### Claim 5 (depends on 4) The shaped article of claim 4, wherein a graspable tab is interposed between the liner sheet and the thermoplastic sheet at least one position along the peripheral edge. ### Claim 6 (depends on 4) The shaped article of claim 4, further comprising a lidding attached to the liner sheet completely around the interior portion. ### Claim 7 (depends on 6) The shaped article of claim 6, wherein the lidding is attached to the liner by way of a gas-tight seal and the space between the lidding and the liner with the seal contains a gas. ### Claim 8 (depends on 6) The shaped article of claim 6, wherein the lidding is attached to the liner by way of a gas-tight seal and wherein the lidding and the liner contain between them at least one item not including any substantial amount of a gas. ### Claim 9 (depends on 1) The shaped article of claim 1, wherein the thermoplastic sheet includes a reservoir portion recessed away from and entirely within the interior portion and wherein at least the liner sheet that is peelably attached most distally from the thermoplastic sheet surface bears a perforation therethrough at the reservoir portion, does not conform to the thermoplastic sheet at the reservoir portion, and is not peelably attached to the thermoplastic sheet at the reservoir portion, whereby liquid in the lumen of the interior portion is able to traverse the liner sheet at the reservoir portion. ### Claim 10 (depends on 9) The shaped article of claim 9, comprising i) a non-perforated liner sheet which is peelably attached to the thermoplastic sheet at each of the reservoir portion, the interior portion, the extension, and the bent portion of the thermoplastic sheet and ii) the perforated liner sheet attached to the non-perforated liner sheet. ### Claim 11 (depends on 1) The shaped article of claim 1, wherein the extension includes the peripheral edge, a flat sealing surface surrounding the concave interior portion, and the bent portion interposed between the peripheral edge and the sealing surface, the sealing surface being suitable for sealing the sealing film thereto using either of VSP and MAP sealing technologies, and the bent portion being bent sufficiently that the peripheral edge is turned at least approximately opposite the periphery. ### Claim 12 (depends on 1) The shaped article of claim 1, wherein the peripheral edge is turned away from the periphery of the tray. ### Claim 13 (depends on 1) The shaped article of claim 1, having the overall shape of a rectangular tray with rounded corners. ### Claim 14 (depends on 1) The shaped article of claim 1, wherein the bent portion includes a rounded portion. ### Claim 15 (depends on 14) The shaped article of claim 14, wherein the rounded portion has a J-shaped conformation. ### Claim 16 (depends on 14) The shaped article of claim 14, wherein the rounded portion has a U-shaped conformation. ### Claim 17 (depends on 14) The shaped article of claim 14, wherein the rounded portion has a spiral conformation. ### Claim 18 (depends on 1) The shaped article of claim 1, wherein the extension bears a flat sealing surface and completely surrounds the concave interior portion of the body. ### Claim 19 (depends on 18) The shaped article of claim 18, wherein a gap exists between the bent portion and the concave interior portion of the body. ### Claim 20 (depends on 19) The tray of claim 19, wherein the gap occurs about the entire periphery of the article. ### Claim 21 (depends on 20) The tray of claim 20, wherein the width of the gap at each position about the concave interior portion of the body is at least half the width, measured in the direction extending peripherally away from the concave portion of the body, of the flat sealing surface at that position. ### Claim 22 (depends on 20) The tray of claim 20, wherein the width of the gap at each position about the concave interior portion of the body being at least three-quarters the width, measured in the direction extending peripherally away from the concave portion of the body, of the sealing surface at that position. ### Claim 23 (depends on 1) The article of claim 1, wherein the shape of the concave interior portion is not circular. ### Claim 24 A shaped article comprising: a) a thermoplastic sheet having a shape which includes a peripheral edge and a body having a non-circular concave interior portion, the thermoplastic sheet including a spacer bearing the peripheral edge, the spacer being connected to the body by way of an extension that extends peripherally away from the body and a bend region interconnecting the spacer and the extension, the bend region having a smooth contour and interconnecting the spacer at an approximately right angle with the extension b) at least one liner sheet conforming to and being laminated against the thermoplastic sheet. ### Claim 25 (depends on 24) The shaped article of claim 24, wherein at least one liner sheet is peelable attached to each of the interior portion, the extension, and the bent portion of the substrate sheet. ### Claim 26 (depends on 24) The shaped article of claim 24, wherein the liner sheet is perforated. ### Claim 27 An article comprising a thermoplastic sheet having a peripheral edge and defining a non-circular shaped body having an extension extending peripherally away from the body, the extension including the peripheral edge, and a bent portion interposed between the peripheral edge and the junction between the body and the extension, the bent portion having a smooth periphery and being sufficiently bent that the peripheral edge of the thermoplastic sheet is displaced from the periphery of the article, yielding an article having a smooth periphery; and a pliable liner peelably attached to the thermoplastic sheet. ### Claim 28 (depends on 27) The article of claim 27, including multiple pliable liners peelably attached to the thermoplastic sheet. ### Claim 29 (depends on 27) The article of claim 27, wherein the liner is delaminated from the thermoplastic sheet at least a portion of the peripheral edge. ### Claim 30 (depends on 27) The article of claim 27, wherein the peelable layer is a non-thermoplastic material.