# US 2019/0168925 A1 · Formed Thermoplastic Article Having a Smoothly-Curved Distal Periphery

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- Number: US 2019/0168925 A1
- Document ID: US20190168925A1
- Status: Published application
- Kind: A1
- Application number: 16/212,846
- Filed: 2018-12-07
- Published: 2019-06-06
- Earliest claimed: 2015-08-31
- Assignees: Converter Manufacturing, LLC
- Applicants: Converter Manufacturing, LLC
- Inventors: Millard F. WALLACE
- Web page: https://patentgrep.com/patent/US20190168925A1

## 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

An article having a smooth, non-circular periphery, the article comprising a shaped thermoplastic substrate sheet, the shape of the substrate sheet including
a body and
a deflectable flange joined at a junction to the body at at least a portion of the periphery, the deflectable flange including
a peripheral edge of the substrate sheet at a position distal from the junction;
a smoothly-curved bend region interposed between the junction and the peripheral edge wherein a proximal portion of the substrate sheet is offset from a distal portion of the substrate sheet by an angle A of from 85 to 135 degrees; and
a curved bent portion interposed between the peripheral edge and the bend region,
wherein the curvatures of the bend region and the bent portion position the peripheral edge away from the periphery.

### Claim 2 (depends on 1)

The article of claim 1, wherein angle A is from 90 to 105 degrees.

### Claim 3 (depends on 1)

The article of claim 1, wherein angle A is from 90 to 95 degrees.

### Claim 4 (depends on 1)

The article of claim 1, wherein the shape of the substrate sheet further includes a substantially planar extension interposed between the junction and the bend region.

### Claim 5 (depends on 1)

The article of claim 1, wherein the deflectable flange includes a substantially flat spacer interposed between the peripheral edge and the bend region.

### Claim 6 (depends on 1)

The article of claim 1, wherein the deflectable flange includes a peripheral flange distal to the bend region, the peripheral flange
bearing the peripheral edge,
being connected to the remainder of the deflectable flange at an elbow, and
being angularly offset at the elbow from the portion of the deflectable flange to which it is connected.

### Claim 7 (depends on 1)

The article of claim 1, wherein the deflectable flange is positioned at an outer periphery of the article.

### Claim 8 (depends on 1)

The article of claim 1, wherein the deflectable flange is positioned at an inner periphery of an orifice that extends through the article.

### Claim 9 (depends on 1)

The article of claim 1, wherein the body includes a substantially flat bottom surrounded by substantially vertical sidewalls.

### Claim 10 (depends on 9)

The article of claim 9, wherein
the shape of the substrate sheet further includes a substantially planar extension interposed between the sidewalls of the body and the bend region,
the plane of the extension is substantially parallel to the bottom, and
the offset angle OA between the plane of the extension and the plane of the deflectable flange at the peripheral edge is at least 105 degrees.

### Claim 11 (depends on 10)

The article of claim 10, wherein the offset angle OA is at least 180 degrees.

### Claim 12 (depends on 9)

The article of claim 9, wherein
the shape of the substrate sheet further includes a substantially planar extension interposed between the sidewalls of the body and the bend region;
the plane of the extension is substantially parallel to the bottom;
the deflectable flange includes a peripheral flange distal to the bend region, the peripheral flange
bearing the peripheral edge,
being connected to the remainder of the deflectable flange at an elbow, and
being angularly offset at the elbow from the portion of the deflectable flange to which it is connected; and
the offset angle OA between the plane of the extension and the plane of portion of the deflectable flange to which the peripheral flange is connected is at least 105 degrees.

### Claim 13 (depends on 12)

The article of claim 12, wherein the offset angle OA is at least 230 degrees.

### Claim 14 (depends on 9)

The article of claim 9, wherein the body has the shape of a rectangular tray having rounded corners and edges.

### Claim 15 (depends on 9)

The article of claim 9, wherein
the shape of the substrate sheet further includes a substantially flat extension interposed between the sidewalls of the body and the bend region; and
the deflectable flange and the body extend away from the same face of the extension.

### Claim 16 (depends on 9)

The article of claim 9, wherein the bent portion of the deflectable flange is bent anti-peripherally.

### Claim 17 (depends on 1)

The article of claim 1, wherein substantially every part of the article is substantially optically clear.

### Claim at position 18

18-23. (canceled)

### Claim 24 (depends on 1)

The article of claim 1, comprising a pliable liner sheet conforming to and being peelably attached to the substrate sheet.

### Claim 25 (depends on 24)

The article of claim 24, wherein the liner sheet is detached from the substrate sheet at at least a portion of the peripheral edge.

### Claim 26 (depends on 1)

The article of claim 1, further comprising a lidding sheet which contacts the article about its entire periphery.

### Claim 27 (depends on 26)

The article of claim 26, wherein the lidding sheet is sealed to the article about its entire periphery.

### Claim 28 (depends on 27)

The article of claim 27, wherein the body has the shape of a container defining a concavity within the periphery, whereby the lidding sheet and the container define a closed compartment.

### Claim 29 (depends on 28)

The article of claim 28, wherein each of the substrate sheet and the lidding sheet inhibits passage of oxygen.

### Claim 30 (depends on 28)

The article of claim 28, wherein each of the substrate sheet and the lidding sheet inhibits passage of water vapor.

### Claim 31 (depends on 1)

The article of claim 1, wherein the deflectable flange extends completely around the body at the periphery.

### Claim 32 (depends on 31)

The article of claim 31, wherein the body has the shape of a rectangular tray having rounded corners and edges.

### Claim 33 (depends on 32)

The article of claim 32, wherein the body includes a substantially flat bottom surrounded by sidewalls and a substantially planar extension interposed between the sidewalls and the bend region, the plane of the extension being substantially parallel to the bottom.

### Claim 34 (depends on 31)

The article of claim 31, wherein the body has the shape of a container defining a concavity, the body having a nesting face with a shape adapted to nest at least partially within the concavity of an identical article when the nesting face is inserted within the concavity of the identical article.

### Claim 35 (depends on 34)

The article of claim 34, wherein the nesting face includes an insertable portion and a support surface, the insertable portion having a shape adapted to pass into the concavity of the identical article and the support surface having a shape adapted to impinge against at least a portion of the deflectable flange of the identical article, whereby impingement of the support surface of the article against the deflectable flange of the identical article limits the extent to which the nesting face can be inserted into the concavity of the identical article.

### Claim at position 31

36-142. (canceled)