Abstract: In an apparatus for manufacturing pressware containers from container blanks there is provided a plurality of inertial blank stop pins disposed so as to position a container blank prior to press forming. The stop pins are rotatable in order to absorb the kinetic energy of the container blanks as they are fed to the apparatus and eliminate blank bounce. In a further aspect of the invention there is provided a method of forming plates utilizing the improved apparatus including the inertial blank stop pins.

Abstract: An improved pressware die set includes mechanical ejectors for removing formed product from the punch. A preferred embodiment includes rocker-style ejectors free from edges or other asperities which may tend to snag and mar the product during the production process. Most preferably, the outward surfaces of the rocker members extend beyond the perimeter of a paperboard blank positioned for forming so the paperboard blank does not encounter an obstruent outward edge during forming.

Abstract: A deep dish disposable container is preferably prepared from a radially scored paperboard blank and has a substantially planar bottom portion, an upwardly projecting sidewall portion and an outwardly extending flange portion. The flange and sidewall are provided with a plurality of circumferentially spaced, radially extending densified regions formed from a plurality of paperboard layers reformed into substantially integrated fibrous structures generally inseparable into their constituent layers having a thickness generally equal to adjacent areas of the sidewall and flange portions to provide uniformity and strength. The deep dish container generally has a height to diameter ratio of from about 0.1 to about 0.16; whereas the radially scored paperboard blank has from about 50 to about 100 radial scores. The product is dimensioned and configured such that there is from about 0.015 to about 0.05 inches of excess paperboard per score about the flange portion in order to provide rigidity to the product.

Abstract: There is provided a container having both male and female sealing regions disposed about its periphery in a pattern making it possible to seal a container with another container having substantially identical sealing regions. The male sealing regions used in the practice of the present invention may take the form of a U-shaped ridge which is undercut along at least one leg of the U in a radial direction. Typically, a container will be thermoformed from lightweight thermoplastic material giving the U-shaped ridge considerable flexibility. The female sealing regions used in the practice of the invention may take the form of an undercut channel adapted to receive and match the undercut U-shaped ridges found in the male portion of the container wherein the walls and base of the channel are sufficiently flexible that the undercut portions of the U-shaped ridge are urged into engagement with the undercut portions of the channel.

Abstract: A pressing apparatus for producing a food service paperboard container from a paperboard blank so that the paperboard container possesses an overturned rim provided with folds includes a first die and a second die that are movable relative to one another. The first die includes a first base and a first platform that is movable with respect to the first base, with the first base having a curved surface for engaging the outer periphery of the paperboard blank. The second die is positioned in opposing relation to the first die and includes a second base and a second platform that is movable with respect to the second base. The second die is movable with respect to the first die and the second base has a curved surface for engaging the outer periphery of the paperboard blank so that the outer periphery of the paperboard blank is pressed between the curved surface of the first base and the curved surface of the second base.

Abstract: There is provided a container having both male and female sealing regions disposed about its periphery in a pattern making it possible to seal a container with another container having substantially identical sealing regions. The male sealing regions used in the practice of the present invention may take the form of a U-shaped ridge which is undercut along at least one leg of the U. Typically, a container will he thermoformed from lightweight thermoplastic material giving the U-shaped ridge considerable flexibility. The female sealing regions used in the practice of the invention may take the form of an undercut channel adapted to receive and match the undercut U-shaped ridges found in the male portion of the container wherein the walls and base of the channel are sufficiently flexible that the undercut portions of the U-shaped ridge are urged into engagement with the undercut portions of the channel and the crest of the ridge is urged into the channel.

Abstract: In a temperature controlled segmented die for forming pressed containers such as plates, trays, bowls or the like including a die segment with a forming surface and an outer movable annular die member there is provided a side mounted temperature probe which extends laterally around the movable annular die member and toward the forming surface of the die segment. The apparatus is particularly useful for forming pressed paperboard containers such as paper plates.

Abstract: A set of nestable containers may be nested. Adhering means, such as an adhesive or a hook and loop fastener, may be provided on the exterior of an outer container of the nest. One(s) of the containers may have anti-jamming means, such as scoring, embossing, a spacer, a hole, a projection, a recess, a friction reducer, and the like, for easing the release of containers from a nest of containers. Containers may be nested in a collapsed condition.

Abstract: Disposable food contact compatible microwaveable containers having one or more micronodular surface are disclosed. These containers, including plates, bowls, cups, trays, buckets, soufflé dishes, and lids are prepared from a polyolefin selected from the group consisting of polypropylene, polypropylene polyethylene copolymer or blends, and mixtures of these, mica, and pigment and are thermoformed into the shape of a the aforementioned containers exhibiting (a) a micronodular surface on at least one side of the surface; (b) a melting point of not less than about 250° F.; said containers being dimensionally stable and resistant to grease, sugar, and water at temperatures up to at least 250° F. and being of sufficient toughness to resist cutting by serrated polystyrene flatware.

Abstract: In a pressware die set, a segmented punch for fabricating a pressed disposable food service article having a substantially planar bottom portion, a sidewall and a rim portion. In one embodiment, the punch is mounted to reciprocate cyclically between an open position and a forming position about an axis of reciprocation and includes outer punch surfaces for forming the sidewall and rim portions of the pressed disposable food service articles, as well as a substantially planar punch surface suitably mounted and dimensioned to engage the substantially planar bottom portion of the disposable food service article. The improved punch includes a knock-out stripper ring juxtaposed with the substantially planar punch surface, defining a knock-out surface and which is reciprocally mounted with respect to the central substantially planar punch surface such that the knock-out surface is contiguous with the substantially planar punch surface when the punch is in a forming position.

Abstract: There is provided a container having both male and female sealing regions disposed about its periphery in a pattern making it possible to seal a container with another container having substantially identical sealing regions. The male sealing regions used in the practice of the present invention may take the form of a U-shaped ridge which is undercut along at least one leg of the U in a radial direction. Typically, a container will be thermoformed from lightweight thermoplastic material giving the U-shaped ridge considerable flexibility. The female sealing regions used in the practice of the invention may take the form of an undercut channel adapted to receive and match the undercut U-shaped ridges found in the male portion of the container wherein the walls and base of the channel are sufficiently flexible that the undercut portions of the U-shaped ridge are urged into engagement with the undercut portions of the channel.

Abstract: In a preferred construction, a food container includes: (i) a container base such as a serving planer, plate or howl having (a) a substantially planar central area, (b) a container base sidewall extending outwardly and upwardly from the central area having: (1) a recessed frustal tapered container base sealing area formed in the container base sidewall, and (2) a container base stop ridge adjacent the frustal tapered container base sealing area, and (c) an outwardly extending convex rim adjoining the container base stop ridge having an outer lip formed thereabout; and (ii) a resilient mating domed lid.

Abstract: Disposable containers include peripheral tabs which are useful for positioning and processing the containers and operate as separators. In a preferred embodiment, the tabs correspond to tabs on a paperboard blank where the tabs are useful for controlling the orientation of the blanks so that printed and shape features may be kept in registration during manufacturing of a disposable servingware container.

Abstract: Disposable food contact compatible microwaveable containers having one or more micronodular surface are disclosed. These containers, including plates, bowls, cups, trays, buckets, soufflé dishes, and lids are prepared from a polyolefin selected from the group consisting of polypropylene, polypropylene polyethylene copolymer or blends, and mixtures of these, mica, and pigment and are thermoformed into the shape of a the aforementioned containers exhibiting (a) a micronodular surface on at least one side of the surface; (b) a melting point of not less than about 250° F.; said containers being dimensionally stable and resistant to grease, sugar, and water at temperatures up to at least 250° F. and being of sufficient toughness to resist cutting by serrated polystyrene flatware.

Abstract: The present invention is directed to rigid disposable food containers provided with a relatively steep sidewall with a generally linear profile and an outwardly flared arcuate flange portion. The containers are further characterized by a flange outer vertical drop wherein the ratio of the length of the vertical drop to the characteristic diameter of the container is greater than about 0.01. By virtue of unique geometry, the containers of the invention exhibit improved rigidity and/or rim stiffness yet have favorable runnability in pressware manufacturing systems characteristic of plates of lower strength.