Abstract: Products and methods of increasing the Rigidity and Rim Stiffness of disposable containers are provided. The containers have an outer flange portion extending outwardly with a brim portion sloping downwardly defining a declivity angle ? with respect to a horizontal generally parallel to the bottom portion and generally include an outward turn at the periphery of the container. A preferred method of improving rigidity includes press-forming: (i) a brim transition portion adjoining the downwardly sloping brim portion of the container and (ii) an outwardly extending annular evert portion adjoining the brim transition portion extending outwardly at an eversion angle ? of at least about 25 degrees with respect to the downwardly sloping brim portion of the flange.

Abstract: A pressware stacking assembly and method for using the same are provided. The stacking assembly may include a stacking surface for supporting a plurality of pressware products and at least one shaped wheel at least partially disposed through the stacking surface. The shaped wheel may include a body having at least three sides disposed about a perimeter thereof and at least one transition section disposed between adjoining sides, wherein each transition section is adapted to lift at least a portion of the pressware products off the stacking surface.

Abstract: A method for making a multilayered paper-containing product, for example a paper plate or tray, includes assembling two or more sheets of paper-containing material cut into blanks. The blanks are pressed together and shaped in a die, usually with a bonding agent being used to secure the blanks. Pleats are formed in the curved portion of the shaped product. However, the pleats on each blank are formed independently so that the folded region formed in the pleats are arranged in a staggered array and are not interleaved with the pleats of the other blank.

Abstract: The present invention provides an improved pressware forming apparatus. At least one of die pairs used in the apparatus can be narrowed in a cross-direction as compared to the cross-directional width of pressware forming tools used in prior an apparatus. The present invention allows addition of at least one additional die pair in the pressware forming tool when used in a standard sized pressware forming apparatus. The present invention also provides components for use in such apparatus and methods of making pressware from the apparatus herein.

Abstract: Embodiments of the invention provide improvements to dies used in the formation of pressware from blanks. In some embodiments, the die includes at least one stop that helps contain the blank as it is fed to the die and that allows for improved adjustability of the stop with respect to the die. In some embodiments, the die includes a defined recess that contains and centers the blank on the die as the blank is fed to the die.

Abstract: Embodiments of the invention provide improvements to dies used in the formation of pressware from blanks In some embodiments, the die includes at least one stop that helps contain the blank as it is fed to the die and that allows for improved adjustability of the stop with respect to the die. In some embodiments, the die includes a defined recess that contains and centers the blank on the die as the blank is fed to the die.

Abstract: A disposable servingware container 10 press-formed from a generally planar paperboard blank has a characteristic diameter, D, and includes a bottom panel 12 having an arched central crown 14 with a convex upper surface 14a, a first annular transition portion 16 extending upwardly and outwardly from the bottom panel, with the proviso that a portion of the arched central crown defines a substantially continuous, convex arched profile 18 spanning at least 75% of the horizontal distance between center 20 of the container and the first annular transition. An optional sidewall portion 26 extends upwardly and outwardly from the first annular transition portion, while a second annular transition portion 28 flares outwardly with respect to the first annular transition portion defining a second radius of curvature, R2. The ratio of R2/D is 0.0125 or less. An outer flange portion 32 extends outwardly with respect to the second annular transition portion and forms the outer perimeter of the container.

Abstract: A heated, segmented pressware die set for making pressware containers from a paperboard blank includes a plurality of guide keys mounted between at least one of an inner member of a punch or die and an outer ring which reciprocates independently. Each guide key extends in an outward direction from the central axis of the die set. The guide keys are positioned, configured and dimensioned to engage the outer ring in order to limit rotation of the outer ring with respect to the inner member of the punch or die. In a preferred construction, the guide keys have radially extending planar surfaces which cooperate with guide channels having like surfaces such that clearances necessary to accommodate thermal expansion are reduced, greatly increasing durability of the tool.

Abstract: Pressware stacking systems and methods for using same. The system can include a conveyor for moving pressware in a first direction; a stop ramp at least partially disposed on the conveyor; and a lifter in communication with the stop ramp. The lifter is adapted to move at least a portion of the stop ramp to an inclined position above the conveyor.

Abstract: A domed lid 12 for a food container 10 is configured for ease of engagement and removal from a container base 14. The lid characteristically includes: (a) a dome portion 16 with a top wall 24 and a sidewall 26; (b) a flange portion 28 extending outwardly away from a lower portion of the sidewall; and (c) a tab portion 30 extending outwardly from the flange. The flange portion is provided with a rim 32 having a variable profile around the rim characterized in that: (i) the rim is provided with a securing undercut portion 36 extending around the majority of its periphery adapted to secure the lid to an outer border of base 14; and (ii) the rim has a pair of relatively passive engagement profile portions 42, 44 on either side of tab 30, extending to the securing undercut portion of the rim, the passive engagement profile portions are configured so that they are undercut less than the securing undercut portion of the lid, thereby facilitating engagement of the lid with, or removal of the lid from, base 14.

Abstract: A pressware stacking assembly and method for using the same are provided. The stacking assembly may include a stacking surface for supporting a plurality of pressware products and at least one shaped wheel at least partially disposed through the stacking surface. The shaped wheel may include a body having at least three sides disposed about a perimeter thereof and at least one transition section disposed between adjoining sides, wherein each transition section is adapted to lift at least a portion of the pressware products off the stacking surface.

Abstract: The present invention relates to rigid-buckling-resistant-fluted containers with an arcuate outer rim. The container such as a pressformed paperboard plate of overall diameter “D” including a generally planar bottom region, an upwardly extending fluted region surrounding the generally planar bottom region, and an outwardly and downwardly extending peripheral region having an arcuate radial profile. The containers being produced of a lightweight board but exhibiting high strength and rigidity relative to the low weight board.

Abstract: A method for making a multilayered paper-containing product, for example a paper plate or tray, includes assembling two or more sheets of paper-containing material cut into blanks. The blanks are pressed together and shaped in a die, usually with a bonding agent being used to secure the blanks. Pleats are formed in the curved portion of the shaped product. However, the pleats on each blank are formed independently so that the folded region formed in the pleats are arranged in a staggered array and are not interleaved with the pleats of the other blank.

Abstract: A heated, segmented pressware die set for making pressware containers from a paperboard blank includes a plurality of guide keys mounted between at least one of an inner member of a punch or die and an outer ring which reciprocates independently. Each guide key extends in an outward direction from the central axis of the die set. The guide keys are positioned, configured and dimensioned to engage the outer ring in order to limit rotation of the outer ring with respect to the inner member of the punch or die. In a preferred construction, the guide keys have radially extending planar surfaces which cooperate with guide channels having like surfaces such that clearances necessary to accommodate thermal expansion are reduced, greatly increasing durability of the tool.

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 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: A disposable servingware container 10 press-formed from a generally planar paperboard blank has a characteristic diameter, D, and includes a bottom panel 12 having an arched central crown 14 with a convex upper surface 14a, a first annular transition portion 16 extending upwardly and outwardly from the bottom panel, with the proviso that a portion of the arched central crown defines a substantially continuous, convex arched profile 18 spanning at least 75% of the horizontal distance between center 20 of the container and the first annular transition. An optional sidewall portion 26 extends upwardly and outwardly from the first annular transition portion, while a second annular transition portion 28 flares outwardly with respect to the first annular transition portion defining a second radius of curvature, R2. The ratio of R2/D is 0.0125 or less. An outer flange portion 32 extends outwardly with respect to the second annular transition portion and forms the outer perimeter of the container.

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: A paperboard plate such as a paper plate includes a generally planar bottom portion, an upwardly and outwardly extending fluted sidewall, wherein the sidewall comprises a plurality of sidewall flutes substantially around the outer perimeter of the plate to define a fluted perimeter. The flutes are suitably present at fewer than 3.5 flutes per inch; the plate has a radial profile with a single transition; and the diameter/flute length ratio is greater than 6. The plates are formed in a punch-through die cutting and forming tool from a plurality of paperboard web layers at increased productivities as compared with conventional heated press-forming.

Abstract: A sealable food container includes a base serving member such as a plate having a generally planar central portion, a sidewall extending generally upwardly and outwardly therefrom and a base outer flange portion extending outwardly from the sidewall. The sidewall defines a sealing area with an undercut annular sealing surface disposed between the substantially planar central portion of the base serving member and the base outer flange portion. The sidewall portion of the plate defines a base stop ridge adjacent the upper edge of the undercut annular sealing surface of the sidewall as well as a laterally extending retaining shelf adjacent the lower edge of the undercut annular sealing surface of the base serving member.