CA2146695C - Decorative debossed rigid paperboard container and method of forming the same - Google Patents
Decorative debossed rigid paperboard container and method of forming the sameInfo
- Publication number
- CA2146695C CA2146695C CA002146695A CA2146695A CA2146695C CA 2146695 C CA2146695 C CA 2146695C CA 002146695 A CA002146695 A CA 002146695A CA 2146695 A CA2146695 A CA 2146695A CA 2146695 C CA2146695 C CA 2146695C
- Authority
- CA
- Canada
- Prior art keywords
- container
- forming
- paperboard
- blank
- rim
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000011087 paperboard Substances 0.000 title claims abstract description 93
- 238000000034 method Methods 0.000 title claims abstract description 36
- 230000000712 assembly Effects 0.000 claims abstract description 17
- 238000000429 assembly Methods 0.000 claims abstract description 17
- 239000000463 material Substances 0.000 claims abstract description 12
- 238000003825 pressing Methods 0.000 claims abstract description 7
- 230000015572 biosynthetic process Effects 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 description 8
- 239000000835 fiber Substances 0.000 description 4
- 238000007639 printing Methods 0.000 description 4
- 230000000295 complement effect Effects 0.000 description 2
- 150000002500 ions Chemical class 0.000 description 2
- 239000011105 molded pulp Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000013055 pulp slurry Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Landscapes
- Making Paper Articles (AREA)
- Containers Having Bodies Formed In One Piece (AREA)
Abstract
A paperboard blank and method of forming such blank are disclosed the method includes forming a paperboard container by initially forming a flat paperboard blank having an outer periphery and positioning the blank between an upper and lower die assembly with the surfaces of the upper and lower die assemblies defining a finished container including a bottom wall, side wall, a planar rim substantially parallel to the bottom wall and a lip extending from a periphery of the planar rim with at least one of the upper and lower die assemblies including an element for forming a decorative pattern in at least the planar rim portion of the container and subsequently pressing the die assembly surfaces together to form the container having the decorative pattern in the planar rim portion of the container. The container is formed from a blank and includes a substantially planar inner region, a side wall region including a generally annular side wall extending upwardly from a periphery of the planar inner region and a rim region extending generally outwardly from a periphery of the side wall region with the rim region including a decorative pattern formed integrally therein. The container may also include a plurality of circumferentially spaced densified regions radially extending through the rim region with the densified regions including substantially three layers of paperboard material. In such a case, the decorative pattern which is debossed into an upper surface of the rim region may be intersected by the radially extending densified regions without obscuring the decorative pattern.
Description
21~6~5 ,. ...
A DECORATIVE DEBOSSED RIGID PAPERBOARD
CONl AINER AND METHOD OF FORMING THE SAME
TFCHNICAT FIFT 1~
nle pres~nt invention relates generally to the formation of pap~rboard containers and more particularly to a rigid paperboard container having a decorative debossed por~ion and method of forming such decorative debossed portion.
RACKGROUND OF THF INVFNTION
Formed fiber containers, such as paper plates and trays, are commonly produced either by molding fibers from a pulp slurry into the desired form of the container or by pressing a paperboard blank between dies into the desired shape. The molded pulp articles, after drying, are fairly strong and rigid but general~y have rough surface characteristics and are not susceptible to printing or other means of decorating such container.
Pressed paperboard containers, on the other hand, can be decorated and coated with a liquid-proof coating be~ore being stamped by the forming dies into the desired shape. Pressed paperboard containers generally cost less and require less storage space than the molded pulp articles.
During the formation of the pressed paperboard containers, sheets of paperboard material are blanked in order to forrn an initial substantially planar container blank which is subsequently placed between forming dies and pressed into the desired configuration. Presently, in order to form a decorative configuration on the paperboard container, the blank either before or after the blanking process is decorated by a printing press which prints a decorative pattern on any desired portion of the paperboard container. Most often, the decorative printing is placed about the outer periphery of the paperboard container.
A DECORATIVE DEBOSSED RIGID PAPERBOARD
CONl AINER AND METHOD OF FORMING THE SAME
TFCHNICAT FIFT 1~
nle pres~nt invention relates generally to the formation of pap~rboard containers and more particularly to a rigid paperboard container having a decorative debossed por~ion and method of forming such decorative debossed portion.
RACKGROUND OF THF INVFNTION
Formed fiber containers, such as paper plates and trays, are commonly produced either by molding fibers from a pulp slurry into the desired form of the container or by pressing a paperboard blank between dies into the desired shape. The molded pulp articles, after drying, are fairly strong and rigid but general~y have rough surface characteristics and are not susceptible to printing or other means of decorating such container.
Pressed paperboard containers, on the other hand, can be decorated and coated with a liquid-proof coating be~ore being stamped by the forming dies into the desired shape. Pressed paperboard containers generally cost less and require less storage space than the molded pulp articles.
During the formation of the pressed paperboard containers, sheets of paperboard material are blanked in order to forrn an initial substantially planar container blank which is subsequently placed between forming dies and pressed into the desired configuration. Presently, in order to form a decorative configuration on the paperboard container, the blank either before or after the blanking process is decorated by a printing press which prints a decorative pattern on any desired portion of the paperboard container. Most often, the decorative printing is placed about the outer periphery of the paperboard container.
- 2 - ~ 6 ~ 5 Because the paperboard blanks are pleplilll~d with a decorative pattern, it is necessary to ensure the ~lignm~nt of the blank within the press when forming such decorative paperboard containers. This results in higher m~mlf~rtllring costs due to the requisite tolerance within which the paperboard blank must be placed between the cooperating dies and the number of mi~ n~ paperboard containers which must be discarded because the decorative pattern is mi~ligned with respect to the formed container.
Additionally, as is discussed in U.S. Patent No. 4,721,499 issued to Marx et al. And assigned to the assignee of the subject invention, it is desirable to form densified regions in the form of cir~;ulllrerelllially spaced pleats formed in the sidewall rim and lip of the container in order to add strength to the overall container structure. In doing so, the pleats often intersect the decorative pattern which has been previously placed on the container resulting in a container which is not aesthetically pleasing to the consumer, particularly if such decorative pattern is a word or a phrase which is obscured by the densified regions.
Accordingly, there is clearly a need for a container having a visible decorative pattern formed thereon which is not obscured by either mi~lignment of the paperboard blank during formation of the container or the formation of densified regions for adding rigidity to the overall container structure. Additionally, there is a need for a decorative paperboard container which can be m~nllf~rtllred in an economical manner wherein the formation of defective containers is minimi7e~1 without sacrificing the time incurred in forming the container. Moreover, this is a need for a container including a decorative surface which is appealing to . :...2 -2146fi~5 ' ,..
th~ consumer and which can be manufactured without the addition of cost~
associated with printing such a decorative pattern.
SUMMARY OF THF INVFN-llON
It is the primary object of the present invention to overcome the above noted shortcomings associated with prior art paperboard containers and their method of manufacture.
A further object of the present invention is to provide a decorative paperboard container which can be manufactured in an economical manner without adding to the steps of present manufacturing processes.
Yet another object of the present invention is to reduce the overall manufacturing costs associated with the formation of decorative paperboard containers by reducing the number of defectively formed containers.
An additional object of the present invention is to provide a method of manufacturing paperboard containers wherein the overall strength of the paperboard container is increased without destroying the decorative formation on the paperboard containers.
An additional object of the present invention is to provide a paperboard container which is manufactured at a reduced cost and which includes a decorative pattern which is not obscured during the process of forming such a container.
Yet another object of the present invention is to form a paperboard container wherein the decorative aspects of the container are formed substantially simultaneously with the formation of the container from a substantially flat paperboard blank.
A further object of the present invention is to provide a proc~ess for manufacturing decorative paperboard containers while reducing the 21~669~
_ - 4 -necessary steps of present manufacturing process thus reducing overall manufacturing costs.
These as well as additional objects of the present invention are achieved by forrning a paperboard container by initially forming a flat paperboard blank having an outer periphery and positioning the blank between an upper and lower die assembly with the surfaces of the upper and lower die assemblies defining a finished container including a bottom wall, side wall, a planar rim substantially parallel to the bottom wall and a lip extending from a periphery of the planar rim with at least one of the upper and lower die assemblies including an element for forming a decorative pattern in at least the planar rim portion of the container and subsequently pressing the die assembly surfaces together to form the container having the decorative panern integrally formed in the planar rim portion of the container. The container is formed from a blank that includes a substantially planar inner region, a side wall region including a generally annular side wall extending upwardly from a periphery of the planar inner region and the rim region extending generally outwardly from a periphery of the side wall region with the rim region including a decorative panern formed integrally therein. The container may also include a plurality of circumferentially spaced densified regions radially extending through the rim region with the densified regions including substantially three layers of paperboard material. In such a case, the decorative pattern which is debossed into an upper surface of the rim region may be intersected by the radially extending densified regions without obscuring the decorative pattern.
These as well as additional advantages will become apparent from the following detailed description when read in light of the several figures.
214663~
~!
BE~F nFSCl~llON OF THF DRA~NGS
Figure 1 is a top view of a paperboard container formed in accordance with the present invention.
Figure 2 is a cross sectional view t~cen along line 2-2 of Figure 1.
Figure 3 is a cross sectional view of the upper and lower die assemblies for forrning a paperboard container in accordance with the present invention.
Figure 4 is a cross sectional perspective view of a paperboard container forrned in accordance with an alternative embodiment of the present invention.
Figure 5 is a cross sectional view of a blank for forming the container of the present invention before such fonning process.
Figure 5A is a cross sectional view ta~en along line 5-5 of Figure 4.
DETArLED DESCR~PTION OF THE PREFERRED EMBODIM~NTS
Reference will now be made in detail to the preferred embodiment of the present invention, an example which is set forth in the above noted drawings. In accordance with the present invention, the paperboard container comprises a substantially planar inner region, a side wall region and a rim region adjoined to and extend;ng about the periphery of the planar region. The container of the present invention may be formed into a plate or bowl thus having a circular configuration or such container may be square or rectangular in shape having angular corners such as a tray.
Further, additional shapes are contemplated including compartmented trays and plates as well as oval platters. In each of the contemplated embodiments, the container includes a rim region having at least one substantially planar portion.
- 214~6~5 As illustrated in Figure 1, the container 10 includes a substantially planar inner region 12 which is surrounded about its periphery by side wall region 11 and adjoining rim region 13. The side wall region 11 includes a generally annular region 14 which flares upwardly and outwardly from a periphery of the planar inner region 12 and a first frusto-conical region 16 which slopes upwardly and outwardly from a periphery of the annular region 14. These features being illustrated in detail in Figure 2. In the rim region 13, outwardly flaring arcuate annular region 18 adjoining an outer periphery of the frusto-conical region 16 is provided with: first portion 20 thereof extending generally upwardly from the first frusto-conical region 16; and a second portion 22 thereof flaring generally outwardly from the annular region 18. A substantially planar region 24 extends substantially tangentially from the second portion 22 of the arcuate annular region 18 and thus extends outwardly from such second portion 22 of the arcuate annular region 18. The planar region 24 may be slightly inclined with respect to the substantially planar inner region 12, however, the region 24 is preferably inclined slightly downwardly in order to add strength to the rim portion of the container. Adjoining the outer periphery of the planar region 24 is an outwardly and downwardly flaring frusto-conical lip 26 which both adds significantly to the strength of the container and aids the consumer in grasping the periphery of the container 10 With reference to Figure 4, the phantom lines 28, 30, 32, 34 and 36 are provided for ease in identifying the various structural segments of the container and do not represent lines actually appearing on the container.
Moreover, the phantom lines do not represent actual demarcations between the sections in that, as explained in greater detail hereinbelow the size relationships between the segments may vary without departing from the 214~9~
spirit and scope of the present invention. Additionally, as is illustrated in Figure 2, the container is forrned from an integral unitary paperboard blank.
As can be seen from Figure l, the paperboard container 10 includes a decorative pattern about planar region 24 with this decorative pattern including alternating shells and scrolls. It should be appreciated that the particular decorative pattern is not of importance with respect to the subject invention but merely the manner in which the decorative pattern is created.
This decorative pattern may be any suitable configuration or may be words or slogans formed about the periphery of the container. As will be discussed in greater detail hereinbelow, the decorative pattern is integrally forrned in the planar region 24 of the paperboard container lO as is illustrated in Figure 2. The debossed regions 40 are formed substantially simultaneously with the formation of the remaining portions of the container. That is, during the formation of the side wall reg;on 11, planar region 24 and lip 26, a decorative pattern formed in the forming die debosses the planar region of ~he paperboard container with any desired decorative pattern. It should be noted that while the decorative pattern is illustrated as being formed in the planar region 24 of the paperboard container 10, such decorative pattern may be simultaneously formed in other regions of the paperboard container as well.
Referring now to ~igure 3, a die assembly for forming the paperboard container in a manner set forth hereinabove is illustrated in detail. A die assembly 100 includes an upper die assembly 102 and a lower die assembly 104. Typically, the lower die assembly 104 is maintained in a substantially stationary position while the upper die assembly 102 is pressed into contact with an upper surface of a paperboard blank plac~d 21~66~
therebetween. However, it is possible with this arrangement to move the di~ assemblies in any manner so long as the paperboard blan~ is sufficiently formed into a paperboard container.
As discussed hereinabove, the upper die assembly 102 and lower die assembly 10~ are utilized to press a flat circular paperboard blank 106 into the shape of the paperboard container 10. The construction of the upper and lower die assemblies and the equipment which is utilized to maneuver such assemblies is substantially conventional. To facilitate the holding and shaping of the blank 106, the dies are segmented in the manner shown.
The lower die assembly 104 includes a circular base portion 108 and a central circular platform 110 which is mounted to be movable with respect to the base 108. The platform 110 is cam operated in a conventional manner and urged toward a normal position such that its flat top forming surface 112 is initially above the forming surfaces 114 of the base 108.
The platforrn 110 is mounted for a sliding movement with respect to the base 108 with the entire base 108 being mounted in a conventional manner.
Because the blank is very tightly pressed at the peripheral area, moisture in the paperboard which is driven therefrom during pressing of the heated dies is released by providing a circular groove 120 which vents to the atmosphere throu~ a passageway 122.
Similarly, the top die assembly 102 is segmented into a circular ring portion 124 and a central platform 126 having a flat forming surface 12~.
The ring portion 124 has complementary forming surfaces 130 which complement the forming surface 114 of the lower die assembly 104. The central platform 126 and ring 124 are slidingly mounted with respect to one another. The forming surface 130 of the upper die assembly further includes deboss elements 132 which are spaced about the periphery of the ' 214~6~
.
g portion of the fo~ming surface 130 which forrns the planar region 24 of the papelboard container. The significance of such debossing elements will be explained in greater detail h~reinbelow Further, it should be noted that the debossing elements may be formed at any position along the forming surface 130 or may even be formed on the planar surface 12~ of the platform 126.
In the pressing operation, the blank 106 is first laid upon the flat forming surface 112 of the platform 110, generally underlying what is to be the inner generally planar region 12 of the paperboard container.
Initially, the surface 128 of the platform 126 contacts an upper surface of the paperboard blank 106 to hold the blank in place as the forming operation begins. Further downward movement of the upper die assembly 102 brings the sprin~ biased forming surface 130 of the outer ring 124 into contact with the edges of the blank 106 to begin to shape the edges of the blank over the underlying surfaces 114 in the areas which will define the side wall 11, planar region 24 and lip 26 of the paperboard container 10.
Eventua~ly, the upper die assembly 102 moves sufficiently far down so that the platforms 110 and 126 and the ring 124 are fully compressed such that the adjacent por~ions of the forming surfaces 128 and 130 are co-planar and the adjacent portions of forming surfaces 112 and 114 are co-planar. The upper die assembly 102 then continues to move downwardly and thus drives the entire lower d;e assembly 104 downwardly against the force of springs (not shown) which support the lower die assembly 104. At the full extent of the downward stroke of the upper die assembly 102, the die exert a force on one another through the formed blank 106. Further, the embossing elements 132 are pressed into an upper surface of the planar region 124 of 2146!~9~
. ~,~", the paperboard blank 106 thus forming a decorative pattern in the desired region of the paperboard container.
In order to aid in the forrnation of the paperboard container, the upper and lower die assemblies 102 and 104 are maintained at a temperature in the range of 200~ F to 400~ F and preferably in the range of 250~ F to 350~ F. Further, during the formation step, the upper and lower die assemblies 102 and 104 are pressed against one another at a pressure in the range of 200 psi to l S00 psi. The paperboard stock used for the blank preferably has a basis weight in the range of 100 pounds to 400 pounds per ream (3,000 sq. ft.) and a thickness or caliper in the range of 0.008 inches to O.OS0 inches. It should be noted, however, that any conventional paperboard stock may be used in forming the paperboard containers in accordance with the present invention.
Referring now to Figures 4, 5 and SA, the present invention is also contemplated for use in paperboard containers formed in accordance with that method set forth ;n U.S. Patent No. 4,721~499 and U.S. Patent No.
S,242, 10~ each of which are assigned to the assignee of the subject invention and hereby incorporated herein by reference. As can be seen from Figure 4, the paperboard container 10 includes a bottom wall 12 upwardly extending side wall 14, first curved section 16 adjoining the side wall 14 to the periphery of the bottom wall 12 and a rim 18 with a curved portion 20 adjoining rim 18 with the periphery of the side wall 14 and a downwardly curved lip 22 outwardly extending from the periphery of the rim 18. Again, the phantom lines in Figure 4 have been provided for ease in identifying the various structural segments of the container and do not represent lines actually appearing on the container. The container further includes a plurality of densified regions 25 radially extending through and 21466~S
circumferentially spaced about the ~nnul~r section of side wall 14, the curved portion 20 and the rim 18. These densified regions are forrned from pleats S0, exaggeratedly represented in Figure 5 including at least three layers 52, 54 and 56 of paperboard material created by score lines during forrning of the container blan~. These pleats are subjected to sufficient pressure to reforrn the fibers of the separate layers 52, 54 and 56 of the paperboard into a cohesive fiber structure having a thickness subst~nti~lly equal to the remaining portion of the paperboard material as is illustrated in ~igure SA.
Reformation of the pleats into a cohesive fibrous structure substantially strengthens the weakest part of the pressed paperboard container. Where the pleats no longer comprise separate layers of the paperboard, there is no tendency for the container to return to its original shape. Indeed, the densified regions resist efforts to flatten the side wall of the rim as such would require increasing the area of the side wall and the rim. In a 9" plate formed in accordance with the present invention, the side wall second curved portion and rim receive a pressure in excess of 500 psi thereby substantially increasing the density in the radially extending densified regions. ~urther, because the decorative pattern is formed substantially simultaneously with the forrnation of the paperboard container, the decorative pattern may intersect the densified regions without significantly affecting the image debossed into the paperboard material.
With prior art decorating processes which print a decorative pattern on the paperboard container, the decorative pattern would become signific~ntly obscured with the formation of the densified regions. Accordingly, with Applicants' invention, a clear and precise decorative pattern can be formed in the rim region of the paperboard container even if such rim includes the 2146~9~
above noted densified regions. While Figures 4 and 5A illustrate the preferred positioning of the decorative pattern, that is, the pattern being formed adjacent th~ de~,ified regions, as discussed hereinabove such positioning is not essential to the formation of the decorative pattern in accordance with the present invention in that the decorative pattern can be integrally formed in the densified regions as well.
While the present invention has been described with reference to preferred embodiments, it will be appreciated by those skilled in the art that the invention may be practiced otherwise than as specifically described herein without departing from the spirit and scope of the invention. It is, therefore, to be understood that the spirit and scope of the invention be limited only by the appended claims.
TNDUSTRIAL APPLICABI~ITY
Containers formed in accordance with the foregoing description may be manufactured by existing manufacturing assemblies with only minor changes being made to the upper die assembly for forming the decorative pattern in an upper surface of a paperboard container. The container set forth hereinabove may be circular as in a plate or bowl, or may be square or rectangular with annular corners such as a tray where it is desired to form a decorative pattern in a portion of the upper surface of the paperboard container.
Additionally, as is discussed in U.S. Patent No. 4,721,499 issued to Marx et al. And assigned to the assignee of the subject invention, it is desirable to form densified regions in the form of cir~;ulllrerelllially spaced pleats formed in the sidewall rim and lip of the container in order to add strength to the overall container structure. In doing so, the pleats often intersect the decorative pattern which has been previously placed on the container resulting in a container which is not aesthetically pleasing to the consumer, particularly if such decorative pattern is a word or a phrase which is obscured by the densified regions.
Accordingly, there is clearly a need for a container having a visible decorative pattern formed thereon which is not obscured by either mi~lignment of the paperboard blank during formation of the container or the formation of densified regions for adding rigidity to the overall container structure. Additionally, there is a need for a decorative paperboard container which can be m~nllf~rtllred in an economical manner wherein the formation of defective containers is minimi7e~1 without sacrificing the time incurred in forming the container. Moreover, this is a need for a container including a decorative surface which is appealing to . :...2 -2146fi~5 ' ,..
th~ consumer and which can be manufactured without the addition of cost~
associated with printing such a decorative pattern.
SUMMARY OF THF INVFN-llON
It is the primary object of the present invention to overcome the above noted shortcomings associated with prior art paperboard containers and their method of manufacture.
A further object of the present invention is to provide a decorative paperboard container which can be manufactured in an economical manner without adding to the steps of present manufacturing processes.
Yet another object of the present invention is to reduce the overall manufacturing costs associated with the formation of decorative paperboard containers by reducing the number of defectively formed containers.
An additional object of the present invention is to provide a method of manufacturing paperboard containers wherein the overall strength of the paperboard container is increased without destroying the decorative formation on the paperboard containers.
An additional object of the present invention is to provide a paperboard container which is manufactured at a reduced cost and which includes a decorative pattern which is not obscured during the process of forming such a container.
Yet another object of the present invention is to form a paperboard container wherein the decorative aspects of the container are formed substantially simultaneously with the formation of the container from a substantially flat paperboard blank.
A further object of the present invention is to provide a proc~ess for manufacturing decorative paperboard containers while reducing the 21~669~
_ - 4 -necessary steps of present manufacturing process thus reducing overall manufacturing costs.
These as well as additional objects of the present invention are achieved by forrning a paperboard container by initially forming a flat paperboard blank having an outer periphery and positioning the blank between an upper and lower die assembly with the surfaces of the upper and lower die assemblies defining a finished container including a bottom wall, side wall, a planar rim substantially parallel to the bottom wall and a lip extending from a periphery of the planar rim with at least one of the upper and lower die assemblies including an element for forming a decorative pattern in at least the planar rim portion of the container and subsequently pressing the die assembly surfaces together to form the container having the decorative panern integrally formed in the planar rim portion of the container. The container is formed from a blank that includes a substantially planar inner region, a side wall region including a generally annular side wall extending upwardly from a periphery of the planar inner region and the rim region extending generally outwardly from a periphery of the side wall region with the rim region including a decorative panern formed integrally therein. The container may also include a plurality of circumferentially spaced densified regions radially extending through the rim region with the densified regions including substantially three layers of paperboard material. In such a case, the decorative pattern which is debossed into an upper surface of the rim region may be intersected by the radially extending densified regions without obscuring the decorative pattern.
These as well as additional advantages will become apparent from the following detailed description when read in light of the several figures.
214663~
~!
BE~F nFSCl~llON OF THF DRA~NGS
Figure 1 is a top view of a paperboard container formed in accordance with the present invention.
Figure 2 is a cross sectional view t~cen along line 2-2 of Figure 1.
Figure 3 is a cross sectional view of the upper and lower die assemblies for forrning a paperboard container in accordance with the present invention.
Figure 4 is a cross sectional perspective view of a paperboard container forrned in accordance with an alternative embodiment of the present invention.
Figure 5 is a cross sectional view of a blank for forming the container of the present invention before such fonning process.
Figure 5A is a cross sectional view ta~en along line 5-5 of Figure 4.
DETArLED DESCR~PTION OF THE PREFERRED EMBODIM~NTS
Reference will now be made in detail to the preferred embodiment of the present invention, an example which is set forth in the above noted drawings. In accordance with the present invention, the paperboard container comprises a substantially planar inner region, a side wall region and a rim region adjoined to and extend;ng about the periphery of the planar region. The container of the present invention may be formed into a plate or bowl thus having a circular configuration or such container may be square or rectangular in shape having angular corners such as a tray.
Further, additional shapes are contemplated including compartmented trays and plates as well as oval platters. In each of the contemplated embodiments, the container includes a rim region having at least one substantially planar portion.
- 214~6~5 As illustrated in Figure 1, the container 10 includes a substantially planar inner region 12 which is surrounded about its periphery by side wall region 11 and adjoining rim region 13. The side wall region 11 includes a generally annular region 14 which flares upwardly and outwardly from a periphery of the planar inner region 12 and a first frusto-conical region 16 which slopes upwardly and outwardly from a periphery of the annular region 14. These features being illustrated in detail in Figure 2. In the rim region 13, outwardly flaring arcuate annular region 18 adjoining an outer periphery of the frusto-conical region 16 is provided with: first portion 20 thereof extending generally upwardly from the first frusto-conical region 16; and a second portion 22 thereof flaring generally outwardly from the annular region 18. A substantially planar region 24 extends substantially tangentially from the second portion 22 of the arcuate annular region 18 and thus extends outwardly from such second portion 22 of the arcuate annular region 18. The planar region 24 may be slightly inclined with respect to the substantially planar inner region 12, however, the region 24 is preferably inclined slightly downwardly in order to add strength to the rim portion of the container. Adjoining the outer periphery of the planar region 24 is an outwardly and downwardly flaring frusto-conical lip 26 which both adds significantly to the strength of the container and aids the consumer in grasping the periphery of the container 10 With reference to Figure 4, the phantom lines 28, 30, 32, 34 and 36 are provided for ease in identifying the various structural segments of the container and do not represent lines actually appearing on the container.
Moreover, the phantom lines do not represent actual demarcations between the sections in that, as explained in greater detail hereinbelow the size relationships between the segments may vary without departing from the 214~9~
spirit and scope of the present invention. Additionally, as is illustrated in Figure 2, the container is forrned from an integral unitary paperboard blank.
As can be seen from Figure l, the paperboard container 10 includes a decorative pattern about planar region 24 with this decorative pattern including alternating shells and scrolls. It should be appreciated that the particular decorative pattern is not of importance with respect to the subject invention but merely the manner in which the decorative pattern is created.
This decorative pattern may be any suitable configuration or may be words or slogans formed about the periphery of the container. As will be discussed in greater detail hereinbelow, the decorative pattern is integrally forrned in the planar region 24 of the paperboard container lO as is illustrated in Figure 2. The debossed regions 40 are formed substantially simultaneously with the formation of the remaining portions of the container. That is, during the formation of the side wall reg;on 11, planar region 24 and lip 26, a decorative pattern formed in the forming die debosses the planar region of ~he paperboard container with any desired decorative pattern. It should be noted that while the decorative pattern is illustrated as being formed in the planar region 24 of the paperboard container 10, such decorative pattern may be simultaneously formed in other regions of the paperboard container as well.
Referring now to ~igure 3, a die assembly for forming the paperboard container in a manner set forth hereinabove is illustrated in detail. A die assembly 100 includes an upper die assembly 102 and a lower die assembly 104. Typically, the lower die assembly 104 is maintained in a substantially stationary position while the upper die assembly 102 is pressed into contact with an upper surface of a paperboard blank plac~d 21~66~
therebetween. However, it is possible with this arrangement to move the di~ assemblies in any manner so long as the paperboard blan~ is sufficiently formed into a paperboard container.
As discussed hereinabove, the upper die assembly 102 and lower die assembly 10~ are utilized to press a flat circular paperboard blank 106 into the shape of the paperboard container 10. The construction of the upper and lower die assemblies and the equipment which is utilized to maneuver such assemblies is substantially conventional. To facilitate the holding and shaping of the blank 106, the dies are segmented in the manner shown.
The lower die assembly 104 includes a circular base portion 108 and a central circular platform 110 which is mounted to be movable with respect to the base 108. The platform 110 is cam operated in a conventional manner and urged toward a normal position such that its flat top forming surface 112 is initially above the forming surfaces 114 of the base 108.
The platforrn 110 is mounted for a sliding movement with respect to the base 108 with the entire base 108 being mounted in a conventional manner.
Because the blank is very tightly pressed at the peripheral area, moisture in the paperboard which is driven therefrom during pressing of the heated dies is released by providing a circular groove 120 which vents to the atmosphere throu~ a passageway 122.
Similarly, the top die assembly 102 is segmented into a circular ring portion 124 and a central platform 126 having a flat forming surface 12~.
The ring portion 124 has complementary forming surfaces 130 which complement the forming surface 114 of the lower die assembly 104. The central platform 126 and ring 124 are slidingly mounted with respect to one another. The forming surface 130 of the upper die assembly further includes deboss elements 132 which are spaced about the periphery of the ' 214~6~
.
g portion of the fo~ming surface 130 which forrns the planar region 24 of the papelboard container. The significance of such debossing elements will be explained in greater detail h~reinbelow Further, it should be noted that the debossing elements may be formed at any position along the forming surface 130 or may even be formed on the planar surface 12~ of the platform 126.
In the pressing operation, the blank 106 is first laid upon the flat forming surface 112 of the platform 110, generally underlying what is to be the inner generally planar region 12 of the paperboard container.
Initially, the surface 128 of the platform 126 contacts an upper surface of the paperboard blank 106 to hold the blank in place as the forming operation begins. Further downward movement of the upper die assembly 102 brings the sprin~ biased forming surface 130 of the outer ring 124 into contact with the edges of the blank 106 to begin to shape the edges of the blank over the underlying surfaces 114 in the areas which will define the side wall 11, planar region 24 and lip 26 of the paperboard container 10.
Eventua~ly, the upper die assembly 102 moves sufficiently far down so that the platforms 110 and 126 and the ring 124 are fully compressed such that the adjacent por~ions of the forming surfaces 128 and 130 are co-planar and the adjacent portions of forming surfaces 112 and 114 are co-planar. The upper die assembly 102 then continues to move downwardly and thus drives the entire lower d;e assembly 104 downwardly against the force of springs (not shown) which support the lower die assembly 104. At the full extent of the downward stroke of the upper die assembly 102, the die exert a force on one another through the formed blank 106. Further, the embossing elements 132 are pressed into an upper surface of the planar region 124 of 2146!~9~
. ~,~", the paperboard blank 106 thus forming a decorative pattern in the desired region of the paperboard container.
In order to aid in the forrnation of the paperboard container, the upper and lower die assemblies 102 and 104 are maintained at a temperature in the range of 200~ F to 400~ F and preferably in the range of 250~ F to 350~ F. Further, during the formation step, the upper and lower die assemblies 102 and 104 are pressed against one another at a pressure in the range of 200 psi to l S00 psi. The paperboard stock used for the blank preferably has a basis weight in the range of 100 pounds to 400 pounds per ream (3,000 sq. ft.) and a thickness or caliper in the range of 0.008 inches to O.OS0 inches. It should be noted, however, that any conventional paperboard stock may be used in forming the paperboard containers in accordance with the present invention.
Referring now to Figures 4, 5 and SA, the present invention is also contemplated for use in paperboard containers formed in accordance with that method set forth ;n U.S. Patent No. 4,721~499 and U.S. Patent No.
S,242, 10~ each of which are assigned to the assignee of the subject invention and hereby incorporated herein by reference. As can be seen from Figure 4, the paperboard container 10 includes a bottom wall 12 upwardly extending side wall 14, first curved section 16 adjoining the side wall 14 to the periphery of the bottom wall 12 and a rim 18 with a curved portion 20 adjoining rim 18 with the periphery of the side wall 14 and a downwardly curved lip 22 outwardly extending from the periphery of the rim 18. Again, the phantom lines in Figure 4 have been provided for ease in identifying the various structural segments of the container and do not represent lines actually appearing on the container. The container further includes a plurality of densified regions 25 radially extending through and 21466~S
circumferentially spaced about the ~nnul~r section of side wall 14, the curved portion 20 and the rim 18. These densified regions are forrned from pleats S0, exaggeratedly represented in Figure 5 including at least three layers 52, 54 and 56 of paperboard material created by score lines during forrning of the container blan~. These pleats are subjected to sufficient pressure to reforrn the fibers of the separate layers 52, 54 and 56 of the paperboard into a cohesive fiber structure having a thickness subst~nti~lly equal to the remaining portion of the paperboard material as is illustrated in ~igure SA.
Reformation of the pleats into a cohesive fibrous structure substantially strengthens the weakest part of the pressed paperboard container. Where the pleats no longer comprise separate layers of the paperboard, there is no tendency for the container to return to its original shape. Indeed, the densified regions resist efforts to flatten the side wall of the rim as such would require increasing the area of the side wall and the rim. In a 9" plate formed in accordance with the present invention, the side wall second curved portion and rim receive a pressure in excess of 500 psi thereby substantially increasing the density in the radially extending densified regions. ~urther, because the decorative pattern is formed substantially simultaneously with the forrnation of the paperboard container, the decorative pattern may intersect the densified regions without significantly affecting the image debossed into the paperboard material.
With prior art decorating processes which print a decorative pattern on the paperboard container, the decorative pattern would become signific~ntly obscured with the formation of the densified regions. Accordingly, with Applicants' invention, a clear and precise decorative pattern can be formed in the rim region of the paperboard container even if such rim includes the 2146~9~
above noted densified regions. While Figures 4 and 5A illustrate the preferred positioning of the decorative pattern, that is, the pattern being formed adjacent th~ de~,ified regions, as discussed hereinabove such positioning is not essential to the formation of the decorative pattern in accordance with the present invention in that the decorative pattern can be integrally formed in the densified regions as well.
While the present invention has been described with reference to preferred embodiments, it will be appreciated by those skilled in the art that the invention may be practiced otherwise than as specifically described herein without departing from the spirit and scope of the invention. It is, therefore, to be understood that the spirit and scope of the invention be limited only by the appended claims.
TNDUSTRIAL APPLICABI~ITY
Containers formed in accordance with the foregoing description may be manufactured by existing manufacturing assemblies with only minor changes being made to the upper die assembly for forming the decorative pattern in an upper surface of a paperboard container. The container set forth hereinabove may be circular as in a plate or bowl, or may be square or rectangular with annular corners such as a tray where it is desired to form a decorative pattern in a portion of the upper surface of the paperboard container.
Claims (25)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of forming a paperboard container comprising:
forming a flat paperboard blank having an outer periphery from a sheet of paperboard material;
forming said blank into a paperboard container having a bottom wall and a rim region with a sidewall extending therebetween; and forming a debossed portion in said rim region substantially simultaneously with the formation of said blank into said container.
forming a flat paperboard blank having an outer periphery from a sheet of paperboard material;
forming said blank into a paperboard container having a bottom wall and a rim region with a sidewall extending therebetween; and forming a debossed portion in said rim region substantially simultaneously with the formation of said blank into said container.
2. The method as defined in claim 1, wherein said debossed portion comprises a plurality of individual debossed elements substantially mutually spaced about said rim region.
3. The method as defined in claim 1, further comprising forming a plurality of radially extending densified regions in said rim region of the container.
4. The method as defined in claim 1, wherein said debossed portion is integrally formed in an upper surface of said rim region.
5. The method as defined in claim 1, wherein said paperboard blank has a basis weight in the range of from 150 to 300 pounds per 3,000 square foot ream paperboard material.
6. The method as defined in claim 3, wherein said plurality of radially extending densified regions are cicumferentially spaced and comprise substantially three layers of paperboard material.
7. The method as defined in claim 6, wherein a thickness of said densified regions is substantially equal to a thickness of circumferentially adjacent portions of said rim region.
8. The method as defined in claim 6, wherein said densified regions are formed adjacent said debossed portion formed in said rim region.
9. The method as defined in claim 1, wherein said paperboard container is formed by a press having upper and lower die assemblies, surfaces of said upper and lower die assemblies defining a finished container including a bottom wall, a side wall, a planar rim substantially parallel to said bottom wall, and a lip extending from a periphery of said planar rim with at least one of said upper and lower die assemblies comprising a deboss forming element.
10. The method as defined in claim 9, wherein said deboss forming element includes a plurality of debossing elements extending from the surface of said upper die assembly.
11. The method as defined in claim 9, further comprising maintaining a temperature of at least one of said die surfaces in a range of from 200°F to 400°F.
12. The method as defined in claim 11, wherein the temperature of said at least one of said die surfaces is in the range of from 250°F to 350°F.
13. The method as defined in claim 9, wherein said die assembly surfaces are pressed together by applying a pressure in a range of from 200 psi to 1500 psi.
14. A method of forming a paperboard container comprising:
providing a flat paperboard blank having an outer periphery;
providing a press having upper and lower die assemblies, surfaces of said upper and lower die assemblies defining a finished container including a bottom wall, a side wall, a planar rim substantially parallel to said bottom wall and a lip extending from a periphery of said planar rim with at least one of said upper and lower die assemblies including a means for forming a decorative pattern in at least said planar rim;
positioning said blank between said die assembly surfaces; and pressing said die assembly surfaces together to form the container having a decorative pattern debossed in said planar rim.
providing a flat paperboard blank having an outer periphery;
providing a press having upper and lower die assemblies, surfaces of said upper and lower die assemblies defining a finished container including a bottom wall, a side wall, a planar rim substantially parallel to said bottom wall and a lip extending from a periphery of said planar rim with at least one of said upper and lower die assemblies including a means for forming a decorative pattern in at least said planar rim;
positioning said blank between said die assembly surfaces; and pressing said die assembly surfaces together to form the container having a decorative pattern debossed in said planar rim.
15. The method as defined in claim 14, wherein said means for forming a decorative pattern includes a plurality of decorative debossing elements extending from the surface of said upper die assembly.
16. The method as defined in claim 14, wherein further including the step of maintaining a temperature of at least one of said die surfaces in a range of 200°F to 400°F.
17. The method as defined in claim 16, wherein the temperature of said at least one of said die surfaces is in the range of 250°F to 350°F.
18. The method as defined in claim 14, wherein the step of pressing said die assembly surfaces together includes applying a pressure in a range of 200 psi to 1500 psi.
19. The method as defined in claim 14, wherein said paperboard blank has a basis weight in the range of 150 to 300 pounds per 3,000 sq. ft. ream paperboard material.
20. A method of forming a paperboard container comprising:
forming a flat paperboard blank having an outer periphery from a sheet of paperboard material;
forming said blank into a paperboard container having a bottom wall and a rim region with a side wall extending therebetween; and forming decorative means for defining a decorative pattern in said blank adjacent said outer periphery, said decorative means being integrally formed in said rim region.
forming a flat paperboard blank having an outer periphery from a sheet of paperboard material;
forming said blank into a paperboard container having a bottom wall and a rim region with a side wall extending therebetween; and forming decorative means for defining a decorative pattern in said blank adjacent said outer periphery, said decorative means being integrally formed in said rim region.
21. The method as defined in claim 20, wherein said decorative means includes a plurality of individual decorative debossed elements substantially mutually spaced about said rim region.
22. The method as defined in claim 20, further comprising the step of forming a plurality of radially extending densified regions in said rim region of the container.
23. A method of forming a paperboard container comprising:
forming a flat paperboard blank having an outer periphery from a sheet of paperboard material;
forming said blank into a paperboard container having a bottom wall and a rim region with a sidewall extending therebetween; and integrally forming decorative means in said rim region for defining a decorative pattern substantially simultaneously with the formation of said blank into said container.
forming a flat paperboard blank having an outer periphery from a sheet of paperboard material;
forming said blank into a paperboard container having a bottom wall and a rim region with a sidewall extending therebetween; and integrally forming decorative means in said rim region for defining a decorative pattern substantially simultaneously with the formation of said blank into said container.
24. The method as defined in claim 23, wherein said decorative means includes a plurality of individual decorative debossed elements substantially mutually spaced about said rim region.
25. The method as defined in claim 23, further comprising the step of forming a plurality of radially extending densified regions in said rim region of the container.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US22608194A | 1994-04-11 | 1994-04-11 | |
| US08/226,081 | 1994-04-11 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2146695A1 CA2146695A1 (en) | 1995-10-12 |
| CA2146695C true CA2146695C (en) | 1998-09-22 |
Family
ID=22847474
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002146695A Expired - Lifetime CA2146695C (en) | 1994-04-11 | 1995-04-11 | Decorative debossed rigid paperboard container and method of forming the same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2146695C (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113047084A (en) * | 2021-03-31 | 2021-06-29 | 中荣印刷集团股份有限公司 | Hot press molding process of paper tray |
-
1995
- 1995-04-11 CA CA002146695A patent/CA2146695C/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| CA2146695A1 (en) | 1995-10-12 |
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| EEER | Examination request | ||
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Effective date: 20150527 |