Dixie Consumer Products LLC

Fort James Corporation

Gpcp IP Holdings LLC

Albert D Johns

Mark B Littlejohn

Mircea T Sofronie

Thomas W Zelinski

Gerald John Van Handel

Michael A Breining

William R Pucci

Alois A Schmidtner

Richard J Rogers

Kenneth J Zirbel

Luke G Stumpf

Paul J England

Grigory I Grischenko

Jay S Lester

Erik J Sjogren

Bruce R Smith

Stephen K Milligan

Gary J Reif

Thomas W Zelinksi

Georganne Shirk

Mircea Sofronie

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 &#x3b1; 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 &#x3b2; of at least about 25 degrees with respect to the downwardly sloping brim portion of the flange.

Pressed paperboard servingware with improved rigidity and rim stiffness

A die assembly for producing paperboard pressware includes an obliquely angled, continuous ring, and/or annular stop member between an inner die member and an outer die ring. Increased surface area of contact between stop components provides greater wear resistance, and the angled contact face maintains alignment of the die components.

Forming die assembly with enhanced stop

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.

Pressware forming apparatus, components therefore and methods of making pressware therefrom

An improved apparatus for making pressware features a vacuum belt feeder which accelerates and decelerates a feed blank for controlled insertion into a forming die as well as retainers to limit bounce back of the blank off of forward stops. A pneumatic ejector on the forming ram facilitates product removal.

Apparatus for making paperboard pressware with controlled blank feed

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.

Segmented pressware die set with anti-twist guide keys

A die assembly for producing paperboard pressware includes a lightweight knockout assembly having a long and narrow ejection member positioned within a slotted adapter plate. The provision of a lightweight knockout assembly reduces frictional wear-related maintenance and downtime.

Lightweight knockout for forming die assembly

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.

Disposable servingware containers with flange tabs

A tooling system in a press for forming a product from a blank of material disposed between a punch assembly and a die assembly and a method of using the same. The tooling system comprises a knockout and a bushing. The knockout further comprises a shaft having opposed ends, a plate fixed to one opposed end, and a tapered portion. The bushing is supported by one of the punch and die assemblies and defines a lumen configured to slidably receive the shaft for axial movement between an extended position and a retracted position. The lumen has a tapered receiving section at one end thereof configured to mate with the tapered portion of the knockout when the shaft is in the extended position.

Tooling system

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.

Rotating inertial pin blank stops for pressware die sets

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.

Pressware die set with product ejectors at outer forming surfaces

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. A first cast-in heater is mounted within a recess in the first die and includes a resistor wire embedded within a thermally conductive cast-in material. A second cast-in heater is mounted within a recess in the second die and includes a resistor wire embedded within a thermally conductive cast-in material.

Growing community of inventors

Saylorsburg, PA, United States of America

Albert D Johns