U.S. patent application number 14/261493 was filed with the patent office on 2015-02-26 for tool for forming a three dimensional article or container.
This patent application is currently assigned to Graphic Packaging International, Inc.. The applicant listed for this patent is Graphic Packaging International, Inc.. Invention is credited to Ronald P. Marx, Patrick H. Wnek.
Application Number | 20150053672 14/261493 |
Document ID | / |
Family ID | 38996724 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150053672 |
Kind Code |
A9 |
Wnek; Patrick H. ; et
al. |
February 26, 2015 |
Tool For Forming A Three Dimensional Article Or Container
Abstract
A forming tool assembly and method for forming a cooking
element. The forming tool assembly has an upper tool assembly and a
lower tool assembly that cooperate to shape the cooking element
from an annular cutout.
Inventors: |
Wnek; Patrick H.; (Sherwood,
WI) ; Marx; Ronald P.; (Freemont, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Graphic Packaging International, Inc. |
Atlanta |
GA |
US |
|
|
Assignee: |
Graphic Packaging International,
Inc.
Atlanta
GA
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20140231420 A1 |
August 21, 2014 |
|
|
Family ID: |
38996724 |
Appl. No.: |
14/261493 |
Filed: |
May 1, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12425417 |
Apr 17, 2009 |
8801995 |
|
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14261493 |
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PCT/US2007/081743 |
Oct 18, 2007 |
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12425417 |
|
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60829976 |
Oct 18, 2006 |
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Current U.S.
Class: |
219/730 ;
264/154; 264/320; 72/339; 72/344; 72/358 |
Current CPC
Class: |
A47J 36/027 20130101;
B31B 2100/00 20170801; B31B 50/44 20170801; B31B 2120/70 20170801;
B21D 45/02 20130101; B65D 1/34 20130101; B21D 22/02 20130101; B31B
50/592 20180501 |
Class at
Publication: |
219/730 ; 72/358;
72/344; 72/339; 264/320; 264/154 |
International
Class: |
A47J 36/02 20060101
A47J036/02; B21D 45/02 20060101 B21D045/02; B21D 22/02 20060101
B21D022/02 |
Claims
1. A method of forming a cooking element from an annular cutout
having an inner edge and an outer edge, the method comprising:
providing a tool comprising a first tool assembly and a second tool
assembly, the first and second tool assemblies having a cooperating
clamping feature, obtaining an annular cutout comprising material
to be formed into the cooking element; clamping the annular cutout
between the clamping feature of the first tool assembly and the
second tool assembly; positioning the first and second tool
assemblies in a closed position to press the cutout between the
tool assemblies and form the cutout into the cooking element while
maintaining a portion of the annular cutout comprising the inner
edge in a substantially fixed position.
2. The method of claim 1 wherein the first tool assembly comprises
a nose having an external surface shaped to generally correspond to
at least a portion of the cooking element and the second tool
assembly comprises a cavity block having a recess, the positioning
the first and second tool assemblies comprises pressing the annular
cutout between the nose and the cavity block to form the annular
cutout into the cooking element.
3. The method of claim 2 wherein the second tool assembly comprises
a knockout axially moveable with respect to the cavity block and
having a lip projecting from an external surface of the knockout,
the first tool assembly comprises a groove on the external surface
of the nose, the clamping the annular cutout comprises contacting
the cutout with the external surface of the nose and the lip and
forcing the lip and a portion of the annular cutout into the
groove.
4. The method of claim 3 wherein the clamping the annular cutout
comprises downwardly moving the nose to force the portion of the
annular cutout into the grove and the positioning the first and
second tool assemblies comprises further downwardly moving the nose
to force the annular cutout into the recess and form the annular
cutout into the cooking element.
5. The method of claim 3 wherein the external surface of the
knockout is an axial surface, and the lip comprises an outer radial
edge of the axial surface.
6. The method of claim 1, wherein the inner edge of the annular
cutout defines a center opening.
7. A cooking element formed by the method of claim 1.
8. The cooking element of claim 7 wherein the cooking element has a
flat upper edge portion, a flat lower edge portion, and at least
one curved portion between the upper and lower edge portion.
9. The cooking element of claim 8 wherein the cooking element
comprises a microwave interactive material.
10. A method of forming a cooking element, the method comprising:
obtaining a tool comprising a first tool assembly and a second tool
assembly; cutting an annular cutout from a blank, the annular
cutout having an outer radial edge, an inner radial edge, and an
opening adjacent the inner radial edge; positioning the tool in an
open position wherein the first tool assembly and the second tool
assembly are spaced apart to form a receiving space therebetween;
conveying the annular cutout to the tool in the open position and
placing the cutout between the first and second tool assembly;
closing the tool so that the first and second tool assemblies form
the annular cutout into a cooking ring.
11. The method of claim 10 wherein the first tool assembly
comprises a nose having an external surface shaped to generally
correspond to at least a portion of the cooking element and the
second tool assembly comprises a cavity block having a recess, the
closing the tool comprises pressing the cutout between the nose and
the cavity block to shape the annular cutout into the cooking
element.
12. The method of claim 11 wherein the second tool assembly
comprises a knockout axially moveable with respect to the cavity
block, the closing the tool comprises initially gripping a portion
of the annular cutout between the nose and the knockout prior to
shaping the annular cutout into the cooking element.
13. The method of claim 11 wherein an inner radial edge portion of
the annular cutout is initially gripped between the nose and the
knockout.
14. The method of claim 11 wherein the first tool assembly
comprises a groove on the external surface of the nose and a lip
projecting from an external surface of the knockout, the initially
gripping the portion of the annular cutout comprises contacting the
annular cutout with the external surface of the nose and the lip to
force the lip and a portion of the cutout into the groove.
15. The method of claim 14 wherein the external surface of the
knockout is an axial surface, and the lip comprises an outer radial
edge of the axial surface.
16. The method of claim 11 wherein the initially gripping the
portion of the annular cutout comprises downwardly moving the nose
and the closing the tool comprises further downward movement of the
nose to effect downward movement of the knockout during forming of
the annular cutout into the cooking ring.
17. A cooking element formed by the method of claim 10, wherein the
cooking element has a flat upper edge portion, a flat lower edge
portion, and at least one curved portion between the upper and
lower edge portion.
18. The cooking element of claim 17 wherein the cooking element
comprises a microwave interactive material.
19. A cooking element for heating a food product, the cooking
element comprising a generally annular body comprising a lower edge
portion, an upper edge portion, a curved portion between the lower
and upper edge portions, and an annular groove between the upper
edge portion and the curved portion.
20. The cooking element of claim 19 wherein the upper edge portion
and the lower edge portion are substantially flat.
21. The cooking element of claim 19 wherein the curved portion is a
first curved portion and the body further comprises a second curved
portion.
22. The cooking element of claim 19 wherein the upper edge portion
has an inner radial edge that at least partially defines an opening
in the cooking element.
23. The cooking element of claim 19 wherein the body comprises a
first layer and a second layer, the first layer comprising
paperboard and the second layer comprising a microwave interactive
material.
24. The cooking element of claim 23 wherein the first layer is an
outer layer and the second layer is an inner layer.
25. The cooking element of claim 19 wherein the body comprises
pleats in the curved portion, the pleats respectively comprising
overlapped material of the body that is compressed to strengthen
the cooking element.
26. The cooking element of claim 19 wherein the annular groove is
initially formed in the cooking element to grasp the cooking
element prior to formation of the curved portion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 12/425,417, filed Apr. 17, 2009, which application is a
continuation of PCT Application No. PCT/US2007/081743 filed Oct.
18, 2007, which PCT application claims the benefit of U.S.
Provisional Application No. 60/829,976 filed Oct. 18, 2006.
INCORPORATION BY REFERENCE
[0002] The disclosures of U.S. patent application Ser. No.
12/425,417, which was filed on Apr. 17, 2009,PCT Application No.
PCT/US2007/081743, which was filed on Oct. 18, 2007, and U.S.
Provisional Application No. 60/829,976, which was filed on Oct. 18,
2006, are hereby incorporated by reference for all purposes as if
presented herein in their entirety.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to tools and methods for
forming materials into articles, elements or containers that may be
used to hold, contain, or prepare food products or other
products.
SUMMARY OF THE INVENTION
[0004] In one aspect, the invention is generally directed to a tool
for forming a cooking element form a cutout. The tool has a
clamping feature that holds a portion of the cutout in a fixed
position during formation of the cooking element.
[0005] In another aspect, the invention is generally directed to a
tool for forming a cooking element from a cutout. The tool
comprises a first tool assembly and a second tool assembly. At
least one of the first tool assembly and the second tool assembly
is moveable between an open position wherein the cutout is received
between the first and the second tool assembly and a closed
position wherein the cutout is formed into the cooking element. The
first and the second tool assembly have a cooperating clamping
feature that holds a portion of the cutout in a fixed position
during formation of cooking element.
[0006] In another aspect, the invention is generally directed to a
method of forming a cooking element. The method comprises providing
a tool and a cutout to be formed into the cooking element and
clamping the cutout between a clamping feature of the tool to hold
a portion of the cutout in a fixed position during formation of the
cooking element.
[0007] In another aspect, the invention is generally directed to a
method of forming a cooking element. The method comprises providing
a tool comprising a first tool assembly and a second tool assembly.
The first and second tool assemblies have a cooperating clamping
feature. The method further comprises providing a cutout comprising
material to be formed into the cooking element and clamping the
cutout between the clamping feature of the first tool assembly and
the second tool assembly. The method further comprises positioning
the first and second tool assemblies in a closed position to press
the cutout between the tool assemblies and form the cutout into the
cooking element, while maintaining a portion of the cutout in a
substantially fixed position.
[0008] In another aspect, the invention is generally directed to a
method of forming a cooking element. The method comprises providing
a tool comprising a first tool assembly and a second tool assembly
and cutting an annular cutout from a blank. The annular cutout has
an outer radial edge, an inner radial edge, and an opening adjacent
the inner radial edge. The method further comprises positioning the
tool in an open position wherein the first tool assembly and the
second tool assembly are spaced apart to form a receiving space
therebetween, conveying the annular cutout to the tool in the open
position and placing the cutout between the first and second tool
assembly. The method further comprises closing the tool so that the
first and second tool assemblies form the annular cutout into a
cooking ring.
[0009] In another aspect, the invention is generally directed to a
cooking element for heating a food product. The cooking element
comprises a generally annular body comprising a lower edge portion,
an upper edge portion, a curved portion between the lower and upper
edge portions, and an annular groove between the upper edge portion
and the curved portion.
[0010] In another aspect, the invention is generally directed to a
cooking element formed from any of the various methods as shown
and/or described herein.
[0011] In another aspect, the invention is generally directed to a
cooking element formed from a forming tool having any of the
various features shown and/or described herein.
[0012] Those skilled in the art will appreciate the above stated
advantages and other advantages and benefits of various additional
embodiments reading the following detailed description of the
embodiments with reference to the below-listed drawing figures.
[0013] According to common practice, the various features of the
drawings discussed below are not necessarily drawn to scale.
Dimensions of various features and elements in the drawings may be
expanded or reduced to more clearly illustrate the embodiments of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a top plan view of an annular cutout used to form
a cooking element of an exemplary embodiment of the present
invention.
[0015] FIG. 2 is a bottom plan view of the annular cutout of FIG.
1.
[0016] FIG. 3 is a schematic of the cooking element formed from a
forming tool of an exemplary embodiment of the present
invention.
[0017] FIG. 3A is a cross-section including the plane 3A-3A of FIG.
3.
[0018] FIG. 4 is a schematic of the cooking element of FIG. 3.
[0019] FIG. 5 is a cross-section of the forming tool in a closed
position.
[0020] FIG. 6 is an enlarged portion of FIG. 5.
[0021] FIG. 7 is a perspective of an upper tool assembly of the
forming tool.
[0022] FIG. 8 is a cross-section of the upper tool assembly.
[0023] FIG. 9 is a cross-section of a lower tool assembly of the
forming tool.
[0024] FIG. 10 is a perspective of the lower tool assembly.
[0025] FIG. 11A-11C are enlarged portions of the forming tool
showing various stages of formation of the cooking element from the
annular cutout.
[0026] Corresponding parts are designated by corresponding
reference numbers throughout the drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0027] The present invention relates generally to various aspects
of materials, packages, elements, articles, containers and methods
of making such materials, packages, elements, articles and
containers. Although several different inventions, aspects,
implementations, and embodiments of the various inventions are
provided, numerous interrelationships between, combinations
thereof, and modifications of the various inventions, aspects,
implementations, and embodiments of the inventions are contemplated
hereby. In one illustrated embodiment, the present invention
relates to forming a heating or cooking element for microwave
cooking of food items. However, in other embodiments, the invention
can be used to form articles or containers not used for microwave
cooking.
[0028] FIG. 3 is a perspective view of a cooking element in the
form of a cooking ring, generally indicated at 1, used to cook a
food product (not shown) such as a frozen pizza. The cooking ring 1
is formed from an annular cutout 5 (FIGS. 1 and 2) that is cut from
a paperboard blank (not shown) having at least one layer of
microwave interactive material 9 (FIG. 2) attached thereto (e.g.,
covering an entire interior surface 29 of the cutout). In
accordance with the exemplary embodiment of the present invention,
the microwave interactive material 9 is, or at least includes, a
susceptor, although other types and various combinations of
microwave interactive elements are also within the scope of the
present invention, as will be discussed in greater detail below. As
will be discussed below in more detail, the cooking ring 1 is
shaped from the annular cutout 5 by a forming tool assembly,
generally indicated at 15 (FIG. 6).
[0029] As shown in FIGS. 1 and 2, the annular cutout 5 has an outer
radial edge 19 and an inner radial edge 21 defining a center
opening 23. The cutout 5 has a plurality of radially directed
uniformly spaced score lines 27 that are typically formed on the
interior surface 29 of the cutout in a manner so that the integrity
of the microwave interactive material 9 is maintained or at least
substantially maintained. In the illustrated embodiment the score
lines 27 extend from the outer radial edge 19 of the cutout 5 to a
location radially spaced from the inner radial edge of the 21. The
score lines 27 create weak areas within the paperboard. The weak
areas facilitate the shaping and forming of the annular cutout 5
into the cooking ring 1 by a die-forming process using the forming
tool 15 of the present invention. Nonetheless, the score lines 27
may possibly be omitted.
[0030] As shown in FIGS. 3 and 4, the cooking ring 1 has a
generally flat, lower circumferential edge portion 35, a first
curved portion 37 extending axially upward from the lower
circumferential edge portion, a second curved portion 41 extending
axially upward from the first curved portion, and a generally flat,
upper circumferential edge portion 45 extending radially inward
from the second curved portion. The upper edge portion 45 has an
annular groove 47 (FIG. 3A) adjacent the second curved portion 41.
The cooking ring 1 has an opening 51 defined by an inner radial
edge 53 that generally corresponds to the opening 23 of the annular
cutout 5. During formation of the cooking ring 1 from the annular
cutout 5, the weak areas in the paperboard at the score lines 27 of
the cutout cause the accumulation of excess paperboard into folds
or pleats 49 which are then compressed to strengthen the cooking
ring. The pleats 49 allow portions of the paperboard material to
overlap and bend during the forming process to form the desired
cross-sectional shape of the cooking ring 1.
[0031] FIG. 5 is a sectional view of the forming tool 15 used to
form a three-dimensional article or container such as the cooking
ring 1. In the illustrated embodiment, the tool 15 includes an
upper (first) tool assembly 61 and a lower (second) tool assembly
63. The upper and lower tool assemblies 61 and 63 are independently
moveable in the vertical direction Z along a central axis A1 of the
assembly to form the annular cutout 5 into the cooking ring 1. It
is understood that the upper and lower tool assemblies 61, 63 are
moved in the vertical direction Z from the position shown in FIG. 5
to form a gap between the assemblies so that an annular cutout 5
traveling in the horizontal direction X is located between the
upper and lower tool assemblies prior to the forming process.
[0032] As shown in FIGS. 6 and 8, the upper tool assembly 61 has an
nose 67 with a flat axial end surface 71 forming a first axial end
73 of the upper tool assembly. As shown in FIG. 7, the axial end 73
includes an annular groove 77 generally adjacent a first curved
radial surface 81 of the nose 67. In the illustrated embodiment,
the annular groove 77 has a square cross-sectional shape, but it is
understood that the groove could have other shapes and be otherwise
located. The nose 67 has a second curved radial surface 85 that is
adjacent to an angled conical surface 89 of the nose. A cylindrical
shaft 93 (FIG. 5) of the nose 67 is received in a guide bushing 95
of the upper tool assembly 61. In the illustrated embodiment, the
upper tool assembly 61 includes a shim 99 on a flange 103 connected
to the cylindrical shaft 93. The shim 99 and flange 103 limit the
downward travel of the nose 67 by contact with the axial end
surface 105 of the guide bushing 95. The thickness of the shim 99
can be changed to affect the distance of travel of the nose 67.
[0033] The upper tool assembly 61 includes a punch 109 having an
axial end 111 that includes a radially outer, angled surface 115
(FIG. 6) and a radially inner, flat annular surface 119 (FIG. 8).
The punch 109 has an axial opening 123 that receives the guide
bushing 95 and cylindrical shaft 93 of the nose 67. The punch 109
has a cylindrical recess 127 in the flat annular surface 119 that
receives a coil spring 131 for applying a force against the nose
67. During downward travel of upper tool assembly 61, the spring
131 optionally allows the nose 67 to be spaced apart from the punch
109 to accommodate bulging of the annular cutout 5 when the score
lines 27 are overlapped to form the cooking ring 1. Alternatively,
the upper tool assembly 61 can be configured so that the nose 67
travels in unison with the punch 90. The nose 67 can be fixedly
attached to the punch 109 or the nose and the punch can combined
into a single component for use in forming the cooking element 1
without departing from the invention. In some embodiments of the
invention, additional shims 99 may be added to limit the downward
travel of the nose 67 so that the nose and the punch 109 move
together (e.g., with the conical surface 89 (FIG. 6) of the nose in
contact with the angled surface 115 of the punch). In some
embodiments, operation of the upper tool assembly with the nose 67
and punch 109 moving together in unison may be beneficial to reduce
wear within the forming tool 15.
[0034] The upper tool assembly 61 includes a clamp ring 135
attached to an outer radial surface 139 of the punch 109 by
radially directed fasteners (not shown). The clamp ring 135 is
attached to a base plate 143 by axially directed fasteners (not
shown). The base plate 143 has an axial opening 145 for receiving
the cylindrical shaft 93 of the nose 67 and the guide bushing 95.
Support brackets 153, 155 are attached to the clamp ring 135 on
respective opposite sides of the clamp ring. As shown in FIGS. 7
and 8, the upper tool assembly 61 includes an insulator sheet 163
attached to the outer axial end surface of the base plate 143. A
heater 167 is connected to the base plate 143 for heating the upper
tool assembly 61. The upper tool assembly 61 includes an actuator
(e.g., air cylinders, springs, or other actuating device(s) not
shown) respectively connected to each of the brackets 153, 155 for
activating the clamp ring 135.
[0035] As shown in FIGS. 5, 9, and 10, the lower tool assembly 63
includes a generally cylindrical cavity block or cavity 175 having
an upper recess 179 with a radial shape to correspond with the
shape of the cooking ring 1. The cavity block 175 has a generally
cylindrical lower recess 183 (FIG. 9), an upper axial end surface
187, and a lower axial end surface 191. The upper recess 179 has an
upper curved radial surface 195 adjacent the axial end surface 187
of the cavity block 175 and corresponding with the shape of the
first curved portion 37 of the cooking ring 1. A lower curved
radial surface 199 extends downward from the upper curved surface
195 and corresponds with the shape of the second curved portion 41
of the cooking ring 1. The cavity 175 can include radially directed
vent holes (not shown) passing from an outer radial surface 201 of
the cavity to the upper recess 179 to facilitate venting during
formation of the cooking ring 1.
[0036] A knockout 205 is received in the lower recess 183 of the
cavity block 175 and has a flat upper axial surface 209 that abuts
the lower edge of the upper recess 179 at the closed position of
the lower tool assembly 63 (FIGS. 5 and 9). The knockout 205
includes a generally cylindrical head 217 having a cylindrical
shaft 225 received in a guide bushing 229 and extending axially
from the cavity block 175. As shown in FIG. 6, the cylindrical head
217 includes a lip 233 (broadly "projection") forming the outer
radial edge of the axial surface 209 of the knockout 205. The head
217 has spaced apart axial openings 237 spaced radially inward from
the lip 233. The lip 233 facilitates clamping of the annular cutout
5 between the upper tool assembly 61 and lower tool assembly 63
during operation of the forming tool 15. The axial openings 237
create low-pressure cavities on the axial surface 209 of the
knockout 205 that grip the annular cutout 5 by receiving portions
of the annular cutout and prevent the cutout from sliding during
formation of the cooking ring 1. The axial openings 237 in the
knockout 205 can be otherwise shaped and/or omitted without
departing from the scope of this invention.
[0037] A base plate 241 is attached to the lower axial surface 191
of the cavity block 175 and has an axial opening 245 that receives
the guide bushing 229 and shaft 225 of the knockout 205. An
insulator sheet 249 is attached to an axial end surface 251 of the
base plate 241 and a heater 257 extends from an external radial
surface 261 of the base plate for heating the lower tool assembly
63. A fitting 263 is attached to the cylindrical shaft 225 of the
knockout 205 by a threaded connection between an upper portion 267
of the fitting and an inner surface 271 of an axial recess 275 in
the lower end of the shaft. In the illustrated embodiment, a bolt
281 is threadably attached to a lower end of the fitting 263. When
the lower tool assembly 63 is assembled for operation, the bolt 281
is removed and an actuator (e.g., air cylinder, not shown) is
optionally attached to the fitting 263 to provide an actuating
force to knockout 205. Alternatively, the lower tool assembly 63
could be fixedly mounted to a support (not shown) and the upper
tool assembly 61 could be connected to an actuator for movement
relative to the lower tool assembly.
[0038] The lower tool assembly 63 includes a blank support plate
293 supported on the base plate 241 by a table spacer 297 (FIG. 9).
The blank support plate 293 is positioned so that an upper surface
301 of the plate supports the annular cutout 5 prior to the cutout
being positioned on the upper axial surface 187 and above the upper
recess 179 of the cavity block 175. The lower tool assembly 63 has
two blank guides 305, 307 attached to opposite sides of the support
plate 293. The blank guides 305, 307 (FIG. 10) each extend upward
from the cavity block 175 and the support plate 293 so as to guide
the annular cutout 5 into position between the upper and lower tool
assemblies 61, 63 of the forming tool 15.
[0039] A method of forming the cooking ring 1 from annular cutout 5
is described below. The cooking ring 1 of the present invention is
formed from the annular cutout 5 by feeding the cutout into the
forming tool assembly 15 and operating the assembly to press and
shape the cutout into the forming ring. FIGS. 11A-11C show the
fully open, partially closed, and fully closed positions of the
upper and lower tool assemblies 61, 63 and corresponding
progression of the formation of the cooking ring 1 from the annular
cutout 5. The forming tool assembly 15 is positioned downstream
from a cutting die (not shown) that cuts the annular cutout 5 from
a blank of material such as paperboard having microwave interactive
material 9 attached thereto. The annular cutout 5 can be moistened
to facilitate forming of the cooking ring 1. After the upper tool
assembly 61 and lower tool assembly 63 have been separated from the
position shown in FIG. 6, the annular cutout 5 is slid across the
blank support plate 293 with its radial outer portion supported by
the upper axial surface 187 of the cavity block 175 and its radial
inner portion positioned above the upper recess 179 of the lower
tool assembly 63. The annular cutout 5 is guided to the proper
position on the lower tool assembly 63 by the blank guides 305, 307
attached to the sides of the blank support plate 293. A conveying
mechanism, such as a conveyor belt or other suitable material
handling mechanism, conveys the cutout to the proper position
between the upper tool assembly 61 and lower tool assembly 63. At
the fully open position of the upper and lower tool assemblies 61,
63 (FIG. 11A), the cutout 5 is supported by the axial end surface
187 of the cavity block 175 and the lip 233 of the knockout 205. As
shown in FIG. 11A, the knockout 205 has been raised relative to the
cavity block 175 so that the top surface of the lip 233 is
approximately level with the axial end surface 187 of the cavity
block.
[0040] After the cutout 5 is positioned above the upper recess 179
of the cavity block, the upper tool assembly 61 is actuated to
initiate downward movement of the nose 67 and punch 109. As shown
in FIG. 11B, the cutout 5 is initially pressed between the nose 67
and knockout 205 and engages the lip 233 so that the cutout is
forced into the annular groove 77 of the nose 67. At this stage,
the interference of the radial inner portion of the annular cutout
5 received in the annular groove 77 and the spacing between the
annular groove and the lip 233 cause the annular cutout to be
gripped and clamped between the upper and lower assemblies 63, 63
to prevent sliding of the cutout during formation of the cooking
ring 1. As shown in FIG. 11C, the radial inner portion of the
annular cutout 5 is gripped by the lip 233 and the groove 77 so
that the inner radial edge 21 of the cutout stays in a fixed
position as the cutting ring 1 is formed. The radial inner portion
of the cutout 5 (generally corresponding to the upper edge portion
45 of the cooking element 1) stays substantially fixed as the
radial outer portion of the cutout (generally corresponding to the
first curved portion 37, second curved portion 41, and the lower
edge portion 35 of the cooking element 1) is pressed by the nose 67
and punch 109 against the upper recess 179 of the cavity block 175
to complete the formation of the cooking ring 1.
[0041] The clamping feature of the lip 233 and groove 77 allows the
forming tool assembly 15 to form a three-dimensional article from a
blank 5 having a precut hole. The clamping feature holds the inner
radial edge 21 of the blank 5 at a fixed location during formation
of the blank into the cooking ring 1 having a three-dimensional
shape. This clamping feature of the lip 233 and the groove 77 forms
the annular groove 47 in the cooking ring 1 and effectively holds
the blank to control the X and Y positioning of the annular cutout
5 as it moves during formation into the shape of the cooking ring
1. It also prevents the punch from pushing through hole 25 in the
annular blank 5. Without the use of the clamping feature, a
secondary cutting operation typically would be required to form the
hole 25 in the three-dimensional article after the article is
formed from the annular blank. Such an additional operation is
undesirable since it would add costs and may reduce the quality of
the article.
[0042] In addition to the capability of forming articles with a
precut center hole in the paperboard blank, the X and Y position
control of the blank during forming is beneficial to the forming of
any three-dimensional article or container either with or without a
center hole in the blank. For example, the forming tool 15 could
form a container being otherwise shaped (e.g., round, oval, square,
rectangular, etc.) from an appropriately sized and shaped blank. In
one embodiment, the container could be a three dimensional
container such as a tray having a bottom wall and at least one side
wall.
[0043] As shown in FIG. 11A, the lip 233 may have a height H1
ranging from approximately 0.01 inches (0.25 mm) to approximately
0.05 inches (1.3 mm), more preferably about 0.03 inches (0.76 mm),
and a radial length R1 from its inner radius to its outer radius of
ranging from approximately 0.01 inches (0.25 mm) to approximately
0.05 inches (1.3 mm), more preferably about 0.03 inches (0.76 mm).
The annular groove 77 may have a height H2 ranging from
approximately 0.05 (1.3 mm) to approximately 0.11 inches (2.8 mm),
more preferably about 0.08 inches (2.0 mm), and a radial length R2
ranging from approximately 0.05 inches (1.3 mm) to approximately
0.11 inches (2.8 mm), more preferably about 0.08 inches (2.0 mm).
The foregoing dimension are illustrative of exemplary dimensions
for the lip 233 and annular groove 77 that correspond to an annular
blank 5 that is a laminated structure having a thickness of
approximately 0.018 inches (0.46 mm). The present invention could
be otherwise shaped and dimensioned to accommodate an annular blank
having a thickness greater than or less than the 0.018 (0.46 mm)
inches without departing from the scope of this invention. The
dimensional information presented herein is intended to be
illustrative of exemplary embodiments of the invention and is not
intended to limit the scope of the invention.
[0044] The clamp ring 135 can be actuated simultaneously with
actuation of the upper and/or lower tool assemblies 61, 63 by
operating the actuators attached to the clamp ring brackets 153,
155 to apply compression force against the radial outer portion of
the annular cutout 5 during formation of the cooking ring 1. The
compression force applied by the clamp ring 135 creates uniform
bunching of the score lines 27 as the score lines are formed into
the pleats 49 during formation of the cooking ring 1. The
compression force applied by the clamp ring 135 prevents excessive
bunching of the annular cutout material. The forming tool assembly
15 forms the pleats 49 of the cooking ring 1 such that the pleats
have a generally U-shaped cross-sectional shape rather than a
Z-shaped cross-sectional shape which would result from excessive
bunching and possibly fracturing, tearing, or weakening of the
paperboard material and/or the microwave interactive material.
[0045] After the cooking ring 1 is shaped, the upper tool assembly
61 is raised and the cooking ring is ejected from the cavity block
175 of the lower assembly 63. The cooking ring 1 is then
transported downstream of the forming tool assembly 15 by a
conveying mechanism (e.g., conveyor belt) for packaging and/or
shipment or for assembly into a finished food product package.
[0046] The upper tool assembly 61 and lower tool assembly 63 are
commonly mounted at approximately a 45.degree. angle in a machine
(not shown) of the type manufactured by Peerless Machine & Tool
Corporation in Marion, Ind., USA. The machine provides the primary
compressive forces to sufficiently close and open the tool
assemblies 61 and 63 of the present invention. The closing and
opening of the tool assemblies 61, 63 by the machine forms the
three-dimensional articles or containers such as cooking ring 1. In
other types of machines, the tool assemblies 61, 63 may include
minor revisions or modifications to permit the tool assemblies to
operate in alternative orientations (e.g., upside down or on their
side). It should be understood that the operating position of tool
assemblies 61 and 63 shown and/or described herein is not intended
to limit the scope of the invention.
[0047] As mentioned above, in accordance with the exemplary
embodiment of the present invention, the microwave interactive
material 9 may comprise a microwave interactive element such as a
susceptor. Susceptors are discussed in greater detail below.
Alternatively, the microwave interactive material 9 can comprise
any other type of microwave interactive elements, materials, and/or
various combinations of microwave interactive elements and
material, as discussed in greater detail below. The microwave
interactive elements and materials may be omitted from article 1
without departing from the scope of this invention.
[0048] For example, the microwave interactive material 9 may be
formed at least partially from one or more microwave energy
interactive elements (hereinafter sometimes referred to as
"microwave interactive elements") that may promote browning and/or
crisping of a particular area of the food item, shield a particular
area of the food item from microwave energy to prevent overcooking
thereof, or transmit microwave energy towards or away from a
particular area of the food item. Each microwave interactive
element comprises one or more microwave energy interactive
materials or segments arranged in a particular configuration to
absorb microwave energy, transmit microwave energy, reflect
microwave energy, or direct microwave energy, as needed or desired
for a particular construct and food item.
[0049] The microwave interactive element may be supported on a
microwave inactive or transparent substrate for ease of handling
and/or to prevent contact between the microwave interactive
material and the food item. As a matter of convenience and not
limitation, and although it is understood that a microwave
interactive element supported on a microwave transparent substrate
includes both microwave interactive and microwave inactive elements
or components, such constructs are referred to herein as "microwave
interactive webs".
[0050] The microwave energy interactive material may be an
electroconductive or semiconductive material, for example, a metal
or a metal alloy provided as a metal foil; a vacuum deposited metal
or metal alloy; or a metallic ink, an organic ink, an inorganic
ink, a metallic paste, an organic paste, an inorganic paste, or any
combination thereof. Examples of metals and metal alloys that may
be suitable for use with the present invention include, but are not
limited to, aluminum, chromium, copper, inconel alloys
(nickel-chromium-molybdenum alloy with niobium), iron, magnesium,
nickel, stainless steel, tin, titanium, tungsten, and any
combination or alloy thereof.
[0051] Alternatively, the microwave energy interactive material may
comprise a metal oxide. Examples of metal oxides that may be
suitable for use with the present invention include, but are not
limited to, oxides of aluminum, iron, and tin, used in conjunction
with an electrically conductive material where needed. Another
example of a metal oxide that may be suitable for use with the
present invention is indium tin oxide (ITO). ITO can be used as a
microwave energy interactive material to provide a heating effect,
a shielding effect, a browning and/or crisping effect, or a
combination thereof For example, to form a susceptor, ITO may be
sputtered onto a clear polymeric film. The sputtering process
typically occurs at a lower temperature than the evaporative
deposition process used for metal deposition. ITO has a more
uniform crystal structure and, therefore, is clear at most coating
thicknesses. Additionally, ITO can be used for either heating or
field management effects. ITO also may have fewer defects than
metals, thereby making thick coatings of ITO more suitable for
field management than thick coatings of metals, such as
aluminum.
[0052] Alternatively, the microwave energy interactive material may
comprise a suitable electroconductive, semiconductive, or
non-conductive artificial dielectric or ferroelectric. Artificial
dielectrics comprise conductive, subdivided material in a polymeric
or other suitable matrix or binder, and may include flakes of an
electroconductive metal, for example, aluminum.
[0053] In one example, the microwave interactive element may
comprise a thin layer of microwave interactive material (generally
less than about 100 angstroms in thickness, for example, from about
60 to about 100 angstroms in thickness) that tends to absorb at
least a portion of impinging microwave energy and convert it to
thermal energy (i.e., heat) at the interface with a food item. Such
elements often are used to promote browning and/or crisping of the
surface of a food item (sometimes referred to as a "browning and/or
crisping element"). When supported on a film or other substrate,
such an element may be referred to as a "susceptor film" or,
simply, "susceptor". However, other microwave energy interactive
elements, such as those described herein, are contemplated
hereby.
[0054] As another example, the microwave interactive element may
comprise a foil having a thickness sufficient to shield one or more
selected portions of the food item from microwave energy (sometimes
referred to as a "shielding element"). Such shielding elements may
be used where the food item is prone to scorching or drying out
during heating.
[0055] The shielding element may be formed from various materials
and may have various configurations, depending on the particular
application for which the shielding element is used. Typically, the
shielding element is formed from a conductive, reflective metal or
metal alloy, for example, aluminum, copper, or stainless steel. The
shielding element generally may have a thickness of from about
0.000285 inches to about 0.05 inches. In one aspect, the shielding
element has a thickness of from about 0.0003 inches to about 0.03
inches. In another aspect, the shielding element has a thickness of
from about 0.00035 inches to about 0.020 inches, for example, 0.016
inches.
[0056] As still another example, the microwave interactive element
may comprise a segmented foil or high optical density evaporated
material (collectively referred to as "segmented foil"), such as,
but not limited to, those described in U.S. Pat. Nos. 6,204,492,
6,433,322, 6,552,315, and 6,677,563, each of which is incorporated
by reference in its entirety. Although segmented foils are not
continuous, appropriately spaced groupings of such segments often
act as a transmitting element to direct microwave energy to
specific areas of the food item. Such foils also may be used in
combination with browning and/or crisping elements, for example,
susceptors.
[0057] Any of the numerous microwave interactive elements described
herein or contemplated hereby may be substantially continuous, that
is, without substantial breaks or interruptions, or may be
discontinuous, for example, by including one or more breaks or
apertures that transmit microwave energy therethrough. The breaks
or apertures may be sized and positioned to heat particular areas
of the food item selectively. The number, shape, size, and
positioning of such breaks or apertures may vary for a particular
application depending on type of construct being formed, the food
item to be heated therein or thereon, the desired degree of
shielding, browning, and/or crisping, whether direct exposure to
microwave energy is needed or desired to attain uniform heating of
the food item, the need for regulating the change in temperature of
the food item through direct heating, and whether and to what
extent there is a need for venting.
[0058] It will be understood that the aperture may be a physical
aperture or void in the material used to form the construct, or may
be a non-physical "aperture". A non-physical aperture may be a
portion of the construct that is microwave energy inactive by
deactivation or otherwise, or one that is otherwise transparent to
microwave energy. Thus, for example, the aperture may be a portion
of the construct formed without a microwave energy active material
or, alternatively, may be a portion of the construct formed with a
microwave energy active material that has been deactivated. While
both physical and non-physical apertures allow the food item to be
heated directly by the microwave energy, a physical aperture also
provides a venting function to allow steam or other vapors to be
released from the food item.
[0059] In some instances, it may be beneficial to create one or
more discontinuities or inactive regions to prevent overheating or
charring of the construct and/or food product, for example, by
forming areas of the blank without a microwave energy interactive
material, removing the microwave energy interactive material that
has been applied, or by deactivating the microwave energy
interactive material in these areas. Further still, one or more
panels, portions of panels, or portions of the construct may be
designed to be microwave energy inactive to ensure that the
microwave energy is focused efficiently on the areas to be browned
and/or crisped, rather than being lost to portions of the food item
not intended to be browned and/or crisped or to the heating
environment.
[0060] As stated above, any of the above elements and numerous
others contemplated hereby may be supported on a substrate. The
substrate typically comprises for example, a polymeric film or
material. As used herein the term "polymer" or "polymeric material"
includes, but is not limited to, homopolymers, copolymers, such as
for example, block, graft, random, and alternating copolymers,
terpolymers, etc. and blends and modifications thereof.
Furthermore, unless otherwise specifically limited, the term
"polymer" shall include all possible geometrical configurations of
the molecule. These configurations include, but are not limited to
isotactic, syndiotactic, and random symmetries.
[0061] The thickness of the film typically may be from about 35
gauge to about 10 mil. In one aspect, the thickness of the film is
from about 40 to about 80 gauge. In another aspect, the thickness
of the film is from about 45 to about 50 gauge. In still another
aspect, the thickness of the film is about 48 gauge. Examples of
polymeric films that may be suitable include, but are not limited
to, polyolefins, polyesters, polyamides, polyimides, polysulfones,
polyether ketones, cellophanes, or any combination thereof. Other
non-conducting substrate materials such as paper and paper
laminates, metal oxides, silicates, cellulosics, or any combination
thereof, also may be used.
[0062] In one example, the polymeric film comprises polyethylene
terephthalate (PET). Polyethylene terephthalate films are used in
commercially available susceptors, for example, the QWIKWAVE.RTM.
susceptor and the MICRORITE.RTM. susceptor laminations, both
available from Graphic Packaging International (Marietta, Ga.).
Examples of polyethylene terephthalate films that may be suitable
for use as the substrate include, but are not limited to,
MELLNEX.RTM., commercially available from DuPont Teijan Films
(Hopewell, Va.), SKYROL, commercially available from SKC, Inc.
(Covington, Ga.), and BARRIALOX PET, available from Toray Films
(Front Royal, Va.), and QU50 High Barrier Coated PET, available
from Toray Films (Front Royal, Va.).
[0063] The polymeric film may be selected to impart various
properties to the paper or paperboard web, for example,
printability, heat resistance, or any other property. As one
particular example, the polymeric film may be selected to provide a
water barrier, oxygen barrier, or a combination thereof. Such
barrier film layers may be formed from a polymer film having
barrier properties or from any other barrier layer or coating as
desired. Suitable polymer films may include, but are not limited
to, ethylene vinyl alcohol, barrier nylon, polyvinylidene chloride,
barrier fluoropolymer, nylon 6, nylon 6,6, coextruded nylon
6/EVOH/nylon 6, silicon oxide coated film, barrier polyethylene
terephthalate, or any combination thereof.
[0064] One example of a barrier film that may be suitable for use
with the present invention is CAPRAN.RTM. EMBLEM 1200M nylon 6,
commercially available from Honeywell International (Pottsville,
Pa.). Another example of a barrier film that may be suitable is
CAPRAN.RTM. OXYSHIELD OBS monoaxially oriented coextruded nylon
6/ethylene vinyl alcohol (EVOH)/nylon 6, also commercially
available from Honeywell International. Yet another example of a
barrier film that may be suitable for use with the present
invention is DARTEK.RTM. N-201 nylon 6,6, commercially available
from Enhance Packaging Technologies (Webster, N.Y.). Additional
examples include BARRIALOX PET, available from Toray Films (Front
Royal, Va.) and QU50 High Barrier Coated PET, available from Toray
Films (Front Royal, Va.), referred to above.
[0065] Still other barrier films include silicon oxide coated
films, such as those available from Sheldahl Films (Northfield,
Minn.). Thus, in one example, a susceptor may have a structure
including a film, for example, polyethylene terephthalate, with a
layer of silicon oxide coated onto the film, and ITO or other
material deposited over the silicon oxide. If needed or desired,
additional layers or coatings may be provided to shield the
individual layers from damage during processing.
[0066] The barrier film may have an oxygen transmission rate (OTR)
as measured using ASTM D3985 of less than about 20 cc/m2/day. In
one aspect, the barrier film has an OTR of less than about 10
cc/m2/day. In another aspect, the barrier film has an OTR of less
than about 1 cc/m2/day. In still another aspect, the barrier film
has an OTR of less than about 0.5 cc/m2/day. In yet another aspect,
the barrier film has an OTR of less than about 0.1 cc/m2/day.
[0067] The barrier film may have a water vapor transmission rate
(WVTR) of less than about 100 g/m2/day as measured using ASTM
F1249. In one aspect, the barrier film has WVTR of less than about
50 g/m2/day. In another aspect, the barrier film has a WVTR of less
than about 15 g/m2/day. In yet another aspect, the barrier film has
a WVTR of less than about 1 g/m2/day. In still another aspect, the
barrier film has a WVTR of less than about 0.1 g/m2/day. In a still
further aspect, the barrier film has a WVTR of less than about 0.05
g/m2/day.
[0068] Other non-conducting substrate materials such as metal
oxides, silicates, cellulosics, or any combination thereof, also
may be used in accordance with the present invention.
[0069] The microwave energy interactive material may be applied to
the substrate in any suitable manner, and in some instances, the
microwave energy interactive material is printed on, extruded onto,
sputtered onto, evaporated on, or laminated to the substrate. The
microwave energy interactive material may be applied to the
substrate in any pattern, and using any technique, to achieve the
desired heating effect of the food item.
[0070] For example, the microwave energy interactive material may
be provided as a continuous or discontinuous layer or coating
including circles, loops, hexagons, islands, squares, rectangles,
octagons, and so forth. Examples of various patterns and methods
that may be suitable for use with the present invention are
provided in U.S. Pat. Nos.6,765,182; 6,717,121; 6,677,563;
6,552,315; 6,455,827; 6,433,322; 6,414,290; 6,251,451; 6,204,492;
6,150,646; 6,114,679; 5,800,724; 5,759,422; 5,672,407; 5,628,921;
5,519,195; 5,424,517; 5,410,135; 5,354,973; 5,340,436; 5,266,386;
5,260,537; 5,221,419; 5,213,902; 5,117,078; 5,039,364; 4,963,424;
4,936,935; 4,890,439; 4,775,771; 4,865,921; and Re. 34,683, each of
which is incorporated by reference herein in its entirety. Although
particular examples of patterns of microwave energy interactive
material are shown and described herein, it should be understood
that other patterns of microwave energy interactive material are
contemplated by the present invention.
[0071] The microwave interactive element or microwave interactive
web may be joined to or overlie a dimensionally stable, microwave
energy transparent support (hereinafter referred to as "microwave
transparent support", "microwave inactive support" or "support") to
form the construct.
[0072] In one aspect, for example, where a rigid or semi-rigid
construct is to be formed, all or a portion of the support may be
formed at least partially from a paperboard material, which may be
cut into a blank prior to use in the construct. For example, the
support may be formed from paperboard having a basis weight of from
about 60 to about 330 lbs/ream, for example, from about 80 to about
140 lbs/ream. The paperboard generally may have a thickness of from
about 6 to about 30 mils, for example, from about 12 to about 28
mils. In one particular example, the paperboard has a thickness of
about 18 mils and a basis weight of from about 100 lbs/ream to
about 300 lbs/ream. Any suitable paperboard may be used, for
example, a solid bleached or solid unbleached sulfate board, such
as SUS.RTM. board, commercially available from Graphic Packaging
InternationaL
[0073] In another aspect, where a more flexible construct is to be
formed, the support may comprise a paper or paper-based material
generally having a basis weight of from about 15 to about 60
lbs/ream, for example, from about 20 to about 40 lbs/ream. In one
particular example, the paper has a basis weight of about 25
lbs/ream.
[0074] Optionally, one or more portions of the various blanks or
other constructs described herein or contemplated hereby may be
coated with varnish, clay, or other materials, either alone or in
combination. The coating may then be printed over with product
advertising or other information or images. The blanks or other
constructs also may be coated to protect any information printed
thereon.
[0075] Furthermore, the blanks or other constructs may be coated
with, for example, a moisture and/or oxygen barrier layer, on
either or both sides, such as those described above. Any suitable
moisture and/or oxygen barrier material may be used in accordance
with the present invention. Examples of materials that may be
suitable include, but are not limited to, polyvinylidene chloride,
ethylene vinyl alcohol, DuPont DARTEK.TM. nylon 6,6, and others
referred to above.
[0076] Alternatively or additionally, any of the blanks or other
constructs of the present invention may be coated or laminated with
other materials to impart other properties, such as absorbency,
repellency, opacity, color, printability, stiffness, or cushioning.
For example, absorbent susceptors are described in U.S. Provisional
Application No. 60/604,637, filed Aug. 25, 2004, and U.S. Patent
Application Publication No. 2006/0049190, published Mar. 9, 2006,
both of which are incorporated herein by reference in their
entirety. Additionally, the blanks or other constructs may include
graphics or indicia printed thereon.
[0077] It will be understood that with some combinations of
elements and materials, the microwave interactive element may have
a grey or silver color this is visually distinguishable from the
substrate or the support. However, in some instances, it may be
desirable to provide a web or construct having a uniform color
and/or appearance. Such a web or construct may be more
aesthetically pleasing to a consumer, particularly when the
consumer is accustomed to packages or containers having certain
visual attributes, for example, a solid color, a particular
pattern, and so on. Thus, for example, the present invention
contemplates using a silver or grey toned adhesive to join the
microwave interactive elements to the substrate, using a silver or
grey toned substrate to mask the presence of the silver or grey
toned microwave interactive element, using a dark toned substrate,
for example, a black toned substrate, to conceal the presence of
the silver or grey toned microwave interactive element,
overprinting the metallized side of the web with a silver or grey
toned ink to obscure the color variation, printing the
non-metallized side of the web with a silver or grey ink or other
concealing color in a suitable pattern or as a solid color layer to
mask or conceal the presence of the microwave interactive element,
or any other suitable technique or combination thereof.
[0078] As another example, the microwave interactive material 9
includes one or more susceptors as well as closed cells formed
between layers of packaging material. Upon exposure to microwave
energy, the cells expand to form inflated cells that thermally
insulate the food item in the package from the environment exterior
to the package. In addition, the inflated cells can force one or
more susceptors into contact with, or at least closer to, the food
being heated, cooked, or the like. One example of a microwave
packaging material that provides inflatable cells is described in
PCT application PCT/US03/03779 titled "Insulating Microwave
Interactive Packaging", the entire disclosure of which is hereby
incorporated by reference herein.
[0079] The foregoing description of the invention illustrates and
describes various embodiments of the present invention. As various
changes could be made in the above construction without departing
from the scope of the invention, it is intended that all matter
contained in the above description or shown in the accompanying
drawings shall be interpreted as illustrative and not in a limiting
sense. Furthermore, the scope of the present invention covers
various modifications, combinations, and alterations, etc., of the
above-described embodiments that are within the scope of the
claims. Additionally, the disclosure shows and describes only
selected embodiments of the invention, but the invention is capable
of use in various other combinations, modifications, and
environments and is capable of changes or modifications within the
scope of the inventive concept as expressed herein, commensurate
with the above teachings, and/or within the skill or knowledge of
the relevant art. Furthermore, certain features and characteristics
of each embodiment may be selectively interchanged and applied to
other illustrated and non-illustrated embodiments of the invention
without departing from the scope of the invention.
* * * * *