Patent ID: 9114902
Filing Date: 2015-08-25
Classification: A47J,B29C,B29L,B32B,B65D,Y10T

Abstract:
1. A method of forming a puncturable container having a sidewall, a heel extending from a bottom of the sidewall, and a base coupled to the heel, said method comprising: positioning a forming base within a base cavity defined by a lower portion of a forming insert; the forming insert comprising an upper portion and a lower portion, said upper portion comprising a sidewall segment and a heel segment extending from a bottom of said sidewall segment, wherein said sidewall segment has a sidewall radius and said heel segment has a heel radius that is less than the sidewall radius; the forming base having a top surface that includes a rim and a step extending axially upward from the rim, wherein the rim has a rim radius that is less than the heel radius and the step has a step radius that is less than the rim radius; extending a multi-layer sheet structure across an opening defined by an upper portion of the forming insert, wherein the multi-layer sheet structure comprises a first layer comprising virgin polypropylene and a second layer comprising (i) virgin polypropylene, (ii) talc, and (iii) recycled material comprising unused ground-up multi-layer sheet structure; and drawing air out of a mold cavity to pull the multi-layer sheet structure towards at least one of the top surface and the upper portion; and pushing the multi-layer sheet structure with a plug into the mold cavity towards at least one of the top surface and the upper portion to form the puncturable container wherein a desired amount of the multi-layer sheet structure is distributed to at least one of the sidewall, the heel, and the base such that the puncturable container withstands being punctured without being crushed.