Patent ID: 12194670

DETAILED DESCRIPTION

A manufacturing process100for forming an article10in accordance with the present disclosure is shown, for example, inFIGS.1and3. Article10may be for example, a lid for a container as shown inFIG.2, a bowl, a tray, a plate, a film, a container such as a pill container, storage container, tamper evident container, a damage or tamper evident indicator, an information indicator selector, or any other suitable article. Illustratively, the article10is a shallow draw article formed with a rotary thermoforming process, however aspects of the present disclosure may be incorporated in other article forming processes such as, for example, deep draw thermoforming, blow molding, casting, molding on a tread of molds, flatbed thermoforming, etc. Components of a system11for performing manufacturing process100are shown inFIG.3.

Manufacturing process100is illustratively an article-manufacturing process100for forming articles10as shown, for example, inFIGS.1and3. The illustrative article10is a lid210which is adapted to mate with a brim of a container such as a cup or a bowl. One embodiment of lid210made by article-manufacturing process100is shown, for example, inFIG.2. Article-manufacturing process100may provide articles10at a faster rate than traditional manufacturing processes and/or with desired characteristics such as, for example, thickness, surface finish, transparency, levelness, and strength. Reference is hereby made to U.S. application Ser. No. 16/057,122, filed Aug. 7, 2018 and titled METHOD AND APPARATUS FOR THERMOFORMING AN ARTICLE, for relating to a method of manufacturing articles, which application is hereby incorporated in its entirety.

Article-manufacturing process100includes an extrusion stage102, a conditioning stage104, a rotary thermoforming stage106, an optional splitting stage107, a cutting stage108, an optional stacking stage110, and an optional bagging stage112as shown, for example, inFIGS.1and3. Extrusion stage102provides a sheet30of polymeric material as suggested inFIG.3. Conditioning stage104establishes a desired surface finish, temperature, and feed rate of sheet30as suggested inFIGS.7and8. Rotary thermoforming stage106thermoforms sheet30to rotary thermoformer16to form continuously article-blank web32as suggested inFIGS.13and16. Cutting stage108cuts article-blank web32to provide at least one article10as shown inFIGS.19-22.

In other embodiments, rotary thermoforming stage106is replaced with another thermoforming stage such as flatbed thermoforming, casting, or blow molding. In other embodiments, conditioning stage104is omitted and a sheet of polymeric material is applied directly from extrusion stage102to rotary thermoforming stage106or other thermoforming stage.

Splitting stage107splits the article-blank web32into two or more strips to assist handling of the article-blank web32at the cutting stage108. In some embodiments, cutting stage108is performed using a rotary cutter configured to adjust its rotational speed on the fly during cutting stage108. In such embodiments, splitting stage107may be omitted. Stacking stage110stacks article10with a plurality of other articles10as shown inFIGS.23-25. Bagging stage112packages the plurality of articles10for storage and transportation as suggested inFIG.3.

In illustrative embodiments, article-manufacturing process100has a line speed between about 50 feet per minute and 500 feet per minute. In some embodiments, article-manufacturing process100has a line speed between about 100 feet per minute and 250 feet per minute. In some embodiments, article-manufacturing process100has a line speed between about 100 feet per minute and 200 feet per minute. In some embodiments, article-manufacturing process100has a line speed between about 110 feet per minute and 200 feet per minute. In some embodiments, article-manufacturing process100has a line speed between about 100 feet per minute and 160 feet per minute. In some embodiments, article-manufacturing process100has a line speed between about 160 feet per minute and 200 feet per minute. In some embodiments, article-manufacturing process100has a line speed between about 110 feet per minute and 120 feet per minute.

The illustrative system11is configured to perform article-manufacturing process100as suggested inFIG.3. The system11shown is a thermoforming system11. The system11includes an extruder12, a conditioning roller14, rotary thermoformer16, and at least one of cutter18,20as shown inFIGS.3-13A and19-22. In some embodiments, system11further includes one or more sheet-movement controllers24as shown inFIG.8. In some embodiments, system11further includes a splitter25as shown inFIG.4. In some embodiments, system11further includes one or more of a pinch belt71, a stacker26, and a bagger as suggested inFIGS.23-26. In some embodiments, extruder12is omitted and a sheet of polymeric material is provided to process100. In such embodiments, a heating stage may occur before conditioning stage104or thermoforming stage106. Sheet of polymeric material could be provided by a third part in some embodiments. In some embodiments, conditioning roller14is omitted and the sheet of polymeric material is applied to a thermoformer without being first applied to a conditioning roller.

Extrusion stage102of article-manufacturing process100uses extruder12to melt polymeric materials as shown inFIGS.3-6. The melted polymeric materials are urged through a die13to form sheet30. Sheet30leaves extruder12and die13in a molten state. In some embodiments, sheet30leaves extruder12and die13at between about 300 degrees Fahrenheit and about 700 degrees Fahrenheit. In some embodiments, sheet30leaves extruder12and die13at between about 300 degrees Fahrenheit and about 500 degrees Fahrenheit. In illustrative embodiments, sheet30leaves extruder12and die13at between about 500 degrees Fahrenheit and about 700 degrees Fahrenheit. In some embodiments, sheet30leaves extruder12and die13at between about 400 degrees Fahrenheit and about 450 degrees Fahrenheit. In some embodiments, extrusion stage102is omitted and sheet30is provided from another source. As one example, sheet30is purchased from a supplier. In some embodiments, extrusion stage102is omitted and another sheet of material such as, for example, a paper sheet is provided and supplied to process100. Process100may further include a stage of heating sheet30before conditioning stage104for example, if sheet30is provided by a third party or extruded and stored before forming into article10.

Die13is presented at an angle relative to conditioning roller14used in conditioning stage104as shown inFIGS.5and6. In some embodiments, die13has a variable presentation angle relative to conditioning roller14between about 40 degrees as shown inFIG.5and about 90 degrees as shown inFIG.6. The presentation angle may be adjusted on the fly during process100.

Conditioning stage104uses conditioning roller14to condition sheet30as suggested inFIGS.7and8. During conditioning stage104, sheet30is directed from extruder12toward conditioning roller14. Sheet30is applied partway around an outer surface42of conditioning roller14to provide a desired surface finish on sheet30, to regulate a feed rate of article-manufacturing process100, and to help control the temperature of sheet30. In the illustrative embodiment, the desired surface finish applied to sheet30is a transparency of sheet30and article10made from sheet30. In some embodiments, sheet30is applied to conditioning roller14such that sheet30is wrapped around one-hundred degrees around conditioning roller14.

Conditioning roller14may be temperature controlled such that sheet30is in its plastic form on conditioning roller14. Sheet30has a temperature of about 300 degrees Fahrenheit to about 350 degrees Fahrenheit after being cooled by conditioning roller14in some embodiments. In some embodiments, conditioning roller14is cooled with fluid at between about 60 degrees and about 90 degrees Fahrenheit. In some embodiments, conditioning roller is cooled with fluid at about 70 degrees Fahrenheit. In some embodiments, conditioning roller is conditioned with fluid at about 230 degrees Fahrenheit. The fluid may be water, oil, propylene glycol, or any other suitable alternative. In illustrative embodiments, conditioning roller14is maintained at a temperature of between about 40 degrees Fahrenheit and about 250 degrees Fahrenheit. In some embodiments, conditioning roller14is maintained at a temperature of between about 60 degrees Fahrenheit and about 100 degrees Fahrenheit.

Conditioning roller14is mounted to rotate about a longitudinal axis40that extends through conditioning roller14as suggested inFIGS.7and8. Conditioning roller14may have a circular cross-section when viewed along longitudinal axis40. Conditioning roller14includes an outer surface42that contacts sheet30and has a texture configured to establish a desired surface finish (sometimes called surface texture) on sheet30. In illustrative embodiments, outer surface42is textured to achieve article10having one or more of a desired thickness, surface finish, transparency, levelness, and strength. In other embodiments, sheet30is applied to a surface different than outer surface42and may be, for example, an inner surface to condition sheet30. Outer surface42is textured to block sheet30from moving axially relative to longitudinal axis40and to control the feed rate of sheet30between extruder12and rotary thermoformer16and, as a result, control the resulting thickness and/or weight of the formed article10. In some embodiments, conditioning roller14includes an outer surface42which has a single texture (continuous surface roughness between ends of roller14) as shown inFIGS.9and10. In some embodiments, conditioning roller14includes an outer surface42which has a variable texture (sometimes called a striped conditioning roller or a non-continuous surface roughness) as shown inFIGS.11and12.

Articles10illustratively have a surface roughness that is less than the surface roughness of textured outer surface42. In some embodiments, outer surface42is smooth or not textured (about 5 Ra microinches or less) and may have a surface roughness that is less than the surface roughness of articles10. When outer surface42is smooth, other sheet control means may be used to maintain desired characteristics of articles10such as thickness, transparency, levelness, and strength. Sheet control means may include one or more of sheet-movement controllers24as described below.

Outer surface42has a surface roughness to provide desired control and feed rate of sheet30while providing a desired transparency and surface finish of articles10. Outer surface42has a roughness of between about 5 Ra (microinches) and about 400 Ra (microinches) in some embodiments. In some embodiments, outer surface42has a roughness of between about 8 Ra (microinches) and about 400 Ra (microinches). In some embodiments, outer surface42has a roughness of less than about 400 Ra (microinches). In some embodiments, outer surface42has a roughness of greater than about 400 Ra (microinches). Outer surface42may have any surface roughness as disclosed herein when process100includes rotary thermoforming sheet30or other thermoforming processes such as flatbed thermoforming, blow molding, casting, etc. because controlling feed rate and location of sheet30with conditioning roller14may be helpful with many types of molding and forming processes.

The surface roughness of outer surface42may be increased as line speed of process100increases. For example, outer surface42may have a portion with a first surface roughness for a first line speed and the portion may have a second surface roughness for a second line speed, the second line speed being greater than the first line speed and the second surface roughness being greater than the second surface roughness. Increasing the surface roughness of outer surface42for increasing line speed may not affect a surface roughness of articles10because sheet30is applied to conditioning roller for less time at higher line speeds and the molds on the thermoformer may have a greater effect on article10surface roughness than conditioning roller surface roughness regardless of line speed.

In one example, outer surface42has a roughness of between about 100 Ra (microinches) and about 240 Ra (microinches). Outer surface42has a roughness of between about 140 Ra (microinches) and about 220 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 140 Ra (microinches) and about 160 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 180 Ra (microinches) and about 220 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 180 Ra (microinches) and about 200 Ra (microinches) in some embodiments.

In another example, outer surface42has a roughness of between about 100 Ra (microinches) and about 350 Ra (microinches). Outer surface42has a roughness of between about 180 Ra (microinches) and about 340 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 300 Ra (microinches) and about 350 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 200 Ra (microinches) and about 300 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 50 Ra (microinches) and about 220 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 70 Ra (microinches) and about 220 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 80 Ra (microinches) and about 220 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 90 Ra (microinches) and about 220 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 80 Ra (microinches) and about 380 Ra (microinches) in some embodiments.

Outer surface42has a roughness of between about 200 Ra (microinches) and about 275 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 280 Ra (microinches) and about 340 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 290 Ra (microinches) and about 330 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 300 Ra (microinches) and about 320 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 280 Ra (microinches) and about 320 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 270 Ra (microinches) and about 330 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 290 Ra (microinches) and about 310 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 300 Ra (microinches) and about 340 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 300 Ra (microinches) and about 330 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 300 Ra (microinches) and about 320 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 260 Ra (microinches) and about 330 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 270 Ra (microinches) and about 320 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 280 Ra (microinches) and about 310 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 250 Ra (microinches) and about 350 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 250 Ra (microinches) and about 330 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 295 Ra (microinches) and about 305 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 295 Ra (microinches) and about 315 Ra (microinches) in some embodiments. Outer surface42has a roughness of between about 285 Ra (microinches) and about 315 Ra (microinches) in some embodiments.

In some embodiments, outer surface42is made from chrome and has a roughness of about 8 Ra (microinches) as shown inFIG.9. In other embodiments, outer surface has a greater roughness as suggested inFIG.10. Outer surface42has a roughness of about 100 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 140 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 160 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 180 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 200 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 220 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 240 Ra (microinches) in some embodiments.

Outer surface42has a roughness of greater than about 200 Ra (microinches) and less than about 400 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 250 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 275 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 300 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 310 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 320 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 330 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 340 Ra (microinches) in some embodiments. Outer surface42has a roughness of about 350 Ra (microinches) in some embodiments.

In embodiments where outer surface42is a variable texture surface (as shown inFIGS.11and12for example), a first portion43(sometimes called a stripe) of outer surface42has a first roughness and a second portion45(sometimes called a stripe) of outer surface42has a second roughness different than first portion43. In some embodiments, first and second portions43,45repeat about roller14along axis40as shown inFIG.11. In some embodiments, second portions45are located only on the ends of conditioning roller14and first portion43extends between second portions45as shown inFIG.12.

First portion43extends circumferentially around roller14and each second portion45extends circumferentially around roller14. First portion43may be sized to fit article blanks38in a footprint of first portion43as suggested inFIG.11. Second portion45may be sized to fit between article blanks38as shown inFIG.11and/or outside article blanks38as shown inFIG.12. First portion43may have a roughness that is less than a roughness of second portion45. Second portion45may be raised radially outward relative to first portion43.

In some embodiments, first portion43has a roughness of about or less than about 400 Ra (microinches). First portion43has a roughness of between about 100 Ra (microinches) and about 240 Ra (microinches) in some embodiments. First portion43has a roughness of between about 140 Ra (microinches) and about 220 Ra (microinches) in some embodiments. First portion43has a roughness of between about 140 Ra (microinches) and about 160 Ra (microinches) in some embodiments. First portion43has a roughness of between about 180 Ra (microinches) and about 220 Ra (microinches) in some embodiments. First portion43has a roughness of between about 180 Ra (microinches) and about 200 Ra (microinches) in some embodiments.

First portion43has a roughness of about 100 Ra (microinches) in some embodiments. First portion43has a roughness of about 140 Ra (microinches) in some embodiments. First portion43has a roughness of about 160 Ra (microinches) in some embodiments. First portion43has a roughness of about 180 Ra (microinches) in some embodiments. First portion43has a roughness of about 200 Ra (microinches) in some embodiments.

Second portion45has a roughness greater than first portion43. The roughness of second portion45is about 400 Ra (microinches) in some embodiments. The roughness of second portion45is greater than about 240 Ra (microinches) in some embodiments. Second portion45is located axially outside article blanks38.

First portions43each have a width of about 4 inches and second portion45has a width of about 0.5 inches in the embodiment shown inFIG.11. First and second portions43,45alternate along longitudinal axis40of the conditioning roller14as shown inFIG.11. Second portions45may each have a width of about 4.5 inches in the embodiment shown inFIG.12and first portion extends entirely between the second portions45. Second portions45are located at a first end and a second end of roller14and first portion43extends entirely between the second portions45.

Conditioning stage104may include a step of blocking sheet30from moving axially and circumferentially along longitudinal axis40relative to conditioning roller14as suggested inFIG.8. In embodiments in which conditioning roller14has a low roughness, for example, sheet30may move axially relative to longitudinal axis40during conditioning stage104. Sheet30may slip on relatively smooth conditioning rollers14which may cause the feed rate and thickness of sheet30to vary. Conditioning stage104may optionally include a sheet-movement controller24to block sheet30from moving axially and circumferentially relative to longitudinal axis40.

Where outer surface42of roller14has a roughness of about or greater than about 100 Ra (microinches), outer surface42provides a desired control and feed rate of sheet30such that sheet-movement controller24may not be used and the blocking step is achieved by outer surface42. In other embodiments, one or more sheet-movement controller24is used when outer surface42has a surface roughness of about 100 Ra (microinches) or less. In some embodiments, one or more sheet-movement controller24is used when outer surface42has a surface roughness of about 8 Ra (microinches) or less.

Sheet-movement controller24urges sheet30toward conditioning roller14to pin sheet30on conditioning roller14as suggested inFIG.8. Pinning sheet30onto conditioning roller14increases friction between sheet30and conditioning roller14. The increased friction blocks axial movement of sheet30relative to conditioning roller14and blocks sheet30from slipping circumferentially on conditioning roller14. Blocking sheet30from slipping may improve control of sheet30in the machine direction which may improve control over gram weight variation of sheet30.

Sheet-movement controller24includes one or more of a static pinner70, an air pinner72, and a vacuum box74, combinations thereof, or any other suitable alternative. Static pinner70electrically charges sheet30to urge sheet30toward conditioning roller14. Air pinner72directs air toward sheet30to urge sheet30toward conditioning roller14. Vacuum box74applies a vacuum to conditioning roller14which urges sheet30toward outer surface42included in conditioning roller14. In some embodiments, static pinner70and air pinner72are spaced apart from conditioning roller14.

A distance between conditioning roller14and die13may be adjusted as suggested inFIG.6A. A distance between conditioning roller14and rotor44may be adjusted. A vertical distance between conditioning roller14and die13is indicated as a distance33. A horizontal distance between conditioning roller14and die is indicated as a distance39. The degrees of wrap35that sheet30is applied to conditioning roller and the tangential points where sheet30meets and exits conditioning roller14may be adjusted based on the location of conditioning roller14relative to die13and rotor44.

The distance between conditioning roller14and die13has an effect on transparency of sheet30and articles10in some embodiments as suggested inFIG.6A. A vertical distance33from a lip of die13to a tangential point of sheet30first touching conditioning roller14may affect transparency values of article10. This may be due to a temperature of sheet30when it contacts conditioning roller14. The greater the vertical distance33up to a point, the longer the melt stream is exposed to relatively cooler ambient air such that the polymeric material is cooled and may take on less of a texture of the conditioning roller14such that articles10have improved transparency, improved transparency being at least one of higher clarity values and lower haze values. In some embodiments, polymeric material held at a lower melt point in extruder12has a lower temperature at conditioning roller14and produces articles with improved transparency. Some embodiments of process100include increasing a vertical height between conditioning roller and die13to increase clarity and/or reduce haze of articles10.

Process100includes varying a temperature of polymeric materials before they contact conditioning roller14to vary a transparency of article10in some embodiments. In some embodiments, varying the temperature of polymeric materials before they contact conditioning roller14includes varying a distance between conditioning roller14and die13. In some embodiments, varying the temperature of polymeric materials before they contact conditioning roller14includes varying a distance the polymeric materials exiting die13and the polymeric materials contacting a first stage such as conditioning rollers14. In some embodiments, varying the temperature of polymeric materials before they contact conditioning roller14includes varying a temperature of the polymeric materials in extruder12.

Rotary thermoforming stage106uses rotary thermoformer16to form continuously article-blank web32from sheet30as suggested inFIG.13. Article-blank web32includes a plurality of article blanks38that can be cut using cutting stage108to form articles10as suggested inFIGS.19-22. Article blanks38are illustratively lid blanks for forming lids210. Other thermoforming stages may be used in place of rotary thermoforming stage106in some embodiments.

In rotary thermoforming stage106, sheet30is applied to a rotary thermoformer16that includes a rotor44and a plurality of article molds46coupled to rotor44to provide an article-blank web32having a plurality of article blanks38formed therein as suggested inFIGS.4and13. Rotor44is configured to rotate clockwise in the illustrative embodiment. In other embodiments, a female sheet path is used and/or rotor44rotates counter-clockwise and sheet30is applied to move counter-clockwise with rotor44.

Rotary thermoformer16includes rotor44mounted to rotate about a rotation axis52and the plurality of article molds46coupled to rotor44as shown inFIG.4. Molds46may have a greater surface roughness than articles10and may have a surface roughness that is less than the surface roughness of roller14. In some embodiments, molds46have a surface roughness of between about 50 and about 70 Ra (microinches). In some embodiments, molds46have a surface roughness of between about 55 and about 65 Ra (microinches).

Sheet30is applied to rotor at a first circumferential position94and is wrapped around rotor44for a predetermined number of degrees and then separates from rotor44at a second circumferential position96to continue downstream to splitting stage107and/or cutting stage108as suggested inFIG.4. First and second circumferential positions94,96can be adjusted by varying the special relationships between roller14, rotor46, and the component directly downstream of rotor46such as, for example, splitter25, cutter18,20, or one or more bicycle wheels or rotors adapted to strip sheet30off of rotor46.

An angle alpha α is defined between first circumferential position94and second circumferential position96as shown inFIG.4. Angle alpha α may be varied so that sheet30remains applied to rotor44for a desired period of time before separating from rotor44. For example, sheet30remains applied to rotor44for a first angle alpha α and, thus, for a first amount of time for a first line speed. If the line speed is varied to a second line speed, alpha α may be varied so that sheet30remains applied to rotor44for a desired period of time before separating from rotor44. As an example, if the second line speed is greater than the first line speed, alpha α may be increased so that sheet30remains applied to rotor44for the same amount of time for both the first line speed and the second line speed.

In some embodiments, angle alpha α is between about 40 degrees and about 340 degrees. In some embodiments, angle alpha α is between about 190 degrees and about 240 degrees. In some embodiments, angle alpha α is between about 200 degrees and about 235 degrees. In some embodiments, angle alpha α is between about 90 degrees and about 140 degrees. In some embodiments, angle alpha α is between about 100 degrees and about 120 degrees. In some embodiments, angle alpha α is between about 90 degrees and about 320 degrees. In some embodiments, angle alpha α is between about 150 degrees and about 250 degrees. In the illustrative embodiment, angle alpha α is about 235 degrees.

Rotary thermoformer16optionally includes curl-blocking strips48that extend radially outward away from rotor44toward sheet30. Rotor44is mounted to rotate about rotation axis52of rotary thermoformer16. Article molds46are coupled to rotor44for rotation therewith. Curl-blocking strips48include a plurality of protrusions50that extend radially outward away from rotor44toward sheet30to engage and block sheet30from curling away from rotor44during the rotary thermoforming stage106.

Rotor44includes a plurality of faces54(sometimes called sides or bands) angled relative to one another about rotation axis52and article molds46are coupled to faces54. Each article mold46may have any desired shape and each article mold46may be uncoupled from rotor44and replaced with a different shaped article mold46. In some embodiments, at least two axially extending columns of article molds46are coupled to each of the plurality of faces54included in rotor44as shown inFIGS.13and13A. In some embodiments, only one axially extending column of article molds46is coupled to each of the plurality of faces54included in rotor44as shown inFIG.13B.

Some polymeric materials such as, for example, polypropylene are prone to curl at the edge during rotary thermoforming. The curled edges may result in article-blank webs and articles being out of desired dimensional tolerance. For example, the articles may be rejected for not being level. Additionally, a sheet having curled edges may be more difficult to convey through the manufacturing process, may be more difficult to handle by hand or machine, and/or may cause issues in downstream operations such as, for example, in the cutting operation.

In one example, an inner side of a sheet30made from polypropylene is cooled by rotor44and an outer side of sheet30is exposed to room temperature air. The temperature difference may be one factor that causes edges34,36of sheet to curl up. Other polymeric materials such as, for example, polystyrene may not exhibit this severity of shrinkage and curl behavior.

Shrinkage rate of the polymeric material may also factor the severity of edge curl of sheet30. The amount of total shrinkage increases as a width of sheet30increases. Polypropylene may have a shrinkage rate of 3-4 times that of polystyrene and/or polyethylene terephthalate. Polypropylene may shrink at a rate of about 0.015 inches to about 0.018 inches per inch. Polystyrene may shrink at a rate of about 0.004 to about 0.007 inches per inch. Polyethylene terephthalate may shrink at a rate of about 0.003 inches to about 0.005 inches per inch. Curl-blocking strips48may reduce or eliminate edge curl of polypropylene sheets or sheets of other polymeric materials having a higher shrinkage rate than polystyrene, for example, to allow the edge curl to be minimized and sufficient for processing and for providing articles with desired characteristics such as levelness.

The shrinkage rate of a polymeric material may be one factor associated with its tendency to experience edge curl. As an example, polymeric materials having a shrinkage rate of greater than about 0.007 inches per 1 inch may be more likely to experience edge curl during rotary thermoforming. As another example, polymeric materials having a shrinkage rate of between about 0.007 inches per 1 inch and about 0.020 inches per one inch may be more likely to experience edge curl during rotary thermoforming. As another example, polymeric materials having a shrinkage rate of between about 0.008 inches per 1 inch and about 0.020 inches per one inch may be more likely to experience edge curl during rotary thermoforming. As another example, polymeric materials having a shrinkage rate of between about 0.007 inches per 1 inch and about 0.018 inches per one inch may be more likely to experience edge curl during rotary thermoforming. As another example, polymeric materials having a shrinkage rate of between about 0.008 inches per 1 inch and about 0.018 inches per one inch may be more likely to experience edge curl during rotary thermoforming. As another example, polymeric materials having a shrinkage rate of between about 0.016 inches per 1 inch and about 0.018 inches per one inch may be more likely to experience edge curl during rotary thermoforming.

Curl-blocking strips48may be used with other thermoforming methods such as, for example, flatbed thermoforming. Curl-blocking strips48block edge curl of sheet30which may be experienced with other thermoforming methods besides rotary thermoforming. Curl-blocking strips48may be useful for thermoforming polymeric materials with relatively high shrinkage rates such as, for example, polypropylene.

Rotary thermoformer16of the present disclosure further includes a curl-blocking strip48that blocks edge curl of the sheet30during rotary thermoforming process106as shown inFIG.13. Curl-blocking strip48is defined by a plurality of protrusions50that extend radially outward away from rotor44toward sheet30to engage and block edges34,36of sheet30from curling away from rotor44during rotary thermoforming stage106as shown inFIGS.14and15. Because edges34,36of sheet30are blocked from curling, article blanks38located adjacent edges34,36of article-blank web32are substantially level and within desired dimensional tolerances. As a result, the potential for article blanks38and articles10being rejected for being out of dimensional tolerance is reduced.

Curl-blocking strips48may help provide structure (rigidity) at an outside end of sheet30to help with transport, indexing of webs, and give greater control of sheet30for pushing through reciprocating press cutter. As discussed elsewhere, curl-blocking strips48can be used with thermoforming processes other than rotary thermoforming and for polymeric materials other than polypropylene such as, for example, polystyrene, to provide such benefits. In some embodiments, curl-blocking strips48are not used and outside edges of sheet30are slit and separated from a center portion of sheet30before cutting stage108. In some embodiments, cutters18,20are sized to accept curled edges of sheet30. In some embodiments, nip rollers are used to flatten curled edges of sheet30. In some embodiments, a reverse curl is applied to the sheet30to compensate for edge curl. In some embodiments, the edges are chilled before thermoforming.

Rotor44includes a first end and an opposite second end as shown inFIG.13. A curl-blocking strip48is located adjacent each of the first end and the second end on one more of faces54. In illustrative embodiments, curl-blocking strips48are coupled to each face54. Article molds46are located axially between curl-blocking strips48. In the illustrative embodiment, a curl-blocking strip48is located adjacent each of the first end and the second end and article molds46are located axially between the pair of curl-blocking strips48. In other embodiments, curl-blocking strips48are formed as protrusions that extend axially away from the ends of rotor44and sheet30is wrapped at least partway over the ends and axially extending protrusions. In some embodiments, curl-blocking strips48are formed as cavities that extend radially into rotor44. In some embodiments, curl-block strips48are not used and a female die or clamps are used to block edge curl.

Curl-blocking strips48are shown as discrete strips. In other embodiments, curl-blocking strips48are continuous and form full hoop ring around rotor44. In other embodiments, curl-blocking strips48extend about 50% or more of a length of a facet of rotor44. In some embodiments, curl-blocking strips48and/or curl-blocking protrusions are integrally formed with rotor44.

One embodiment of curl-blocking strip48includes a pattern of diamond shaped protrusions50as shown inFIG.14. As sheet30is applied to rotor44of rotary thermoformer16, edges34,36of sheet30mold onto diamond shaped protrusions50which block edges34,36from curling. In other embodiments, protrusions50may be any other shape or combination of shapes that block edges34,36from curling.

Curl-blocking strips48are defined by the plurality of protrusions50as shown inFIG.13-15. Protrusions50form a pattern and are integrally formed with rotor44in some embodiments. In other embodiments, curl-blocking strips48may be uncoupled from rotor44and replaced with different curl-blocking strips48. In the illustrative embodiments, protrusions50are raised diamond shaped. Each curl-blocking strip48is located axially between an edge34,36and an outermost lid blank38. Because curl-blocking strips48are optional, curl-blocking strips48may be uncoupled from or not formed in rotor44in some embodiments.

As shown inFIG.14, each curl-blocking strip48includes a plurality of rows of protrusions50. Illustratively, curl-blocking strip48includes seven rows of protrusions50. In other embodiments, curl-blocking strip48includes one or more rows of protrusions50. Each protrusion is generally ellipse shaped with pointed ends51,53. Protrusions in a given row are oriented with their ends51,53aligned in a first direction. Protrusions in adjacent rows are oriented with their ends51,53aligned in a second direction. In the illustrative embodiment, the second direction is different than the first direction. As shown inFIG.14, the second direction is offset from the first direction by about 90 degrees. The alternating first and second direction alignments block sheet30from pulling/curling off in any direction.

Each protrusion has a steep side surface55such that side surface55has no draft or little draft). In some embodiments, side surface55extends away from face54of rotor44by about 90 degrees. Having no or little draft on side surface55blocks sheet30from easily releasing from curl-blocking strip48until sheet30moves perpendicularly away from curl-blocking strip48. Side surface55and pointed ends51,53may cooperate to block sheet30from releasing from curl-blocking strip48in a lateral direction. As a result, sheet30may release from curl-blocking strip48when sheet30moves away from curl-blocking strip48in about a perpendicular direction. Side surface55has a height of about 0.060 inches in the illustrative embodiment. In other embodiments, side surface55has a height of about 0.030 to about 0.080 inches.

During rotary thermoforming stage106, sheet30is wrapped at least partway about rotary thermoformer16to cause sheet30to thermoform to article mold46and curl-blocking strip48(if present) and form article-blank web32as suggested inFIG.13. A portion of sheet30engages faces54and article molds46as rotor44rotates about axis52. Rotation of rotor44causes the edge of each face54and article molds46to stretch sheet30away from roller14. Rotation of rotor44causes sheet30to mold to face54and article molds46.

As shown inFIGS.4and18, rotary thermoforming stage106of the present disclosure is performed without plug assist or positive pressure being applied on one side of sheet30to form article-blank web32. That is, no clam shell, plug, male mating mold, or female mating mold is urged toward rotor44to apply pressure to an outer face of sheet30. Illustratively, rotor44is a one sided tooling (no external mating mold(s)). In some embodiments, a vacuum is applied to rotor44to urge sheet30onto rotor44. In some embodiments, the molds on rotor44are male. In some embodiments, the molds on rotor44are female.

The circumferential width of each face54may have an effect on controlling sheet30and the thickness uniformity of sheet30and article-blank web32. To fit two or more columns of molds46onto a single face54may result in faces54with relatively large widths. Faces with too large of widths may result in article-blank webs32that have non-uniform thicknesses due to the stretching of sheet30caused by rotation of the faces. As such, some embodiments include faces54with a single columns of molds46as shown inFIG.13B.

In some embodiments, a vacuum is applied to rotor44. In some embodiments, the vacuum is between about one and about thirty inches of mercury. In some embodiments, the vacuum is between about ten and about thirty inches of mercury. In some embodiments, the vacuum is between about ten and about twenty inches of mercury. In some embodiments, the vacuum is between about fifteen and about twenty inches of mercury. In some embodiments, the vacuum is about one to 30 inches of mercury. In some embodiments, the vacuum is about fifteen inches of mercury.

Rotary thermoformer16may be temperature controlled by flowing fluid through rotary thermoformer16for example. In some embodiments, rotary thermoformer16is cooled with fluid at between about 60 degrees and about 90 degrees Fahrenheit. In some embodiments, rotary thermoformer16is cooled with fluid at about 70 degrees Fahrenheit. In illustrative embodiments, rotary thermoformer16has a temperature of between about 30 degrees Fahrenheit and about 150 degrees Fahrenheit. In some embodiments, rotary thermoformer16has a temperature of between about 60 degrees Fahrenheit and about 100 degrees Fahrenheit.

Rotary thermoforming sheet30forms article-blank web32as suggested inFIG.13. Article-blank web32is moved away from rotor44as rotary thermoformer16continues to rotate about rotation axis52. Article-blank web32includes article blanks38formed by article molds46as shown inFIG.16. In the illustrative embodiment, article blanks38are lid blanks. Article blanks38are cut downstream to provide articles10and, in the illustrative embodiment, lids210.

In embodiments that use curl-blocking strips48, a strip pattern56is formed in article-blank web32by curl-blocking strips48as shown inFIG.16. Strip pattern56is located between an edge34,36and an article blank38. Strip pattern56is thermoformed to curl-blocking strip48during rotary thermoforming stage106which blocks edges34,36of article-blank web32from curling. In contrast, a prior art article-blank web comprising certain polymeric materials and formed in a rotary thermoforming stage without curl-blocking strip48is shown inFIG.17and the edges of the article-blank web are curled outward. Strip pattern56also provides additional structure to edges34,36which may improve handling of article-blank web32in downstream stages of article-manufacturing process100.

Rotary thermoforming stage106includes an optional strip cooling step in some embodiments as shown inFIG.18. The cooling step uses strip-cooling air blowers80to direct relatively cool fluid toward sheet30and curl-blocking strips48. The cooling step comprises directing forced fluid toward rotor44at a location aligned axially with curl-blocking strips48. In other words, air blowers80may direct forced fluid toward sheet30and curl-blocking strips48. The cooling step may increase the speed of thermoforming sheet30to curl-blocking strips48which may decrease edge curl experienced by sheet30. In other embodiments, fluids other than air may be directed toward sheet30using air blowers80. Illustratively, a first and second air blower are arranged to blow air toward curl-blocking strips48located at each end of rotor44at a first pressure and a third blower is arranged to blow air at sheet30axially between curl-blocking strips48at a second pressure that is less than the first pressure.

Outlets of air blowers80are positioned up to about 48 inches away from sheet30in some embodiments. In one embodiment, for example, an outlet of an air blower80is positioned about 5 inches away from sheet30. Blown or compressed air may be directed toward sheet30. In some embodiments, air blowers80direct compressed air at between about 1 and about 40 psi toward sheet30. Air directed toward sheet30from air blowers80has a relatively lower temperature than a temperature of sheet30located just prior to air blowers80. Air blown by blowers80has a temperature of below about 350 degrees Fahrenheit in some embodiments. In some embodiments, air blown by blowers80has a temperature of below about 200 degrees Fahrenheit. In other examples, the air blown by blowers80has a temperature lower than a temperature of sheet30.

In some embodiments, a sheet30of polymeric material of a first formula is extruded and conditioned and smaller sheets of polymeric material of a second formula are located in or on molds of the thermoformer. The sheet30is over molded onto the smaller sheets so that article10has a portion with a desired second formula without forming the entire article10from the first formula. This may be desirable for example if the second formula is more expensive than the first formula. In some embodiments, ink films are located in or on molds to apply an ink layer to sheet30.

In some embodiments, article-blank web32is moved to splitting stage107after rotary thermoforming stage106as shown inFIG.3. In other embodiments, splitting stage107is performed at any point downstream of providing sheet30and may be performed between any other stages. During splitting stage107, article-blank web32is conducted through splitter25to separate article-blank web32into two or more strips47in the machine direction as suggested inFIG.4. Splitting stage107may be desired when sheet30comprises high shrinkage polymers like polypropylene or other polymers having a shrinkage rate of about 0.008 inches per inch or greater. By splitting sheet30into two or more strips, the magnitude of shrinkage of each strip is less than the shrinkage of the entire sheet30. For example, a 30 inch sheet may experience 0.48 inches of shrinkage while two strips of 15 inches may each experience 0.24 inches of shrinkage. As a result, aligning the strips with cutter in the transverse direction (axially relative to rotor rotation axes) may be easier and more accurate than aligning an entire sheet30with the greater shrinkage across the sheet.

The splitter25may include a plurality of rotor blades configured to cut through article-blank web32as it is conducted from thermoforming stage106to cutting stage108. The rotor blades may be moved relative to the sheet to engage or disengage the sheet as desired. For example, the blades could be moved to a disengaged position to not split sheet30in some embodiments.

Splitting article-blank web32into multiple strips47may improve handling and control of article-blank web32during cutting stage108. For example, a transverse position of each strip47may be independently adjusted as each strip47is conducted to cutting stage108to allow for variation in each row of article blanks38included in article-blank web32. In contrast, adjustment of a transverse position of a whole (un-split) article-blank web32may be limited because the adjustment would affect all rows of article blanks38.

In some embodiments, article-blank web32is split in a middle of article-blank web32to form two strips47of about equal width. In some embodiments, article-blank web32is split to separate each row of article blanks38into its own strip47. In some embodiments, splitting stage107is used when rotary cutter20has fixed position dies that are not adjustable. In some embodiments, rotary cutter20includes the adjustable position dies and splitting state107is omitted.

Article-blank web32is moved to cutting stage108after rotary thermoforming stage106or optionally after splitting stage107as shown inFIG.3. In illustrative embodiments, cutting stage108uses either reciprocating cutter18or rotary cutter20to cut articles10from article blanks38formed in article-blank web32as suggested inFIGS.19-22. In other embodiments, article-blank web32is cut using laser or water jet cutters.

Cutting stage108makes incisions in article-blank web32to form a carrier web and preformed articles coupled with carrier web in illustrative embodiments. The preformed articles are coupled with carrier web at one or more discrete joints that are configured to be broken (punched out) in response to a force being applied to the preforms in a separating step to provide articles10while leaving minimal or no traces of the discrete joints on articles10. In other embodiments, cutting stage108incorporates separating stage and cutting stage108makes incisions in article-blank web32to fully cut and separate articles10from article-blank web32.

Forming preform articles coupled with the carrier web may provide improved handling and collection of articles10after cutting stage107because the preforms can be separated from the carrier web while being grasped by a machine such as a conveyer belt and then continue downstream to stacking stage110or bagging stage112. In other embodiments, articles10are fully cut and separated from article-blank web32simultaneously which may result in a plurality of loose articles10.

In some embodiments, cutting stage108includes reciprocating cutter18as shown inFIGS.19and20. Article-blank web32is moved between an upper-press die58and a lower-press die60included in reciprocating cutter18. Upper-press die58and lower-press die60are moved toward one another and crush cut article-blank web32to provide article10. During the cutting, movement of article-blank web32is temporarily stopped while upper-press die58and the lower-press die60move relative to one another. Portions of article-blank web32may be cut from the continuously formed web32into panels before cutting stage108for cutting using reciprocating cutter18because of the start and stop characteristics of reciprocating cutter18.

In some embodiments, articles10are lids210that are cut using reciprocating cutter18. Sheet30may have a thickness (sometimes called the gauge of the sheet) of about twelve thousandths of an inch or greater when using reciprocating cutter18.

In some embodiments, cutting stage108includes rotary cutter20as shown inFIGS.21and22. Article-blank web32is moved between an upper-rotor die62and a lower-rotor die64included in rotary cutter20. Upper-rotor die62and lower-rotor die64each rotate about a corresponding rotation axis63,65relative to one another. Article-blank web32is moved continuously through rotary cutter20during the cutting stage.

Upper-rotor die62includes a rotor75and a plurality of upper dies76coupled with rotor75for movement therewith as shown inFIG.21. The plurality of upper dies76are arranged in axially extending columns and the columns are spaced apart circumferentially around rotor75. Each upper die76is formed to include an article-receiver aperture90shaped to receive article10. Edges of each upper die76are arranged to cut a perimeter and other desired features of article blanks38.

Each upper die76is individually movable axially, radially via shims for example, and/or circumferentially relative to rotor75. Each column of upper dies76may be movable axially, radially, and/or circumferentially relative to rotor75to adjust a position of upper dies76. Illustratively, upper dies76and columns of upper dies76are slidable relative to rotor75. Each upper die76and column of upper dies76are fixed in selected positions with fasteners, clamps, or any other suitable alternative method. Each individual upper die76and column of upper dies76are fixed in their selected positions before manufacturing process100begins and remain fixed in their selected positions during manufacturing process100.

Lower-rotor die64includes a rotor77and a plurality of lower dies78coupled with rotor77for movement therewith as shown inFIG.21. The plurality of lower dies78are arranged in axially extending columns and the columns are spaced apart circumferentially around rotor77. Edges of each lower die78are arranged to cut a desired feature of article blanks38such as a straw slot88for example.

Each lower die78is individually movable axially, radially, and/or circumferentially relative to rotor77. Each column of lower dies78may be movable axially, radially, and/or circumferentially relative to rotor77to adjust a position of lower dies78. Illustratively, lower dies78and columns of lower dies78are slidable relative to rotor75. Each lower die78and column of lower dies78are fixed in selected positions with fasteners, clamps, or any other suitable alternative method. Each individual lower die78and column of lower dies78are fixed in their selected positions before manufacturing process100begins and remain fixed in their selected positions during manufacturing process100.

A rotational speed of upper-rotor die62and/or lower-rotor die64may be adjusted during cutting stage108in real time so that dies66,88are more accurately aligned with each axial column of article blanks38when cutting the axial column of article blanks38as suggested inFIGS.4and21. In some embodiments, a sensor92detects a position of article blanks38upstream of rotary cutter20as suggested inFIG.4. The rotational speed of upper-rotor die62and/or lower-rotor die64are adjusted based on the sensed position of article blanks38so that dies76,78align with and cut article blanks38more accurately when the sensed article blanks38are received by rotary cutter20. The upper rotor die62and the lower rotor die64are geared together in the illustrative embodiment and rotate at the same speed. In some embodiments, dies62,64rotate at a fixed speed to match a shrinkage rate of sheet30.

Sensor92may be configured to detect the position of multiple article blanks38, for example, when splitter25is used to split article-blank web32into several strips. In some embodiments, the transverse position of article-blank web32or strips47of article-blank web32may be adjusted as they are fed to rotary cutter20to more accurately position article blanks38relative to dies76,78included in rotary cutter20. Sensor92is illustratively sends a light beam horizontally toward sheet30and captures portions of the beam reflected to sensor92. Sensor92may detect a locating feature included with sheet30and the measurement of the location of the feature relative to the dies62,64is used to vary the rotational speed of the dies62,64. Multiple sensors92may be used if sheet30is split at splitting stage107.

In some embodiments, mechanical locating features such as a tread of molds are used to locate article blanks38relative to dies76,78. In some embodiments, sheet30is moved relative to dies62,64. In some embodiments, articles10are measured after cutting stage108and the rotational speed of dies76,78is adjusted based on the measured articles.

In some embodiments, articles10are lids210and are cut using rotary cutter20. In such embodiments using rotary cutter20, sheet30may have an average thickness of between about one and about fifty-five thousandths of an inch. In some embodiments, sheet30has an average thickness of between about one and about nine thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of about six thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of about nine thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of between about eight and about nine thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of between about six and about ten thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of between about eight and about twelve thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of about twelve thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of less than about twelve thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has an average thickness of about eleven thousandths of an inch when rotary cutter20is used for the cutting stage. In some embodiments, sheet30has thickness of about ten thousandths of an inch when rotary cutter20is used for the cutting stage. Other articles10such as, for example, trays, bowls, containers, etc. may be formed by sheet30having similar thicknesses when rotary cutter20is used for the cutting stage.

In some embodiments, rotary cutter20is maintained at about 70 degrees Fahrenheit. Using rotary cutter20with rotary thermoformer16may allow for the production of articles10having a desired transparency and sheet thickness. As an example, rotary thermoformer16may allow for lids210with a desired transparency and rotary cutter20may allow for lids210to have an average thickness of between about six and about ten thousandths of an inch.

Sheet30has a width greater than about 30 inches in illustrative embodiment. In some embodiments, the width of sheet30is between about 30 inches and about 100 inches. In some embodiments, the width of sheet30is between about 30 inches and about 80 inches. In some embodiments, the width of sheet30is between about 50 inches and about 80 inches. In some embodiments, the width of sheet30is between about 50 inches and about 70 inches. In some embodiments, the width of sheet30is between about 50 inches and about 60 inches. In some embodiments, the width of sheet30is between about 55 inches and about 60 inches.

The present disclosure provides methods and apparatus for manufacturing continuously a plurality of articles10from a sheet having a width of greater than about 30 inches. Edge curl of sheet30increases at least as a function of the width of sheet30. In conventional processes, the edge curl is too great for sheets having a width of 30 inches or greater. Shrinkage rate of sheet30is at least one factor that affects edge curl on the sheet. The shrinkage rate of a sheet is applied per inch width such that as the width of the sheet increases, the shrinkage of the sheet and, therefore, edge curl of the sheet increases. According to the present disclosure, curl-blocking strips48and optionally air blowers80minimize edge curl of sheet30and allow for sheet30to have a relatively large width. Splitter25and/or varying rotational speed of the cutter20, and/or temperature of the rotor tool44and cooling air may minimize the effects of sheet30shrinking. In some embodiments, the edges of sheet30are separated from the web with or without using edge curl-blocking strips48after thermoforming and before cutting so that the curled edges are removed before sheet30is provided to cutter18,20.

The gram weight standard deviation for a given model of article10can indicate the consistency of the thickness of articles10. Low variation in thickness between articles10of the same model may provide products with higher consistency. Process100is configured to produce transparent polypropylene articles on a rotary thermoformer with about equal or less standard deviation as compared to polypropylene articles i) formed on a flatbed thermoformer and ii) having greater thicknesses than polypropylene articles10. A smaller thickness being desired for articles such as lids. Polymeric materials such as polypropylene formed on a flatbed thermoformer may be subject to forces that orient the material and make it more difficult to form articles from the material. Flatbed thermoforming such materials may have a limit on a thickness of the sheets because of the orienting result of the forces applied to the sheet. In contrast, those same materials may be used to form articles10having smaller wall thickness using rotary thermoformer16.

Process100is configured to produce polypropylene articles10on a rotary thermoformer with about equivalent standard deviation as compared to polystyrene articles i) formed on a flatbed thermoformer and ii) having similar thickness to that of polypropylene articles10. Process100is configured to produce polypropylene articles10on a rotary thermoformer with about equivalent to or less standard deviation as compared to polystyrene articles i) formed on a rotary thermoform and ii) having similar thickness to that of polypropylene articles10.

The following gram weight standard deviations apply to articles10formed from outermost rows of blanks38in article-blank web32and may have the worst standard deviation of the article-blank web due to potential sheet shrinkage and/or edge curl. In some embodiments, the gram weight standard deviation of a plurality of articles10of the same model is between about 0.040 and about 0.180 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is between about 0.050 and about 0.170 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is between about 0.050 and 0.110 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is between about 0.085 and 0.090 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is between about 0.050 and 0.080 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is between about 0.050 and 0.090 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is between about 0.060 and 0.10 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is about 0.050 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is no greater than about 0.050 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is no greater than about 0.060 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is no greater than about 0.10 using rotary thermoforming stage106. In some embodiments, the gram weight standard deviation of articles10is about 0.14 using rotary thermoforming stage106.

The gram weight standard deviation of articles10is less than about 8 percent of the total gram weight of article10in some embodiments using rotary thermoforming stage106. The gram weight standard deviation of articles10is less than about 4 percent of the total gram weight of article10in some embodiments using rotary thermoforming stage106. The gram weight standard deviation of articles10is about or less than about 2 percent of the total gram weight of article10in some embodiments using rotary thermoforming stage106. As one example, lid210has a target total gram weight of 2.5 grams and the standard deviation is about 0.050. The gram weight range of a plurality of articles10of the same model may be described in terms of a number of sigma. In one example, the range may be plus and minus three sigma or three standard deviations.

In one example, the polymeric material includes a polypropylene impact copolymer, walls of article10have a thickness of about 0.010 inches, article10is formed on a rotary thermoformer, and the standard deviation is about 0.10. In one example, the polymeric material includes a polypropylene impact copolymer, walls of article10have a thickness of about 0.012 inches, article10is formed on a rotary thermoformer, and the standard deviation is about 0.06.

In some embodiments, at least one of upper-rotor die62and lower-rotor die64includes the plurality of dies76,78formed to include article-receiver apertures90as shown inFIG.21. Article blanks38are moved into article-receiver apertures90which align article blanks38ahead of cutting. As a result, article blanks38may be more accurately cut to desired dimensional tolerances. In the illustrative embodiment, rotary cutter20further cuts an auxiliary cut88into article10at the same time as cutting article10from article blank38which may eliminate other cutting steps and machines. Auxiliary slot88is illustratively a straw slot formed in lid210, but other auxiliary cuts are envisioned. In other embodiments, no auxiliary cut88is made in article10.

Rotary cutter20dispenses cut articles10in a plurality of lines in some embodiments. Dispensing cut articles10in a line may help in inspecting, collecting, stacking, and bagging of cut articles10.

Stacking stage110of article-manufacturing process100is optional and shown inFIGS.23-26. Stacking stage110may be performed by manually stacking articles10, pushing articles10into a stack, using a wheel stacker, or any other suitable alternative methods. As shown inFIGS.23and24, stacking stage uses a pinch belt71and a star-wheel stacker26to stack articles10into a stack66of articles10in the illustrative embodiment. Illustratively, the articles10are lids210and are stacked using star-wheel stacker26.

Star-wheel stacker26is mounted to rotate about a stacker axis and is formed to include a plurality of notches27that extend into star-wheel stacker26for receiving articles10. Articles10are directed continuously into star-wheel stacker26which aligns each article10with a plurality of articles10to form stack66of articles10. Pinch belts71may be used to provide streams of single rows of articles10. The single rows of articles10may allow for better inspection of articles10and for diverting a single rejected article10or a row of rejected articles10out of process100and into a waste process.

Stacking stage110further includes a canister67in some embodiments as shown inFIGS.25and26. Canister67is arranged to receive a plurality of stacks66of articles10. Canister67is configured to be pickable by a robot69during article-manufacturing process100as suggested inFIG.26. Robot69is configured to move canisters67of stacked articles10to a conveyer belt that moves stacked articles10to an optional bagging stage112. In bagging stage112, articles10are bagged and transported and/or stored as suggested inFIG.3.

Article10is a shallow draw article such as lid10in some embodiments. Shallow draw thermoformed articles10made using the article-manufacturing process100of the present disclosure may have a draw ratio of about 2.0 or less where the draw ratio is the height/diameter of article10(or height/width for non-round articles). In some embodiments, the draw ratio is between about 0.065 and about 2.0. In some embodiments, the draw ratio is between about 0.065 and about 0.11. In some embodiments, the draw ratio is between about 0.07 and about 0.1. In some embodiments, the draw ratio is between about 0.1 and about 0.6. In some embodiments, the draw ratio is about 2.05.

Shallow draw thermoformed articles10made using the article-manufacturing process100of the present disclosure may have a final height of up to about 5 inches. In other embodiments, articles10may have a final height greater than 5 inches depending on the draw ratio. In illustrative embodiments where article10is a drink cup lid210, drink cup lid210has a height of between about 0.28 inches and about 0.33 inches. In other embodiments, shallow draw articles10may have a height of about 4.7 inches. In other embodiments, shallow draw articles10may have a height between about 0.7 inches and about 2.2 inches. In other embodiments, shallow draw articles10may have a height between about 0.3 inches and about 4.7 inches. In other embodiments, shallow draw articles10may have a height between about 1.0 inch and about 3.6 inches. In other embodiments, shallow draw articles10may have a height between about 0.3 inches and about 1 inch. In other embodiments, other thermoforming processes are used in place of shallow draw and the height may be greater than about 4.7 inches and the draw ratio is greater than about 2.

A method of making a thermoformed article may include a number of steps. The method may include extruding a sheet comprising polymeric materials, conditioning the sheet on a conditioning roller, rotary thermoforming the sheet to provide a web, and cutting the web to provide a thermoformed article. In some embodiments, the rotary thermoforming stage includes applying the sheet to a rotary thermoformer. The conditioning roller may have an outer surface having a surface roughness of between about 100 Ra (microinches) and about 240 Ra (microinches).

The rotary thermoformer includes a rotor mounted to rotate about a rotation axis of the rotary thermoformer and at least one article mold coupled to the rotor for rotation therewith. In some embodiments, the rotary thermoformer includes a curl-blocking strip including a plurality of protrusions that extend radially outward away from the rotor toward the sheet to engage and block the sheet from curling away from the rotor during the rotary thermoforming stage.

In illustrative embodiments, sheet30and, thus, thermoformed article10such as, for example, lid210is made with polymeric material. In some embodiments, the polymeric materials include one or more of polypropylene, ethylene, polyethylene, polylactic acid, polyactide, and polyethylene terephthalate. In some embodiments, polymeric materials include polystyrene. In some embodiments, polymeric materials include high impact polystyrene.

In some embodiments, sheet30and, thus, thermoformed article10is made from non-aromatic polymeric materials such that article10is free from polystyrene. In other words, article10is free from aromatic materials in some embodiments. As used herein, the term non-aromatic polymer refers to a polymer that is devoid of aromatic ring structures (e.g., phenyl groups) in its polymer chain. A non-aromatic polymeric material is a polymeric material free of aromatic polymers, styrenenic polymers, or polystyrene. In illustrative examples, the non-aromatic polymeric materials include polypropylene.

Aromatic molecules typically display enhanced hydrophobicity when compared to non-aromatic molecules. As a result, it would be expected that a polypropylene-based polymeric material instead of a polystyrene-based polymeric material would result in a change in hydrophobicity with a concomitant, but not necessarily predictable or desirable, change in surface adsorption properties of the resulting material. In addition, by virtue of the hydrocarbon chain in polystyrene, wherein alternating carbon centers are attached to phenyl groups, neighboring phenyl groups can engage in so-called pi-stacking, which is a mechanism contributing to the high intramolecular strength of polystyrene and other aromatic polymers. No similar mechanism is available for non-aromatic polymers such as polypropylene. Moreover, notwithstanding similar chemical reactivity and chemical resistance properties of polystyrene and polypropylene, polystyrene can be either thermosetting or thermoplastic when manufactured whereas polypropylene is exclusively thermoplastic. As a result, to the extent that surface adsorption properties, manufacturing options, and strength properties similar to those of polystyrene are sought, likely alternatives to polystyrene-based polymeric materials would be found in another aromatic polymer rather than in a non-aromatic polymer.

The use of non-aromatic materials may affect recyclability, insulation, microwavability, impact resistance, or other properties. At least one potential feature of an article formed of non-aromatic polymeric material according to various aspects of the present disclosure is that the article can be recycled. Recyclable means that a material can be added (such as regrind) back into an extrusion or other formation process without segregation of components of the material, i.e., an article formed of the material does not have to be manipulated to remove one or more materials or components prior to re-entering the extrusion process. In contrast, a polystyrene article may not be recyclable. In one example, an article made from non-aromatic or styrene-free materials may simplify recycling.

In illustrative embodiments, article10is transparent. Outer surface42of conditioning roller14is textured to have a surface roughness value that provides a desired control of sheet30and transparency and surface finish of article10. In accordance with the present disclosure, the term transparent incorporates a range of transparency values including translucent to fully transparent values. Furthermore, the term transparent encompasses transmittance, wide angle scattering (sometimes referred to as haze), narrow angle scattering (sometimes referred to as clarity or see-through quality), and any other factor affecting the ability to see through article10. In other embodiments, article10is not transparent.

Illustratively, article10is lid210that is transparent to allow a consumer to view contents of interior liquid-storage region of cup on which lid210is mated through article10. Lid210is transparent and made of non-aromatic polymeric materials. The transparency may be defined by clarity and haze values and examples of clarity and haze values for articles10formed using conditioning rollers14having different outer surface42texture roughness are shown inFIG.27. Articles10having a desired transparency may be formed using roller14having outer surface42with a surface roughness of less than about 400 Ra. In illustrative embodiments, articles10having a desired transparency are formed using roller14having outer surface42with surface roughness of between about 100 Ra and about 240 Ra.

The clarity of article10as discussed herein is measured using ASTM D 1746 which is hereby incorporated by reference herein in its entirety. In some examples, the clarity of article10is in a range of about 0% to about 100%. In some examples, the clarity of article10is in a range of about 10% to about 99%. In some examples, the clarity of article10is in a range of about 20% to about 100%. In some examples, the clarity of article10is in a range of about 30% to about 100%. In some examples, the clarity of article10is in a range of about 40% to about 100%. In some examples, the clarity of article10is in a range of about 50% to about 100%. In some examples, the clarity of article10is in a range of about 60% to about 100%. In some examples, the clarity of article10is in a range of about 70% to about 100%. In some examples, the clarity of article10is in a range of about 80% to about 100%. In some examples, the clarity of article10is in a range of about 90% to about 100%.

In some examples, the clarity of article10is in a range of about 40% to about 95%. In some examples, the clarity of article10is in a range of about 50% to about 95%. In some embodiments, the clarity of article10is in a range of about 55% to about 95%. In some embodiments, the clarity of article10is in a range of about 60% to about 95%. In some embodiments, the clarity of article10is in a range of about 55% to about 65%. In some embodiments, the clarity of article10is in a range of about 65% to about 75%. In some embodiments, the clarity of article10is in a range of about 70% to about 95%. In some embodiments, the clarity of article10is in a range of about 70% to about 90%. In some embodiments, the clarity of article10is in a range of about 70% to about 85%. In some embodiments, the clarity of article10is in a range of about 70% to about 80%. In some embodiments, the clarity of article10is in a range of about 65% to about 85%.

In illustrative embodiments, the clarity of article10is greater than about 70%. In some embodiments, the clarity of article10is greater than about 60%. In some embodiments, the clarity of article10is greater than about 65%. In some embodiments, the clarity of article10is greater than about 75%.

In some examples, the clarity of article10is about 56.2%. In some examples, the clarity of article10is about 58.5%. In some examples, the clarity of article10is about 63.7%. In some examples, the clarity of article10is about 60.2%. In some examples, the clarity of article10is about 70.2%. In some examples, the clarity of article10is about 80.9%. In some examples, the clarity of article10is about 94.8%. In some examples, the clarity of article10is about 74.2%. In some examples, the clarity of article10is about 71.2%. In some examples, the clarity of article10is about 70.3%. In some examples, the clarity of article10is about 65.8%. In some examples, the clarity of article10is about 63.2%. In some examples, the clarity of article10is about 54.6%. In some examples, the clarity of article10is about 47.7%.

The haze of article10as discussed herein is measured using ASTM D 1003 procedure B which is hereby incorporated by reference herein in its entirety. In some examples, the haze of article10is in a range of about 0% to about 60%. In some examples, the haze of article10is in a range of about 10% to about 60%. In some examples, the haze of article10is in a range of about 0% to about 70%. In some examples, the haze of article10is in a range of about 0% to about 80%. In some examples, the haze of article10is in a range of about 0% to about 90%. In some examples, the haze of article10is in a range of about 0% to about 100%.

In some examples, the haze of article10is in a range of about 10% to about 40%. In some examples, the haze of article10is in a range of about 20% to about 38%. In some examples, the haze of article10is in a range of about 20% to about 40%. In some examples, the haze of article10is in a range of about 30% to about 40%. In some examples, the haze of article10is in a range of about 14% to about 25%. In some examples, the haze of article10is in a range of about 0% to about 30%. In some examples, the haze of article10is in a range of about 10% to about 30%. In some examples, the haze of article10is in a range of about 20% to about 28%. In some examples, the haze of article10is less than about 60%. In some examples, the haze of article10is less than about 50%. In some examples, the haze of article10is less than about 40%. In some examples, the haze of article10is less than about 30%.

In illustrative embodiments, the haze of article10is less than about 30%. In some embodiments, the haze of article10is less than about 29%. In illustrative embodiments, the haze of article10is less than about 28%. In illustrative embodiments, the haze of article10is less than about 40%.

In some examples, the haze of article10is about 36.9%. In some examples, the haze of article10is about 23.0%. In some examples, the haze of article10is about 21.5%. In some examples, the haze of article10is about 20.2%. In some examples, the haze of article10is about 23.5%. In some examples, the haze of article10is about 18.8%. In some examples, the haze of article10is about 14.1%. In some examples, the haze of article10is about 28.3%. In some examples, the haze of article10is about 31.4%. In some examples, the haze of article10is about 32.4%. In some examples, the haze of article10is about 32.8%. In some examples, the haze of article10is about 39.9%. In some examples, the haze of article10is about 29.1%.

In some examples, the clarity of article10is greater than about 70% and the haze is less than about 30%. In some examples, the clarity of article10is about 74.2% and the haze is about 28.3%. In some examples, the clarity of article10is about 71.2% and the haze is about 32.8%. In some examples, the clarity of article10is about 63.2% and the haze is about 32.8%.

When forming transparent articles10, the average haze and the average clarity of articles10may be varied at least by varying the surface roughness of outer surface42of roller14. Table 1 shown below provides characteristics of a number of example transparent articles10formed using conditioning rollers14with different average surface roughness values on the portion of the outer surface42that aligns with molds46.

TABLE 1Example Article Data SummaryExampleExampleExampleExampleExampleExampleExamplel234567Average8Ral00Ra140-160-400/200/340-400RaRoughness160Ra200Ra400Ra360Ra(microinches)Average32.431.428.332.833.539.929.1HazeAverage70.365.874.271.270.554.647.7ClarityAverage0.0100.01200.0120.0110.0120.0110.008Sheet Gauge(inches)Gram Weight0.1700.0900.0850.1100.050N/AN/AStandardDeviation(grams)Gram Weight1.0200.5400.5100.6600.300N/AN/ARange(+/−3σ)

The surface roughness of conditioning roller14is greater than typical smooth rollers14to provide greater control of sheet30as opposed to providing a surface roughness or texture to article10. Greater controller of sheet30may be desired for forming transparent and/or polypropylene sheets or sheets of polymeric material having a higher shrinkage rate such as a shrinkage rate of about or greater than about 0.007 inches per inch. Molds46on thermoformer16contact sheet30after roller14and, as a result, molds46may have a greater impact on surface roughness of article10than roller14. The surface roughness of roller14may be increased in response to increasing a line speed of process100. Increasing the surface roughness of roller14in such situations may not affect the surface roughness of articles10.

Article10is transparent and has a surface roughness that is less than a surface roughness of outer surface42. Article10is transparent and has a surface roughness of between about 5 Ra (microinches) and about 40 Ra (microinches) in some embodiments. Article10is transparent and has a surface roughness of between about 10 Ra (microinches) and about 30 Ra (microinches) in some embodiments. Article10is transparent and has a surface roughness of between about 10 Ra (microinches) and about 20 Ra (microinches) in some embodiments. Illustratively, article10has a surface roughness of between about 13 Ra (microinches) and about 16 Ra (microinches) in some embodiments. Article10has a surface roughness of about 13.6 Ra (microinches) in some embodiments. Article10has a surface roughness of about 13 Ra (microinches) in some embodiments. Article10has a surface roughness of about 15.6 Ra (microinches) in some embodiments. Article10has a surface roughness of about 15 Ra (microinches) in some embodiments. Article10has a surface roughness of about 14.8 Ra (microinches) in some embodiments.

Outer surface42of conditioning roller14has a surface roughness at least 2 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 3 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 4 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 5 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 8 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 10 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 12 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 13 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 15 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 20 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 25 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness at least 13 times greater than the surface roughness of article10in some embodiments.

Outer surface42of conditioning roller14has a surface roughness of between about 2 and 5 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness of between about 2 and 30 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness of between about 10 and 25 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness of between about 5 and 10 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness of between about 5 and 15 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness of between about 10 and 25 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness of between about 10 and 20 times greater than the surface roughness of article10in some embodiments. Outer surface42of conditioning roller14has a surface roughness of between about 20 and 30 times greater than the surface roughness of article10in some embodiments.

In one example, sheet30comprises 40% or more by weight of sheet30polypropylene, outer surface42of roller14has a surface roughness of between about 100 Ra (microinches) and about 200 Ra (microinches), and article10is produced having a surface roughness of between about 10 Ra (microinches) and about 20 Ra (microinches). In another example, sheet30comprises 40% or more by weight of sheet30polypropylene, outer surface42of roller14has a surface roughness of between about 160 Ra (microinches), and about 200 Ra (microinches) and article10has a surface roughness of between about 13 Ra (microinches) and about 16 Ra (microinches).

Illustratively article10is lid210which includes a ring-shaped brim mount82, a central closure84, and a plurality of deformable product-identification domes86as shown, for example, inFIG.2. Reference is hereby made to U.S. application Ser. No. 15/946,023, filed Apr. 5, 2018 and titled DRINK CUP LID for disclosure relating to lids in accordance with the present disclosure, which is hereby incorporated by reference in its entirety herein.

Brim mount82is configured to mount with a brim included in a container. Central closure84is appended to brim mount82and adapted to block access into an interior liquid-storage region of the container. Product-identification domes86append from central closure84and are configured to move from an un-deformed arrangement to a deformed arrangement to indicate visually a selected flavor of a liquid beverage stored in the container. In some embodiments, deformable product-identification domes86are omitted from lid210.

In some embodiments, each product-identification dome86is less transparent in the deformed arrangement than the un-deformed arrangement to indicate visually a selected flavor of a liquid beverage stored in an interior liquid-storage region of a cup. In some embodiments, each product-identification dome86is relatively opaque (sometimes referred to as craze or whitening) in the deformed arrangement as compared to the un-deformed arrangement to indicate visually a selected flavor of a liquid beverage stored in an interior liquid-storage region of a cup. In some embodiments, each product-identification dome86has portions that are transparent and portions that become relatively opaque (crazed or whitened) in the deformed arrangement as compared to having all portions being relatively transparent in the un-deformed arrangement to indicate visually a selected flavor of a liquid beverage stored in an interior liquid-storage region of a cup. A consumer may be able to see through product-identification domes86when product-identification domes86are in the un-deformed arrangement and the deformed arrangement.

Product-identification domes86share the clarity and haze values of article10when product-identification domes86are in the first arrangement. In other words, product-identification domes86share the clarity and haze values of article10before product-identification domes86are depressed downward.

Article10is made, for example, by thermoforming sheet30in an article-manufacturing process in accordance with the illustrative embodiments of the present disclosure. In some embodiments, sheet30is a single-layer sheet that comprises a polymeric mixture. In other embodiments, sheet30is a multi-layer sheet. In one aspect, the polymeric mixture may be formed through an extrusion process of a formulation. In some embodiments, article10is made from a polymeric non-aromatic sheet of material having a formulation.

Illustratively, the formulation for forming sheet30may be added to a hopper on an extrusion machine and heated to produce a molten material in an extruder. The molten material may be extruded to produce the single-layer sheet30. In some embodiments, the single-layer sheet30has a density between 0.8 g/cm3and 1.1 g/cm3. In some embodiments, the single-layer sheet has a density of about 0.902 g/cm3. In some embodiments, the single-layer sheet has a density of about 0.9 g/cm3.

The polymeric mixture of sheet30may comprise, for example, a plastic polymer, a material, or a resin, and may optionally include one or more additives. Examples of plastic polymers, resins, or materials suitable for single-layer sheet30include high density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene (PP), and copolymers of any combination of ethylene, propylene, butylene, and any other suitable alpha-olefin. In some aspects, the plastic polymer, material, or resin may be called a base resin.

In one aspect, the polypropylene may be a polypropylene homopolymer, a polypropylene copolymer, a polypropylene impact copolymer, or combinations thereof. In some embodiments, the polypropylene may contain an additive. In some aspects, the polypropylene copolymer is a random copolymer.

In some examples, sheet30comprises a polymeric mixture comprising a first polypropylene and a second polypropylene. In some examples, the first polypropylene may be a homopolymer. In some examples, the second polypropylene may be a polypropylene impact copolymer. In some examples, sheet30comprises a first polypropylene, a second polypropylene, and a polypropylene random copolymer.

In some examples, the polypropylene homopolymer may be a high crystallinity homopolymer. In some examples, the polypropylene homopolymer may comprise a nucleating agent. In some examples, the polypropylene homopolymer is Braskem INSPIRE™ 6025N.

In some examples, a polypropylene impact copolymer comprises a copolymer of ethylene and propylene. In some examples, a polypropylene impact copolymer is a heterophasic in-situ blend comprising an ethylene/propylene rubber (EPR) component. In some examples, a polypropylene impact copolymer is a heterophasic in-situ blend comprising an ethylene/propylene rubber (EPR) component distributed inside a semi-crystalline polypropylene homopolymer matrix. Illustratively, a polypropylene impact copolymer comprises a rubber phase and a polypropylene matrix phase. In some examples, a polypropylene impact copolymer may be produced with a Ziegler Natta catalyst. In some examples, a polypropylene impact copolymer is a semi-crystalline thermoplastic resin. In some examples, the polypropylene impact copolymer contains a nucleating agent. In some examples, the polypropylene impact copolymer is LyondellBasell Pro-fax™ SC204.

In some embodiments, sheet30has a rubber content up to about 50% by weight of sheet. In some embodiments, sheet30comprises at least 0.05%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 12%, 14%, 16%, 18%, 20%, 25%, 30%, 35%, or 40% by weight rubber. In some embodiments, the rubber content of sheet30can be selected from a first series of ranges of about 0.5% to about 50%, about 0.5% to about 40%, about 0.5% to about 30%, about 0.5% to about 20%, about 0.5% to about 18%, about 0.5% to about 16%, about 0.5% to about 10%, or about 0.5% to about 5% by weight of the single-layer sheet. In some embodiments, the rubber content of sheet30can be selected from a second series of ranges of about 0.5% to about 20%, about 1% to about 20%, about 2% to about 20%, about 2.5% to about 20%, about 2.5% to about 20%, about 3% to about 20%, about 3.5% to about 20%, about 4% to about 20%, about 4.5% to about 20%, about 5% to about 20%, about 6% to about 20%, or about 7% to about 20% by weight of sheet30. In some embodiments, the rubber content of sheet30can be selected from a third series of ranges of about 0.5% to about 20%, about 1% to about 20%, about 1.5% to about 20%, about 2% to about 20%, about 2% to about 15%, about 2% to about 10%, about 2% to about 8%, or about 2% to about 5% by weight of the single-layer sheet. In some examples, the rubber content is about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5% about 4%, about 4.5% about 5%, about 6%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 12%, about 14%, about 16%, about 18%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, or about 50% by weight of sheet30.

In some examples, sheet30comprises a polymeric mixture comprising a base resin and a secondary resin. Illustratively, sheet30may comprise up to 99% base resin. In some examples, sheet30may comprise up to 99% secondary resin. Sheet30may comprise an amount of base resin selected from a range of about 5% to about 95%, about 10% to about 95%, about 10% to about 85%, about 20% to about 85%, about 20% to about 75%, about 30% to about 75%, about 40% to about 75%, or about 40% to about 60% by weight of sheet. In some embodiments, sheet30may comprise an amount of base resin selected from a range of about 15% to about 75%, about 15% to about 65%, about 15% to about 50%, about 20% to about 50%, or about 25% to about 45% by weight of sheet. sheet30may comprise an amount of base resin of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 48%, about 49%, about 50%, about 51%, about 52%, about 55%, about 60%, about 65%, about 70%, about 80%, or about 95% by weight of sheet. Sheet30may comprise an amount of secondary resin selected from a range of about 5% to about 95%, about 10% to about 95%, about 10% to about 85%, about 20% to about 85%, about 20% to about 75%, about 25% to about 70%, about 30% to about 75%, about 40% to about 75%, about 45% to about 65%, or about 40% to about 60% by weight of sheet. Sheet30may comprise an amount of secondary resin of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 48%, about 49%, about 50%, about 51%, about 52%, about 55%, about 60%, about 65%, about 70%, about 80%, or about 95% by weight of sheet. In some examples, sheet30comprises about 50% base resin and about 50% secondary resin. In some examples, sheet30comprises about 50% base resin and about 49% secondary resin. In some examples, the single-layer sheet comprises about 35% base resin and about 55% secondary resin. In some embodiments, the base resin is a polypropylene. In some embodiments, the secondary resin is a polypropylene. In some examples both the base resin and the secondary resin are a polypropylene. In some embodiments, the base resin is a polypropylene homopolymer. In some embodiments, the secondary resin is a polypropylene impact copolymer. In some embodiments, the base resin is a polypropylene impact copolymer. In some embodiments, the secondary resin is a polypropylene homopolymer.

In some examples, sheet30comprises a polymeric mixture comprising a polypropylene homopolymer and a polypropylene impact copolymer. Illustratively, sheet30may comprise up to 99% polypropylene homopolymer. In some examples, sheet30may comprise up to 99% polypropylene impact copolymer. Sheet30may comprise an amount of polypropylene homopolymer selected from a range of about 5% to about 95%, about 10% to about 95%, about 10% to about 85%, about 20% to about 85%, about 20% to about 75%, about 30% to about 75%, about 40% to about 75%, or about 40% to about 60% by weight of sheet. In some embodiments, sheet30may comprise an amount of polypropylene homopolymer selected from a range of about 15% to about 75%, about 15% to about 65%, about 15% to about 50%, about 20% to about 50%, or about 25% to about 45% by weight of sheet. Sheet30may comprise an amount of polypropylene homopolymer of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 48%, about 49%, about 50%, about 51%, about 52%, about 55%, about 60%, about 65%, about 70%, about 80%, or about 95% by weight of sheet. Sheet30may comprise an amount of polypropylene impact copolymer selected from a range of about 5% to about 95%, about 10% to about 95%, about 10% to about 85%, about 20% to about 85%, about 20% to about 75%, about 25% to about 70%, about 30% to about 75%, about 40% to about 75%, about 45% to about 65%, or about 40% to about 60% by weight of sheet. Sheet30may comprise an amount of polypropylene impact copolymer of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 48%, about 49%, about 50%, about 51%, about 52%, about 55%, about 60%, about 65%, about 70%, about 80%, or about 95% by weight of sheet. In some examples, sheet30comprises about 50% polypropylene homopolymer and about 50% polypropylene impact copolymer. In some examples, sheet30comprises about 50% polypropylene homopolymer and about 49% polypropylene impact copolymer. In some examples, the single-layer sheet comprises about 35% polypropylene homopolymer and about 55% polypropylene impact copolymer.

In some embodiments, sheet30has a rubber content up to about 50% by weight of sheet. In some embodiments, sheet30comprises at least 0.05%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 12%, 14%, 16%, 18%, 20%, 25%, 30%, 35%, or 40% by weight rubber. In some embodiments, the rubber content of sheet30can be selected from a first series of ranges of about 0.5% to about 50%, about 0.5% to about 40%, about 0.5% to about 30%, about 0.5% to about 20%, about 0.5% to about 18%, about 0.5% to about 16%, about 0.5% to about 10%, or about 0.5% to about 5% by weight of the single-layer sheet. In some embodiments, the rubber content of sheet30can be selected from a second series of ranges of about 0.5% to about 20%, about 1% to about 20%, about 2% to about 20%, about 2.5% to about 20%, about 2.5% to about 20%, about 3% to about 20%, about 3.5% to about 20%, about 4% to about 20%, about 4.5% to about 20%, about 5% to about 20%, about 6% to about 20%, or about 7% to about 20% by weight of sheet30. In some embodiments, the rubber content of sheet30can be selected from a third series of ranges of about 0.5% to about 20%, about 1% to about 20%, about 1.5% to about 20%, about 2% to about 20%, about 2% to about 15%, about 2% to about 10%, about 2% to about 8%, or about 2% to about 5% by weight of the single-layer sheet. In some examples, the rubber content is about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5% about 4%, about 4.5% about 5%, about 6%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 12%, about 14%, about 16%, about 18%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, or about 50% by weight of sheet30.

In some embodiments, the polypropylene homopolymer has a melt flow as measured by ASTM Method D1238 (230° C., 2.16 kg) of a range of about 1 g/10 min to about 10 g/10 min, about 1 g/10 min to about 5 g/10 min, or about 1 g/10 min to about 4 g/10 min. In some examples, the polypropylene homopolymer has a melt flow as measured by ASTM Method D1238 (230° C., 2.16 kg) of about 1 g/10 min, about 1.5 g/10 min, about 2 g/10 min, about 2.5 g/10 min, about 3 g/10 min, about 3.5 g/10 min, about 4 g/10 min, about 5 g/10 min, about 6 g/10 min, about 7 g/10 min, about 8 g/10 min, or about 10 g/10 min.

In some embodiments, the polypropylene homopolymer has a flexural modular as measured by ASTM Method D790A (0.05 in/min, 1% secant) of a range of about 100,000 psi to about 700,000 psi, about 100,000 psi to about 600,000 psi, about 100,000 psi to about 500,000 psi, or about 200,000 psi to about 500,000 psi. In some examples, the polypropylene homopolymer has a flexural modular as measured by ASTM Method D790A (0.05 in/min, 1% secant) of about 100,000 psi, about 200,000 psi, about 250,000 psi, about 300,000 psi, about 350,000 psi, about 400,000 psi, about 500,000 psi, about 600,000 psi, or about 700,000 psi.

In some embodiments, the polypropylene impact copolymer has a melt flow as measured by ASTM Method D1238 (230° C., 2.16 kg) of a range of about 1 g/10 min to about 10 g/10 min, about 1 g/10 min to about 8 g/10 min, about 2 g/10 min to about 8 g/10 min, or about 2 g/10 min to about 6 g/10 min. In some examples, the polypropylene impact copolymer has a melt flow as measured by ASTM Method D1238 (230° C., 2.16 kg) of about 1 g/10 min, about 2 g/10 min, about 2.5 g/10 min, about 3 g/10 min, about 3.5 g/10 min, about 4 g/10 min, about 4.5 g/10 min, about 5 g/10 min, about 5.5 g/10 min, about 6 g/10 min, about 7 g/10 min, about 8 g/10 min, or about 10 g/10 min.

In some embodiments, the polypropylene impact copolymer has a flexural modular as measured by ASTM Method D790A (0.05 in/min, 1% secant) of a range of about 100,000 psi to about 700,000 psi, about 100,000 psi to about 600,000 psi, about 100,000 psi to about 500,000 psi, or about 200,000 psi to about 500,000 psi. In some examples, the polypropylene impact copolymer has a flexural modular as measured by ASTM Method D790A (0.05 in/min, 1% secant) of about 100,000 psi, 200,000 psi, about 230,000 psi, about 250,000 psi, about 300,000 psi, about 350,000 psi, about 400,000 psi, about 500,000 psi, about 600,000 psi, or about 700,000 psi.

In some embodiments, the polypropylene impact copolymer has a rubber content up to about 50% by weight of the polypropylene impact copolymer. In some embodiments, the polypropylene impact copolymer comprises at least 0.05%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 12%, 14%, 16%, 18%, 20%, 25%, 30%, 35%, or 40% by weight rubber. In some embodiments, the rubber content of the polypropylene impact copolymer can be selected from a first series of ranges of about 0.5% to about 50%, about 0.5% to about 40%, about 0.5% to about 30%, about 0.5% to about 20%, about 0.5% to about 18%, about 0.5% to about 16%, or about 0.5% to about 10% by weight of the polypropylene impact copolymer. In some embodiments, the rubber content of the polypropylene impact copolymer can be selected from a second series of ranges of about 0.5% to about 30%, about 1% to about 30%, about 3% to about 30%, about 5% to about 30%, about 6% to about 30%, or about 7% to about 30% by weight of the polypropylene impact copolymer. In some embodiments, the rubber content of the polypropylene impact copolymer can be selected from a third series of ranges of about 0.5% to about 30%, about 1% to about 30%, about 1% to about 20%, about 2% to about 20%, about 2% to about 15%, about 3% to about 15%, about 3% to about 10%, or about 5% to about 10% by weight of the polypropylene impact copolymer. In some examples, the rubber content is about 0.5%, about 1%, about 3%, about 4%, about 5%, about 6%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 12%, about 14%, about 16%, about 18%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, or about 50% by weight of the polypropylene impact copolymer.

In some embodiments, sheet30comprises a polymeric mixture further comprising an additive. Exemplary additives include a copolymer, clarifiers, process aids, slip agents, combinations thereof, or any suitable material for improving the single-layer sheet. In some embodiments, the additive is a clarifier. In some embodiments, the clarifier is a polypropylene random copolymer. In some embodiments, the additive is a copolymer. In some embodiments, the additive is a random copolymer. In some embodiments, the copolymer is an ethylene-polypropylene copolymer. In some embodiments, the copolymer is a random ethylene-polypropylene copolymer. In some embodiments, sheet30comprises Braskem RP650. In some embodiments, the additive is Braskem RP650.

In some embodiments, the additive may be up to about 20% or up to about 10% by weight of the polymeric mixture of sheet30. In some embodiments, the additive may be selected from a range of about 0.5% to about 20%, about 0.5% to about 15%, about 5% to about 15%, about 0.5% to about 10%, about 0.5% to about 5%, or about 0.5% to about 3% by weight of sheet30. In some embodiments sheet30comprises about 0.5%, about 1%, about 1.5%, about 2%, about 3%, about 4%, about 5%, about 6%, about 8%, about 10%, about 12%, about 14%, about 16%, about 18%, or about 20%, by weight of an additive. In some embodiments, the polymeric mixture of sheet30comprises about 0.5% to about 5% ethylene-propylene copolymer. In some embodiments, the polymeric mixture comprises about 0.5% to about 15% ethylene-propylene random copolymer. In some embodiments, the polymeric mixture comprises about 5% to about 15% ethylene-propylene random copolymer.

In some embodiments, sheet30consists of a polymeric mixture comprising a first polypropylene and a second polypropylene in accordance with the present disclosure. In some embodiments, sheet30comprises a polymeric formulation consisting of a first polypropylene, a second polypropylene, and an additive. In some embodiments, sheet30comprises a polymeric formulation consisting of a first polypropylene, a second polypropylene, and a random copolymer. In some embodiments, sheet30comprises a polymeric formulation consisting of a first polypropylene, a second polypropylene, and an ethylene-propylene copolymer. In some embodiments, sheet30comprises a polymeric formulation consisting of a first polypropylene and a second polypropylene.

In some embodiments, sheet30consists of a polymeric mixture comprising a base resin and a secondary resin in accordance with the present disclosure. In some embodiments, sheet30comprises a polymeric formulation consisting of a base resin, a secondary resin, and an additive. In some embodiments, sheet30comprises a polymeric formulation consisting of a base resin, a secondary resin, and a random copolymer. In some embodiments, sheet30comprises a polymeric formulation consisting of a base resin, a secondary resin, and an ethylene-propylene copolymer. In some embodiments, sheet30comprises a polymeric formulation consisting of a polypropylene homopolymer and an polypropylene impact copolymer. In some embodiments, sheet30comprises a polymeric formulation consisting of a polypropylene homopolymer, a polypropylene impact copolymer, and a polypropylene random copolymer.

In some embodiments, sheet30consists of a polymeric mixture consisting of a base resin and a secondary resin in accordance with the present disclosure. In some embodiments, sheet30consists of a polymeric formulation consisting of a base resin, a secondary resin, and an additive. In some embodiments, sheet30consists of a polymeric formulation consisting of a base resin, a secondary resin, and a random copolymer. In some embodiments, sheet30consists of a polymeric formulation consisting of a base resin, a secondary resin, and an ethylene-propylene copolymer. In some embodiments, sheet30consists of a polymeric formulation consisting of a polypropylene homopolymer and an polypropylene impact copolymer. In some embodiments, sheet30consists of a polymeric formulation consisting of a polypropylene homopolymer, a polypropylene impact copolymer, and a polypropylene random copolymer.

The following numbered clauses include embodiments that are contemplated and non-limiting:

Clause 1. A method of providing an article, the method comprising

providing a sheet comprising polymeric materials.

Clause 2. The method of clause 1, any other suitable clause, or combination of suitable clauses, further comprising molding the sheet onto a mold to provide an article-blank web.

Clause 3. The method of clause 2, any other suitable clause, or combination of suitable clauses, further comprising cutting the article-blank web to form a carrier web and an article preform coupled with the carrier web after molding the sheet.

Clause 4. The method of clause 3, any other suitable clause, or combination of suitable clauses, separating the article preform from the carrier web to provide the article.

Clause 5. The method of clause 4, any other suitable clause, or combination of suitable clauses, further comprising conditioning the sheet with a surface of a rotating roller and the surface of the rotating roller has a surface roughness of greater than about 80 Ra and less than about 380 (microinches).

Clause 6. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the mold is included in a rotary thermoformer, the molding stage includes applying the sheet onto the mold included in the rotary thermoformer to provide the article-blank web, and the polymeric materials has a shrinkage rate of about or greater than about 0.008 inches per inch.

Clause 7. The method of clause 6, any other suitable clause, or combination of suitable clauses, wherein the polymeric materials include polypropylene.

Clause 8. The method of clause 7, any other suitable clause, or combination of suitable clauses, wherein the polypropylene comprises rubber.

Clause 9. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the molding stage includes applying the sheet to a single sided tool.

Clause 10. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the polymeric materials comprise polypropylene and the article has a wall thickness of about 0.012 inches and is within three sigma of a standard deviation of 0.06.

Clause 11. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the polymeric materials comprise polypropylene and the article has a wall thickness of about 0.010 inches and is within three sigma of a standard deviation of 0.1.

Clause 12. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein controlling edge curl includes applying the sheet to edge-curl blocking strips.

Clause 13. The method of clause 12, any other suitable clause, or combination of suitable clauses, wherein the molding stage is performed using a rotary thermoformer and the edge-curl blocking strips are coupled with the rotary thermoformer.

Clause 14. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the cutting stage is performed with a rotor die that includes a rotor configured to rotate about an axis and dies coupled with the die and the dies are adjustable axially, radially, and circumferentially relative to the rotor about the axis.

Clause 15. The method of clause 4, any other suitable clause, or combination of suitable clauses, further comprising splitting the article-blank web into at least two strips after the molding stage and before the cutting stage.

Clause 16. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the molding stage is performed using a rotary thermoformer and the article has a clarity of about or greater than about 40% as measured using ASTM D 1746 and a haze of about or less than about 70% as measured using ASTM D 1003 procedure B.

Clause 17. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the sheet has a thickness of about or less than about 0.012 inches and the polymeric materials have a shrinkage rate of about or greater than about 0.008 inches per inch.

Clause 18. The method of clause 17, any other suitable clause, or combination of suitable clauses, wherein the polymeric materials comprise polypropylene.

Clause 19. The method of clause 4, any other suitable clause, or combination of suitable clauses, wherein the providing stage includes extruding the sheet comprising polymeric materials.

Clause 20. A method of providing a thermoformed article, the method comprising

providing a sheet comprising polymeric materials.

Clause 21. The method of clause 20, any other suitable clause, or combination of suitable clauses, further comprising conditioning the sheet with a surface of a rotating roller.

Clause 22. The method of clause 21, any other suitable clause, or combination of suitable clauses, wherein the rotating roller has a surface roughness of less than about 400 Ra (microinches).

Clause 23. The method of clause 22, any other suitable clause, or combination of suitable clauses, further comprising thermoforming the sheet onto a mold to provide an article-blank web having a plurality of article blanks formed therein after conditioning the sheet.

Clause 24. The method of clause 23, any other suitable clause, or combination of suitable clauses, further comprising cutting the article-blank web after thermoforming the sheet to provide the thermoformed article.

Clause 25. The method of clause 24, any other suitable clause, or combination of suitable clauses, wherein the thermoforming stage is performed using a rotary thermoformer.

Clause 26. The method of clause 25, any other suitable clause, or combination of suitable clauses, wherein the cutting stage is performed using a rotary cutter.

Clause 27. The method of clause 24, any other suitable clause, or combination of suitable clauses, wherein cutting the article-blank web includes rotating a rotor die included in a rotary cutter about an axis, measuring a distance between the rotor die and a first article blank included in the plurality of article blanks located upstream of the rotor die, varying a rotational speed of the rotor die based on the distance, and applying pressure to the article-blank web with the rotor die.

Clause 28. The method of clause 24, any other suitable clause, or combination of suitable clauses, further comprising splitting the article-blank web into at least two strips before cutting the article-blank web.

Clause 29. The method of clause 24, any other suitable clause, or combination of suitable clauses, wherein the cutting stage is performed using a rotor die that includes a rotor arranged to rotate about an axis and a plurality of dies coupled with the rotor for rotation about the axis and each of the plurality of dies are configured to selectively move at least one of axially, radially, and circumferentially relative to the rotor to adjust a position of the die.

Clause 30. The method of clause 24, any other suitable clause, or combination of suitable clauses, wherein the thermoformed article has a clarity of about or greater than about 50% as measured using ASTM D 1746 and a haze of about or less than about 60% as measured using ASTM D 1003 procedure B.

Clause 31. The method of clause 30, any other suitable clause, or combination of suitable clauses, wherein the surface roughness of the surface of the rotating roller is between about 100 Ra and about 240 Ra (microinches).

Clause 32. The method of clause 31, any other suitable clause, or combination of suitable clauses, wherein the polymeric materials comprise polypropylene.

Clause 33. The method of clause 32, any other suitable clause, or combination of suitable clauses, wherein the polymeric materials comprise a polypropylene impact copolymer.

Clause 34. The method of clause 33, any other suitable clause, or combination of suitable clauses, wherein the thermoforming stage includes applying the sheet to a rotary thermoformer, the rotary thermoformer including a rotor mounted to rotate about a rotation axis of the rotary thermoformer, the mold which is coupled to the rotor for rotation therewith, and a curl-blocking strip coupled to the rotor and including a plurality of protrusions that extend radially outward away from the rotor toward the sheet to engage and block the sheet from curling away from the rotor during the rotary thermoforming stage.

Clause 35. The method of clause 24, any other suitable clause, or combination of suitable clauses, wherein providing the sheet includes extruding the sheet through a die.

Clause 36. A method of providing a thermoformed article, the method comprising extruding a sheet comprising polymeric materials.

Clause 37. The method of clause 36, any other suitable clause, or combination of suitable clauses, further comprising rotary thermoforming the sheet onto a mold to provide an article-blank web after conditioning the sheet without applying an external mold to the sheet during the rotary thermoforming stage.

Clause 38. The method of clause 37, any other suitable clause, or combination of suitable clauses, further comprising cutting the article-blank web after rotary thermoforming the sheet to provide the thermoformed article.

Clause 39. The method of clause 38, any other suitable clause, or combination of suitable clauses, further including conditioning the sheet with a surface of a rotating roller before the rotary thermoforming stage.

Clause 40. The method of clause 38, any other suitable clause, or combination of suitable clauses, further comprising splitting the article-blank web into at least two strips after rotary thermoforming the sheet and before cutting the article-blank web.

Clause 41. The method of clause 38, any other suitable clause, or combination of suitable clauses, wherein the cutting stage includes rotating a rotor die included in a rotary cutter and applying pressure to the article-blank web with the rotor die.

Clause 42. The method of clause 41, any other suitable clause, or combination of suitable clauses, further comprising measuring a distance between the rotor die and a first article blank included in the plurality of article blanks and located upstream of the rotor die and varying a rotational speed of the rotor die based on the distance.

Clause 43. The method of clause 42, any other suitable clause, or combination of suitable clauses, further comprising splitting the article-blank web into at least two strips after rotary thermoforming the sheet and before cutting the article-blank web.

Clause 44. The method of clause 43, any other suitable clause, or combination of suitable clauses, wherein the rotor die includes a rotor arranged to rotate about an axis and a plurality of dies coupled with the rotor for rotation about the axis and each of the plurality of dies is configured to move selectively axially relative to the rotor to adjust a position of the die.

Clause 45. The method of clause 44, any other suitable clause, or combination of suitable clauses, wherein each of the plurality of dies are configured to move selectively at least one of radially and circumferentially relative to the rotor.

Clause 46. The method of clause 41, any other suitable clause, or combination of suitable clauses, wherein the rotor die includes a rotor arranged to rotate about an axis and a plurality of dies coupled with the rotor for rotation about the axis and each of the plurality of dies configured to selectively move axially, radially, and circumferentially relative to the rotor to adjust a position of the die.

Clause 47. The method of clause 38, any other suitable clause, or combination of suitable clauses, wherein the sheet has an average thickness of less than about 0.012 inches.

Clause 48. The method of clause 47, any other suitable clause, or combination of suitable clauses, wherein the thermoformed article has a clarity of about or greater than about 50% as measured using ASTM D 1746 and a haze of about or less than about 60% as measured using ASTM D 1003 procedure B.

Clause 49. The method of clause 38, any other suitable clause, or combination of suitable clauses, wherein the polymeric materials include only non-aromatic polymeric materials and the polymeric materials include at least polypropylene.

EXAMPLES

The following examples are set forth for purposes of illustration only. Parts and percentages appearing in such examples are by weight unless otherwise stipulated. All ASTM, ISO, and other standard test methods cited or referred to in this disclosure are incorporated by reference in their entirety.

Example 1

Formulation and Extrusion

An exemplary single-layer sheet30in accordance with certain aspects of the present disclosure is provided in the instant example. Sheet30in this example is a single-layer sheet.

A polymeric mixture comprised a polypropylene homopolymer, a polypropylene impact copolymer, and a polypropylene random copolymer. The polypropylene homopolymer was Braskem INSPIRE™ 6025N. The polypropylene impact copolymer was LyondellBassell Pro-fax™ SC204. The clarifier was Braskem RP650. The percentages by weight of the components were about:

50%Braskem INSPIRE ™ 6025N49%LyondellBassell Pro-fax ™ SC2041%Braskem RP650

The polypropylene homopolymer, the polypropylene impact copolymer, and the polypropylene random copolymer were added to an extruder hopper and combined via blending to provide a formulation. The formulation was then heated in the extruder to form a molten material. The molten material was extruded to form a single-layer sheet. The single-layer sheet was thermoformed to form a lid in accordance with the present disclosure.

Example 2

Formulation and Extrusion

An exemplary single-layer sheet30in accordance with certain aspects of the present disclosure is provided in the instant example. Sheet30in this example is a single-layer sheet.

A polymeric mixture comprised a polypropylene homopolymer and a polypropylene impact copolymer. The polypropylene homopolymer was Braskem INSPIRE™ 6025N. The polypropylene impact copolymer was LyondellBassell Pro-fax™ SC204. The percentages by weight of the components were about:

50%Braskem INSPIRE ™ 6025N50%LyondellBassell Pro-fax ™ SC204

The polypropylene homopolymer and the polypropylene impact copolymer were added to an extruder hopper and combined via blending to provide a formulation. The formulation was then heated in the extruder to form a molten material. The molten material was extruded to form a single-layer sheet. The single-layer sheet was thermoformed to form a lid in accordance with the present disclosure.

Example 3

Formulation and Extrusion

An exemplary single-layer sheet30in accordance with certain aspects of the present disclosure is provided in the instant example. Sheet30in this example is a single-layer sheet.

A polymeric mixture comprised a polypropylene homopolymer, a polypropylene impact copolymer, and a polypropylene random copolymer. The polypropylene homopolymer was Braskem INSPIRE™ 6025N. The polypropylene impact copolymer was LyondellBassell Pro-fax™ SC204. The clarifier was Braskem RP650. The percentages by weight of the components were about:

35%Braskem INSPIRE ™ 6025N55%LyondellBassell Pro-fax ™ SC20410%Braskem RP650

The polypropylene homopolymer, the polypropylene impact copolymer, and the polypropylene random copolymer were added to an extruder hopper and combined via blending to provide a formulation. The formulation was then heated in the extruder to form a molten material. The molten material was extruded to form a single-layer sheet. The single-layer sheet was thermoformed to form a lid in accordance with the present disclosure.

Example 4

Formulation and Extrusion

An exemplary single-layer sheet in accordance with certain aspects of the present disclosure is provided in the instant example. The sheet in this example is a single-layer sheet.

A polymeric mixture comprised a polypropylene impact copolymer and a polypropylene homopolymer. The polypropylene impact copolymer was LyondellBassell Pro-fax™ SC204. The polypropylene homopolymer was Braskem INSPIRE™ 6025N. The percentages by weight of the components were about:

65%LyondellBassell Pro-fax ™ SC20435%Braskem INSPIRE ™ 6025N

The polypropylene impact copolymer and the polypropylene homopolymer were added to an extruder hopper and combined via blending to provide a formulation. The formulation was then heated in the extruder to form a molten material. The molten material was extruded to form a single-layer sheet. The single-layer sheet was thermoformed to form a lid in accordance with the present disclosure.

Example 5

Formulation and Extrusion

An exemplary single-layer sheet in accordance with certain aspects of the present disclosure is provided in the instant example. The sheet in this example is a single-layer sheet.

A polymeric mixture comprised a polypropylene impact copolymer and a polypropylene homopolymer. The polypropylene impact copolymer was LyondellBassell Pro-fax™ SC204. The polypropylene homopolymer was Braskem INSPIRE™ 6025N. The percentages by weight of the components were about:

75%LyondellBassell Pro-fax ™ SC20425%Braskem INSPIRE ™ 6025N

The polypropylene impact copolymer and the polypropylene homopolymer were added to an extruder hopper and combined via blending to provide a formulation. The formulation was then heated in the extruder to form a molten material. The molten material was extruded to form a single-layer sheet. The single-layer sheet was thermoformed to form a lid in accordance with the present disclosure.

Example 6

Formulation and Extrusion

An exemplary single-layer sheet in accordance with certain aspects of the present disclosure is provided in the instant example. The sheet in this example is a single-layer sheet.

A polymeric mixture comprised a polypropylene impact copolymer, a polypropylene homopolymer, and a polypropylene random copolymer. The polypropylene impact copolymer was LyondellBassell Pro-fax™ SC204. The polypropylene homopolymer was Braskem INSPIRE™ 6025N. The clarifier was Braskem RP650. The percentages by weight of the components were about:

55%LyondellBassell Pro-fax ™ SC20425%Braskem INSPIRE ™ 6025N20%Braskem RP650

The polypropylene impact copolymer, the polypropylene homopolymer, and the polypropylene random copolymer were added to an extruder hopper and combined via blending to provide a formulation. The formulation was then heated in the extruder to form a molten material. The molten material was extruded to form a single-layer sheet. The single-layer sheet was thermoformed to form a lid in accordance with the present disclosure.

Example 7

Formulation and Extrusion

An exemplary single-layer sheet in accordance with certain aspects of the present disclosure is provided in the instant example. The sheet in this example is a single-layer sheet.

A polymeric mixture comprised a polypropylene impact copolymer. The polypropylene impact copolymer was LyondellBassell Pro-fax™ SC204. The percentages by weight of the components were about:

100% LyondellBassell Pro-fax™ SC204

The polypropylene impact copolymer was added to an extruder hopper to provide a formulation. The formulation was then heated in the extruder to form a molten material. The molten material was extruded to form a single-layer sheet. The single-layer sheet was thermoformed to form a lid in accordance with the present disclosure.

Articles10may be used in cold or refrigerated environments such as in cold climates or may be used soon after being stored in a cold storage location. Edges and features of articles10of the present disclosure may resist cracking due to being deformed to cause localized crazing (whitening) when cold. Even still, rounded edges may experience improved resistance to cracking in response to being deformed at cold temperatures or at room temperature as compared to non-rounded or sharp edges on article10. Curved edges may minimize cracking of article10at and around the curved edges. In the illustrative embodiment, features86of lid210include several curved edges that connect the panels of feature86with a top plate of feature86as suggested inFIG.2.

In some embodiments, formulas having at least about 40% by weight polypropylene impact copolymer reduce or eliminate cracking of the edges of articles10when articles10have a temperature of about 55 degrees Fahrenheit or less and are deformed to cause crazing. In some embodiments, formulas having at least about 50% by weight polypropylene impact copolymer reduce or eliminate cracking of the edges of articles10when articles10have a temperature of about 55 degrees Fahrenheit or less and are deformed to cause crazing. In some embodiments, formulas having at least about 55% by weight polypropylene impact copolymer reduce or eliminate cracking of the edges of articles10when articles10have a temperature of about 55 degrees Fahrenheit or less and are deformed to cause crazing.