Patent ID: 7299605

Claim:
An anti-curling process for manufacturing foil packages from laminated foil sheets, comprising: providing a planar, pre-cut metal foil laminate top sheet and an opposed, pre-cut metal foil laminate bottom sheet, each pre-cut metal foil laminate sheet comprising a top polymeric sheet, an inner metal foil sheet, and a bottom polymeric sheet; orienting the sheets such that the bottom polymeric sheets of the metal foil laminates are opposed and facing each other; providing a mold having a mold cavity, said mold cavity having a periphery and a depth, wherein the periphery is substantially curved at any horizontal cross-section along the depth of the mold cavity; forming a package cavity in the bottom metal foil laminate sheet using the mold such that the package cavity has a periphery and a depth, said package cavity surrounded by walls and a bottom, wherein the periphery is substantially curved at any horizontal cross-section along the depth of the cavity, and wherein there is an outwardly extending flange member about the periphery of the cavity after the forming; and, mounting the top sheet to the bottom sheet such that the package cavity in the bottom sheet is enclosed, wherein after the forming of the package cavity the outwardly extending flange member of the bottom sheet is substantially uncurled.