Patent ID: 7021031

Claim:
A process for providing a packaged device, said device comprising a pre-formed sheet and a coating composition, said process comprising the steps of: a) providing an unsealed package; b) applying a coating composition in the package; c) placing a pre-formed sheet in the package, wherein said pre-formed sheet is made by a process comprising the steps of: i) providing a sol phase composition comprising from about 10% to about 99.5% water and from about 0.5% to about 20% polysaccharide gelling agent having a sol-gel transition point between about 25° C. and about 80° C.; ii) heating said sol phase composition to a temperature of at least 5° C. higher than the sol-gel transition point; iii) pre-cooling the sol phase composition to a temperature of between 0° C. and 5° C. higher than the sol-gel transition point; iv) forming first and second surfaces by pressing the pre-cooled sol phase composition between two liners, the two liners being supplied by two counter-rotating rollers facing each other, wherein the rollers further comprise cooling means and the two liners further provide textures to the first and second surfaces; v) cooling the pressed sol phase composition into a gel phase composition; vi) cutting the gel phase composition by a die to provide said pre-formed sheet; d) sealing the package; wherein said pre-formed sheet is free of a supporting substrate and has a flex angle of from about 15° to about 80°, and wherein the steps a), b), c) and d) are in communication with each other to provide a continuous line process.