CN108349150B - 形成的具有平滑边缘的热塑性制品 - Google Patents

形成的具有平滑边缘的热塑性制品 Download PDF

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CN108349150B
CN108349150B CN201680062056.7A CN201680062056A CN108349150B CN 108349150 B CN108349150 B CN 108349150B CN 201680062056 A CN201680062056 A CN 201680062056A CN 108349150 B CN108349150 B CN 108349150B
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article
flange
region
peripheral
deflectable
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CN108349150A (zh
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米勒德·F·华莱士
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Converter Manufacturing LLC
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Converter Manufacturing LLC
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Priority to CN202010706625.5A priority Critical patent/CN112045973A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/38—Cutting-out; Stamping-out
    • B26F1/40—Cutting-out; Stamping-out using a press, e.g. of the ram type
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
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Abstract

本披露涉及形成具有平滑边缘的成形热塑性制品。许多热塑性制品在从原料片材成型或切割制品时形成尖锐的边缘。这种尖锐的边缘可能会损坏它们所接触的薄塑料膜或肉体，因此期望使边缘平滑。本文描述的是通过翻卷该尖锐边缘来形成此类尖锐边缘制品的平滑周边的方法。平滑化操作通过以下操作来进行：形成包括靠近该周边尖锐边缘的弯曲区域的可挠曲凸缘；通过将该可挠曲凸缘的一部分插入框架状上部主体的腔体中来使其挠曲；可选地通过将压头插入该腔体中而进一步使该部分挠曲；然后加热和冷却该弯曲区域以产生平滑的周边。替代性地，通过在施加或不施加热量的情况下施加足以引起不可逆弯曲的压力来形成该平滑的周边。

Description

形成的具有平滑边缘的热塑性制品
技术领域
本披露总体上涉及形成成形热塑性制品的领域。
背景技术
由热塑性材料形成成形制品是众所周知的。可以使用多种不同的方法(例如，热成形、铸造、模制、和纺丝)来将形状赋予熔融的热塑性塑料或已经软化或熔融的预成型热塑性片材。
从成形制品的一个或多个边缘修剪废料是常见的修整技术，但若留下尖锐的边缘，则可能造成肉体损伤或者撕裂或切割与边缘接触的材料。成形热塑性塑料的一种常见用途是形成可以用塑料薄膜密封的容器，例如旨在容纳食物并旨在用透明塑料膜密封的托盘、碗或箱。这种容器的密封通常涉及将膜跨过形成于容器中的隔室延伸或拉伸并将膜围绕隔室的周边密封，该周边通常位于包括隔室的制品的修剪边缘附近。如果边缘尖锐，则它可能会切割或破坏膜，影响密封处理。
如果成形热塑性制品的尖锐边缘可以能够降低损伤或损坏密封膜的风险的方式移开，这将是有益的。本文披露的主题解决了现有的成形热塑性制品的这个缺点。
发明内容
本披露涉及一种在由热塑性材料制成的制品上形成平滑边缘的方法。该方法包括在主体的边缘处形成可挠曲凸缘的步骤。该可挠曲凸缘包括在周边凸缘的周边端部处的热塑性材料的周边边缘。该周边凸缘通过弯头连接到间隔件并且在周边延伸超出该间隔件一段周边凸缘距离。该间隔件通过弯曲区域连接到主体，该弯曲区域在间隔件与主体之间限定锐角。在由上部主体限定的腔体的内部内推动可挠曲凸缘，在弯头与内部之间的距离小于周边凸缘距离，使得当腔体内部的一部分撞击在周边凸缘上时可挠曲凸缘在弯曲区域处挠曲。对弯曲施加足够的热量以软化弯曲区域处的热塑性材料。将上部主体和制品分开，由此弯曲区域在冷却时保持挠曲，从而在制品上产生平滑边缘。这种方法可用于在制品的整个周边周围形成平滑边缘。为此，该可挠曲凸缘是在该制品的所有边缘周围形成的，并且腔体的内部被构造成当在该内部内推动可挠曲凸缘时同时撞击在该制品的所有边缘周围的可挠曲凸缘上。
本披露还涉及一种形成密封隔室的方法。该方法包括以下步骤：将热塑性片材热成形以形成具有由基本上平面的密封表面围绕的凹形隔室的制品；将制品从片材周边切割至密封表面；如上所述在制品的整个周边周围形成平滑边缘；然后将顶部片材密封到密封表面以形成密封隔室。在该方法的一个实施例中，在将顶部片材密封到密封表面之后在密封表面的周边周围被周边地修剪。在另一个实施例中，将顶部片材热封到密封表面上。
本披露进一步涉及一种形成密封隔室的方法。该方法包括以下步骤：将热塑性片材热成形以形成具有由基本上平面的密封表面围绕的凹形隔室的制品；将制品从片材周边切割至密封表面；如上所述在制品的整个周边周围形成平滑边缘；然后在该制品周围缠绕和密封柔性塑料膜以形成该密封隔室。
在本文所述的方法中，在该腔体的内部内推动该可挠曲凸缘之后并且在将该上部主体和该制品分开之前，将压头推入该内部中并且紧密抵靠该内部，在该可挠曲凸缘后面达到该压头的表面撞击并且进一步使该弯曲区域处的该可挠曲凸缘挠曲的程度。例如，该表面可以为基本上平面的。该表面也可以基本上垂直于内部的撞击在周边凸缘上的部分。该表面可以与内部的撞击在周边凸缘上的部分限定钝角。该表面相对于内部可以具有凹形轮廓。
在不基于加热的实施例中，本披露涉及一种在由热塑性材料制成的制品上形成平滑边缘的方法。该方法包括在主体的边缘处形成可挠曲凸缘，该可挠曲凸缘包括位于周边凸缘的周边端部处的热塑性材料的周边边缘。该周边凸缘通过弯头连接到间隔件并且在周边延伸超出该间隔件一段周边凸缘距离。该间隔件通过弯曲区域连接到主体，该弯曲区域在间隔件与主体之间限定锐角。在由上部主体限定的腔体的内部内推动可挠曲凸缘，在间隔件与内部之间的距离小于周边凸缘距离。由此，当腔体内部的一部分撞击在周边凸缘上时可挠曲凸缘在弯曲区域处挠曲。对弯曲区域施加足够的压力以使弯曲区域处的热塑性材料不可逆地弯曲。将上部主体和制品分开，由此该弯曲区域在去除压力时保持挠曲，从而在该制品上产生平滑边缘。
附图说明
图1由图1A、图1B和图1C组成，并且示出了本文所述的结构和方法的基本操作。平行直线“//”表示为了清楚而省略的部分。
图1A示出了具有在其边缘处形成的可挠曲凸缘160的热塑性制品100的截面图。该实施例中的可挠曲凸缘160包括延伸部50、弯曲区域150、间隔件140和周边凸缘120。延伸部50将制品的成形主体10连接到可挠曲凸缘的弯曲区域150。间隔件140可以置于弯曲区域150与周边凸缘120之间。周边凸缘120通过弯头130连接到间隔件140，该弯头在该实施例中示出为直角弯管并且终止于热塑性材料的周边边缘110处(在此图中用粗实线表示)，制品100由该热塑性材料形成。
图1B示出了插入上部主体200内部的热塑性制品100。在该实施例中，由于可挠曲凸缘160在弯曲区域150内的一个或多个点处的弯曲，因此周边凸缘120的周边边缘110撞击在上部主体200的内表面202上导致可挠曲凸缘160挠曲。
图1C示出了将压头300插入热塑性制品100后面的上部主体200的内部(即，当压头300插入图1B所示的结构中时)的结果。将压头300紧密抵靠上部主体200的内表面202，并且周边凸缘120的周边边缘110撞击压头300的上表面302，导致可挠曲凸缘160的甚至更大的挠曲并在弯曲区域150内诱发弯曲的一个或多个点处产生制品100的圆形周边。
图2由图2A、图2B、图2C和图2D组成，并且示出了匹配的上部主体200和压头300，用于使在成形热塑性制品的周边上形成的一个或多个可挠曲凸缘160挠曲，该成形热塑性制品具有带圆角的矩形托盘的构造。图2A示出了设置在压头300之上的上部主体200，并且图2B示出了与压头300接合的上部主体200。图2C是图2B中示出的接合的上部主体200和压头300的剖面图，并且示出了压头300的一部分配合在上部主体200中的凹陷部的内表面中并且与其紧密相对。图2D是图2C中所示部分的细节，并且示出了压头300与上部主体200的内部之间的紧密相对。在图2D中，压头300的上表面302的倾斜构造是明显的。
图3由图3A、图3B和图3C组成，它们是透明的成形热塑性制品的平滑化拐角的图像，该热塑性制品具有带圆角的矩形托盘的构造。使用类似于图2中所示的上部主体200和压头300来使制品平滑化。在图3A中，手指在托盘的内部可见，并且平滑化拐角在手指的左侧可见。托盘的平滑化直边从平滑化拐角延伸(在图中向下)。可看到周边凸缘在平滑化拐角处的褶皱，并且可看到周边凸缘在平滑化直边下方的挠曲。图3B是也从托盘边沿下方看到的类似制造的托盘的平滑化拐角的另一视图。图3C是平滑化拐角的视图，其中手指指向通过弯曲、软化和冷却可挠曲凸缘的弯曲区域形成的平滑区域。例如，如图3A和图3B所示，由于形成托盘的热塑性材料的相对尖锐的边缘在拐角下方弯曲，所以该平滑区域可例如被推靠在塑料薄膜上而不易于将其撕裂。
图4示出了通过使用本文所述的方法形成的储存容器制品100截取的截面(平行直线“//”表示为了清楚而省略的部分)。在该图中，制品100具有在图中可见的容器的每个侧面上形成的可挠曲凸缘160。单个上部主体200延伸穿过整个容器，包括围绕可挠曲凸缘160所在的侧面。已在制品100后面的上部主体200中的腔体内部插入单个压头300(图中仅示出两个部分)。形成制品100的热塑性片材的周边边缘110在每个可挠曲凸缘160处抵接压头300的上表面302，使得可挠曲凸缘160通过在每个可挠曲凸缘160的弯曲区域150的一个或多个部分处折曲而朝向制品100的主体向内挠曲。在处施加其量足以软化热塑性片材的热量使得可挠曲凸缘160大致保持该图中所示的构造，其中热塑性片材的周边边缘110反周向地定位(即，在制品100的周边内，在该图中发生在由表示的位置处)，从而在冷却软化部分时为所形成的容器产生平滑的周边。
图5示出了通过使用本文所述的方法形成的储存容器制品100截取的截面(平行直线“//”表示为了清楚而省略的部分)。在该图中，制品100具有在图中可见的容器的每个侧面上形成的可挠曲凸缘160。可挠曲凸缘160已通过在每个可挠曲凸缘160处由单个压头300(图中仅示出两个部分)的上表面302与其抵接而向内挠曲。形成制品100的热塑性片材的周边边缘110在每个可挠曲凸缘160处抵接压头300的上表面302，使得可挠曲凸缘160通过在每个可挠曲凸缘160的弯曲区域150的一个或多个部分处折曲而朝向制品100的主体向内挠曲。在处施加其量足以软化热塑性片材的热量使得可挠曲凸缘160大致保持该图中所示的构造，其中热塑性片材的周边边缘110反周向地定位(即，在制品100的周边内，在该图中发生在由表示的位置处)，从而在冷却软化部分时为所形成的容器产生平滑的周边。在该实施例中，压头300的两个部件被示出为具有不同的轮廓(一个平坦的和一个曲面的)，以说明可由不同轮廓引起的挠曲的差异。
图6A和图6B示出了在由热塑性材料片材热成形的托盘形制品中形成的可挠曲凸缘。在这些图的每个图中，手指触摸已从片材上切出托盘的位置的尖锐边缘。在这些图中，可挠曲凸缘还没有被软化、挠曲和冷却，因此尖锐的边缘仍然在托盘的周边周围定位。相比之下，尖锐的边缘已经向内挠曲并远离图3所示的托盘的周边。
由图7A、图7B和图7C组成的图7示出了一个实施例，其中由热塑性片材形成的、位于水平表面(水平实线)上的制品100(平行直线“//”表示为了清楚而省略的部分)具有其如本文所述平滑化的周边边缘。在该实施例中，上部主体200(在该横截面中示出的两个部分)下降到制品100上方，使得制品的两个可挠曲凸缘160中的每一个向内挠曲。在图7A中，当上部主体200朝向水平表面下降到制品上时，上部主体200的向外展开的部分刚好接触制品100的周边凸缘120；可挠曲凸缘开始在标记为“B”的区域处挠曲。在图7B中，上部主体200已经下降到水平表面上，并且制品100的周边凸缘120朝向制品100的主体10部分地向内挠曲。在图7C中，压头300已被插入制品100后面的上部主体200中的腔体内，并且通过在标记为“B”的区域处弯曲形成制品的热塑性片材来进一步挠曲周边凸缘120(以及，与它们一起，可挠曲凸缘160)。
具体实施方式
本文所披露的主题涉及成形热塑性制品的形成，并且更具体地讲涉及形成为使得制品的一个或多个边缘具有如下构造的制品，在该构造中形成制品的热塑性片材的周边边缘从制品的表面转向离开，使得施加在该表面上的易碎材料(例如，肉或薄的柔性塑料片材)不接触该边缘。由于这些边缘可为尖锐的，特别是当边缘已被切割或破坏时，引导边缘离开制品的表面可以防止损坏与该表面接触的易碎材料。本文所披露的主题特别用于形成容器，该容器将用被施加在容器表面上的易碎塑料膜密封。
简而言之，本文所述的用于形成具有平滑边缘的成形热塑性制品的基本方法涉及在制品的周边边缘处形成可挠曲凸缘。该可挠曲凸缘包括周边凸缘，该周边凸缘从制品沿周向突出并且通过形成制品的热塑性材料中的弯头(例如，90度转弯)附接到间隔件部分。制品的主体通过弯曲部分附接到间隔件，该弯曲部分限定了间隔件与主体的邻近弯曲部的部分之间的角度(优选为大致直角)。可挠曲凸缘插入主体中的腔体内部，使得周边凸缘撞击腔体的壁，由此使可挠曲凸缘沿制品主体的方向挠曲。在这种挠曲时，热量被施加到弯曲区域，该热量足以软化或熔融弯曲区域处的热塑性材料，使得当弯曲区域冷却时可挠曲凸缘保持朝向主体挠曲。可选地，可以将压头插入可挠曲凸缘之后的腔体中，并且压头的与挠曲的周边凸缘接触的表面可引起可挠曲凸缘的进一步挠曲，进一步使制品的周边边缘在冷却后远离制品的周边移开。以此方式，热塑性材料的平滑、“卷起”边缘形成制品的最外侧周边，而热塑性材料的周边边缘保留在制品的最外侧周边内，在这种情况下该边缘的锐度不太可能损坏与制品的最外侧周边接触的易碎材料。
现在更详细地描述成形制品的各个元件和方面以及制造它们的方法。
成形制品
本文所述的方法被认为适用于具有宽范围形状和尺寸的制品，特别是当通过常规方法制造时通常具有尖锐周边边缘的制品。制造具有平滑边缘的成形热塑性制品的动机部分来自于制造具有足够钝(非尖锐)的边缘的常用储存托盘(例如，用于储存诸如新鲜或冷冻肉类、水果或蔬菜的食物的塑料托盘)的需求，足够钝是在正常使用条件下，托盘可以用塑料薄膜诸如聚偏二氯乙烯膜包裹或与其接触而膜不会被托盘边缘切割或刺破。然而，一旦开发了本文所述的方法，就可以认识到，平滑的圆形边缘在各种其他情况下都是所需的，诸如防止抓握托盘和其他成形制品的人的肉体受伤。
举例来说，制造诸如肉托盘的成形制品的常用方法是通过将热塑性塑料片材热成形。在热成形方法中，将长的热塑性塑料片材的一部分升温到热塑性塑料软化并可模制的温度。将软化的热塑性塑料施加在一个或多个模具的表面上(通常借助于负气压以确保软化的热塑性膜紧贴模具表面)。当膜冷却时(例如，在与模具表面接触时)，热塑性塑料硬化并变得不易变形，导致热塑性膜获得并保持通过模制方法施加于其上的形状。在热成形方法中多个铸件通常由单片膜中的同一制品制成，并且通过在制品的周边周围切割(例如，冲切)膜而将各个制品从膜中释放。该方法倾向于在膜的切割部分处产生尖锐的边缘，包括围绕制品周边的全部或部分(即，从膜中切出制品的位置)的尖锐边缘。
进一步举例来说，热塑性材料可以在挤出机中熔融并注入限定模制品形状的模具腔中。冷却后，可打开模具以释放模制品。在模制方法中，热塑性材料通常出现在制成品的不期望其出现的部件处，例如当熔融热塑性塑料在模具板之间或熔融热塑性塑料被送入封闭模具所通过的端口处流动时发生的“闪蒸”。这些非期望的部件本身可以是尖锐的，并且当从模制品上切下这些非期望的部件时可留下尖锐的边缘。
本文所述的制品的尺寸和形状并不重要。通常，成形制品将是期望抓握制品或使制品的周边边缘与一种或多种易碎材料之间接触的制品。不管生产制品的方法如何，本文所述的边缘平滑化方法可以从通常具有这种尖锐边缘的热塑性制品上去除一个或多个尖锐边缘。
平滑化方法
热塑性制品的周边—特别是由热塑性材料的弯曲或成形片形成的周边—可通过包括以下步骤的方法来平滑化：在待平滑边缘的周边附近形成可挠曲凸缘、使凸缘的弯曲部分挠曲以使边缘从制品周边移开、至少在凸缘处于挠曲位置时软化弯曲部分、并在凸缘处于挠曲位置时重新硬化弯曲部分。该方法在图1中被示出。
图1A示出了具有主体10(在该图中具有不规则形状)和与主体10连接的可挠曲凸缘的热塑性制品100。可挠曲凸缘包括周边凸缘120，该周边凸缘包括形成制品100的热塑性片材的周边边缘110。可挠曲凸缘还包括置于制品100的主体10与周边凸缘120之间的弯曲区域150。弯曲区域150通过延伸部50与主体10分开，该延伸部在该实施例中仅是热塑性片材的平坦部分。在该实施例中，周边凸缘120类似地通过热塑性片材的被称为间隔件140的平坦部分与弯曲区域分开。周边凸缘120通过弯头连接到可挠曲凸缘的其余部分，在该实施例中，弯头是形成为直角的热塑性片材的一部分。
图1A是这种制品100的横截面，其中黑实线表示形成制品的热塑性片材的横截面。周边边缘110形成制品100的周边，因为制品100的任何其他部分不会向右侧延伸得更远(在该图中)，所以间隔件140和周边凸缘120的其他部分比片材的周边边缘110更靠近主体10。因此，如果将对象推靠在制品100的右侧(在图1A中)，则该对象将倾向于接触周边边缘110，并且该周边边缘110的锐度可能会例如通过切割、损坏或损伤该对象而影响该对象。
在图1B中，热塑性制品100被插入上部主体200的内部腔体内，该上部主体的内表面202撞击周边凸缘120，使其朝向制品100的主体10向内(即，反周向地)挠曲。在该实施例中，形成制品100的热塑性片材的周边边缘110和弯曲区域150的最周边部分两者大致等距地定位在主体10的周边周围。优选地，可挠曲凸缘160向内挠曲得足够远，使得热塑性片材的周边边缘110容纳在上部主体200的内部腔体内。如果将足以软化热塑性片材的热量施加到弯曲区域150(大约在图1B中标识为“”的位置处)并且片材随后被冷却(优选低于其玻璃化转变温度)，则可挠曲凸缘160将即使在上部主体200与制品100分开之后仍保持图1B所示的构造。
图1C示出了可选的但是优选的步骤，其中压头300被插入制品100后面的上部主体200中的腔体内(即，至少将可挠曲凸缘160夹在上部主体200与压头300之间)。该步骤(相对于图1B中所示的实施例)进一步将可挠曲凸缘160朝向制品100的主体10挠曲，由此使热塑性片材的(可能尖锐的)周边边缘110进一步从制品的周边移开(即，更远离上部主体200的内表面202)。将可挠曲凸缘160的弯曲区域150充分加热以在其处于图1C所示的构造时至少将其软化并且随后将其冷却至其玻璃化转变温度以下，这样便将可挠曲凸缘“冻结”在所示构造。在该构造中，形成制品的片材的尖锐周边边缘110在可挠曲凸缘160的其他部分(例如，弯曲区域150和延伸部50，如果存在的话)下“折起”，并且因此较不易于接近与制品周边接触的对象(并且较不易于撕裂、切割或损伤与制品周边接触的材料)。
在图1C所示的实例中，当将制品放置在上部主体200的腔体内时，压头300的与可挠曲凸缘160的周边凸缘120撞击的部分具有楔形横截面。这样的压头可用于将周边凸缘120和周边边缘110反周向地引导，因为在内部将压头沿从周边边缘110朝向弯曲区域150的方向推进得越远，则周边凸缘120和周边边缘110将沿反周向方向挠曲得越远。然而，压头300的这些部分不必是楔形的。可以使用基本上任何形状的压头300，当压头300被插入制品100后面的上部主体200中时该压头将使周边凸缘120和周边边缘110反周向地挠曲，例如可使用钝的或圆形的(在其上表面302处为凸的或凹的)或这些中的任何的组合。
在这些方法中重要的是，形成制品100的热塑性片材的可能尖锐的周边边缘110应偏离制品的周边，并且在该位置通过加热软化并冷却在片材挠曲时弯曲的一部分片材而在该位置“固定”。所加热的、弯曲的、和冷却的区域优选地至少包括可挠曲凸缘160的弯曲区域150，因为该区域被设计成用于平滑化折曲并且为容器产生平滑的周边。还可以进行对可挠曲凸缘的其他部分(例如，延伸部50、间隔件140、弯头130、和/或周边凸缘120)的软化、折曲和硬化，并且可有助于制品周边的平滑性。替代性地，可挠曲凸缘160的这些部分中的任何部分都可以简单地在没有加热的情况下弯曲，只要施加足够的弯曲力使得热塑性材料在弯曲位置处不可逆地弯曲(而不是仅在去除压力时可逆地挠曲)即可。本文所披露的可挠曲凸缘160提供用于实践该方法的便利结构。
可挠曲凸缘160
可挠曲凸缘160包括至少三个部分，包括弯曲区域150、周边凸缘120、和位于这两者之间的弯头130。弯曲区域150可选地通过延伸部50连接到制品100的其余部分。周边凸缘120通过弯头130连接到弯曲区域150、可选地具有介于弯曲区域150与弯头130之间的间隔件140。图1A中展示了具有这些部分中的每一个部分的原型可挠曲凸缘160(附接到制品100的主体10)。
与周边凸缘120的至少最周边部分相比，弯曲区域150与反周向地(更靠近主体10)放置。当周边凸缘120向内挠曲时(即，诸如通过将制品的周边压靠在固体物体上而反周向地)，弯曲区域150的功能是挠曲。弯曲区域的挠曲提供平滑的表面，因为热塑性片材的周边边缘110不位于弯曲区域内；而是位于周边凸缘120上。如图1A所示，弯曲区域150优选地具有平滑曲线的构造，具有相当大的曲率半径(例如，0.5毫米至数毫米或更大)，使得可挠曲凸缘160的向内挠曲产生制品的平滑周边。与脆弱材料(诸如，薄塑料膜或动物皮肤)接触热塑性片材的周边边缘110时相比，接触该平滑周边的相同脆弱材料不太可能受到损坏。由弯曲区域形成的角度(例如，在图1A中所示的弯曲区域150上方约90度)不是关键，并且可以为便于制造进行选择。例如，该角度可以是钝角、直角或甚至是锐角。弯曲区域150的曲率半径也不是关键，但是优选地基本上大于弯头130的曲率半径。
弯曲区域150可以通过延伸部50与制品100的其余部分连接。可以从弯曲区域150(例如，与曲面的弯曲区域150不同的平坦区域)不连续地辨别出延伸部50或基本上不可区分(例如，与弯曲区域150的曲率不易区分的略弯曲的区域)。延伸区域的尺寸不是关键；该尺寸的范围可为不存在(即，弯曲区域150开始于制品100的主体10的边缘处)到几毫米、若干毫米或更长。延伸部50的一个功能是将(被施加片材软化热量的)弯曲区域150与制品100的不期望可能的热致变形的其他部分分开。延伸部50的另一功能可以是为制品100提供功能性表面，例如邻近弯曲区域150的表面，在该表面处可以将薄塑料膜(该薄塑料膜可以压靠弯曲区域150而几乎没有损坏该膜的风险)粘附到制品100或与该制品熔合(例如，以覆盖制品中形成的腔体，该腔体由延伸部50为其一部分的可挠曲凸缘160界定)。延伸部50还可以用于结构性功能，诸如为制品的区段提供支撑或刚性(例如，通过在容器中的腔体周围形成相对刚性的“边沿”以抑制容器在应用盖子时折曲)。延伸部50的又一功能可以是当可挠曲凸缘160反周向挠曲时提供该可挠曲凸缘可以占据的空间。因为延伸部50和周边凸缘120位于在弯曲区域150的相对侧，弯曲区域150(例如，在将制品100插入上部主体200内并且将压头300插入制品后面时)足够的折曲可以使周边凸缘120(和间隔件140)接近或甚至接触延伸部50。
周边凸缘120包括形成制品的热塑性片材(可能尖锐)的周边边缘110。该周边边缘沿周向延伸超过弯曲区域150，使得当制品插入上部主体200的腔体中时它将撞击上部主体200的内表面202，如图1B所示。该周边边缘从弯头130延伸到周边边缘110，并且以由弯头130限定的偏移角度从弯曲区域150或间隔件140(如果存在的话)的方向延伸。当制品被插入上部主体200的腔体中时，周边凸缘120的功能是与上部主体200的内表面202接合(即撞击或被撞击)，由此使得可挠曲凸缘160向内(反周向)挠曲。除了反周向地移动片材的周边边缘110并引起可挠曲凸缘160在其弯曲区域150中的折曲或弯曲之外，该挠曲还定位周边凸缘120以在压头300被插入制品100后面的腔体中时使其进一步反周向挠曲。当压头300如此插入时，撞击在周边凸缘120上，并且在压头进一步推进到腔体中时，引起可挠曲凸缘160在其弯曲区域150中的附加折曲或弯曲，以及周边边缘110的附加反周向的挠曲。
周边凸缘120的长度(弯头到周边边缘)不是关键，但应该选择为便于压头300与周边凸缘120的接合以及随着压头在上部主体200的内部内推进而通过压头300移动周边凸缘120。通常，周边凸缘120的长度至少部分地受到从形成制品的材料切割制品的能力的影响。弯头130可以部分地用于将热塑性片材定位在可以方便地切割热塑性片材的位置，以从前体片材产生成形制品。因为通过这种切割形成的周边边缘110在“翻卷”可挠曲凸缘160之前是制品周边处的尖锐度或粗糙度的来源，所以切割尽可能靠近弯头130的片材可能是有利的(即，使周边凸缘120尽可能小)，以减少必须移动的热塑性材料的体积，以便将尖锐或粗糙的周边边缘110从制品的周边移开。
弯头130介于弯曲区域150与周边凸缘120之间，并且其功能是连接并传递它们之间的力。也就是说，通过上部主体200或压头300在外周凸缘120上的撞击而施加到该周边凸缘的压缩力通过弯头130(和间隔件140，如果存在的话)转换成施加到弯曲区域150的扭转力。压缩力到扭转力的这种转换确保了当力施加到周边凸缘120时弯曲区域150折曲。因此，上部主体200和/或压头300两者对周边凸缘120施加的力使周边边缘110反周向挠曲(即，将可能尖锐的边缘移离制品周边)，并且引起弯曲区域150的弯曲(即，在制品周边处产生由折曲的热塑性片材形成的平滑周边)，从而产生具有平滑周边的制品，即使制品是通过产生尖锐周边边缘的工艺形成时也是如此。实际上，弯头导致施加到周边凸缘120的力引起可挠曲凸缘160从制品的周边“卷下”，有效地将热塑性片材的尖锐边缘从制品周边的材料“隐藏”起来。
间隔件140可置于弯曲区域150与弯头130之间。可以从弯曲区域150(例如，与曲面的弯曲区域150不同的平坦区域)不连续地辨别出间隔件140或基本上不可区分(例如，与弯曲区域150的曲率不易区分的略弯曲的区域)。延伸区域的尺寸不是关键；该尺寸的范围可为不存在(即，弯曲区域150开始于弯头130处)到几毫米、若干毫米或更长。间隔件140(如果存在的话)的一个功能是用作“杠杆”，通过该杠杆作用在弯头130上的力(例如，通过周边凸缘120与上部主体200和压头300中的一者或两者之间的撞击)被传送到弯曲区域150。间隔件140(如果存在的话)的另一功能可以是适当地定位周边凸缘120以接合上部主体200和压头300中的一者或两者。间隔件140(如果存在的话)的又一个功能是增加热塑性片材的可能尖锐的周边边缘110在弯曲区域150折曲时可以从制品的周边反周向移动的距离。在所有其他条件相同的情况下，间隔件140越长，则当制品如上所述制成时，可能的尖锐边缘将离制品周边越远。
热塑性塑料
本文所述的方法和制品可以用基本上任何热塑性材料来执行和制作。重要的是，至少在本文所述的可挠曲凸缘160中，材料能够通过加热软化，并且在冷却时能够再硬化。基本上所有的热塑性塑料表现出特征温度，在该特征温度以上这些热塑性塑料软化并变得柔软或可加工，并且在该温度以下这些热塑性塑料变得更具刚性并保持它们的形状。用于本文所述的制品和方法的期望的热塑性塑料在容器的预期最终用途的正常条件下保持其形状。还期望使用可在制造环境中容易获得的条件下软化的热塑性塑料。合适的热塑性塑料的实例包括聚乙烯、聚丙烯、聚对苯二甲酸乙二醇酯、和聚氯乙烯。其他合适的热塑性塑料对本领域的技术人员而言是显而易见的。
热塑性制品包括热塑性材料，包括形成或存在本文所述的可挠曲凸缘160的制品的至少部分。热塑性材料的特性并不关键，非热塑性材料的存在或不存在也无关紧要。在存在非热塑性材料的情况下(例如，在层压金属箔或纸板层的热塑性片材中)，热塑性材料在未软化的非熔融状态下赋予制品的刚性优选地足以限定制品的构造，即使在非热塑性材料弯曲时也是如此。制品可以包括一个或多个可剥离层，例如共同未决的美国专利申请13/415,781中所述。
上部主体200
上部主体200执行许多功能。总体而言，其功能是在将热量施加到其弯曲区域150的一个或多个部分的同时，将本文所述的可挠曲凸缘160容纳在上部主体200的腔体内。该容纳功能可以防止在本文所述的周边平滑化操作期间可挠曲凸缘160或其部分的不期望的变形(或引导期望的变形)。上部主体200的内部腔体的形状还可以在可挠曲凸缘弯曲时影响其形状，特别是当可挠曲凸缘被软化时。例如，在图1B中，上部主体200包括具有内部直角的腔体，弯曲区域150的一部分被强制进入该腔体中；特别是在弯曲区域150软化时，腔体的该部分的直角形状将倾向于使弯曲区域150符合直角形状。例如，热源可以是上部主体200的一部分，应用于上部主体200以用于传导热量。上部主体200在其插入腔体中时撞击并且被撞击在可挠曲凸缘160的周边凸缘120上。当使用压头300时，上部主体200还用于防止可挠曲凸缘160被挤出腔体，并且当可挠曲凸缘160被压头300压缩时，该上部主体还可以限制弯曲区域150的挠曲。
构成上部主体的材料不是关键，但是这些材料应该适合承受本文所述的制造条件。也就是说，这些材料不应该在加工过程中使用的温度下熔融或降解。可以使用各种各样的金属、陶瓷、石材和聚合物材料。
重要的是选择上部主体200的形状，使得当本文所述的制品100插入上部主体中的腔体中时，将发生上部主体200中的腔体的内部与周边凸缘120之间的冲击。上部主体可以具有足以同时将多个周边凸缘120撞击在制品上或者撞击在制品上出现的单个周边凸缘120(例如，在制品的整个周边边缘周围出现的一个)的大部分或全部的形状。如图2所展示，上部主体200可以由固体材料块形成，该固体材料块覆盖制品的整个表面，同时撞击出现在制品的一个或多个部分上的周边凸缘120。例如，图2中描绘的上部主体200被设计成撞击单个周边凸缘120，该单个周边凸缘完全围绕具有圆角的矩形托盘型容器形状的制品的周边延伸。
当热量施加到弯曲区域150时，本文所述的制品的弯曲区域150将典型地位于上部主体200的腔体内。出于这个原因，上部主体应该以便于施加这种热量的方式来构造。例如，上部主体200可以包括在其中的热源(例如，电操作的加热板或棒)，该热源施加于其上或与其流体连接。替代性地，上部主体200可以包括一个或多个端口，加热的流体(例如，加热的气体或液体)可以通过这些端口从源流入其中的腔体的内部。选择用来将热量传递到弯曲区域150(和/或周边凸缘的其他部分，诸如间隔件140、弯头130、和周边凸缘120)的方法不是关键，并且可以使用各种众所周知的热传递方法和设备中的任何一种。如果上部主体200能够传导热量并且被冷却，则在可挠曲凸缘160的成形期间存在于其中的热量可以流到上部主体200，并且该热流可以例如用于冷却并且由此使可挠曲凸缘160在上部主体200与压头300之间被压缩时在其挠曲位置变硬。
压头300
当制品置于上部主体200中时，压头300的主要功能是撞击并施加压缩力到可挠曲凸缘160的周边凸缘120。该压缩力倾向于朝着弯曲区域150和延伸部50(如果存在的话)向上驱动周边凸缘120并且沿反周向驱动，由此使热塑性片材的可能尖锐的周边边缘110背离如此形成的制品的周边。因此，只要施加此类压缩力，压头300的设计就不是特别关键。如图1C和图4中所展示，具有成角度的上表面302的压头300在压缩周边凸缘120时将倾向于沿着该角度的方向引导周边凸缘120。因此，可能有利的是将压头300的上表面302成形为在压缩发生时将周边凸缘120反周向地“推动”的构造。
像上部主体200一样，制造压头300的材料不是关键。能够承受操作温度和压力的金属、陶瓷、石材和聚合物材料是合适的，并且可由技术人员容易地选择。如果压头300能够传导热量并且被冷却，则在可挠曲凸缘160的成形期间存在于其中的热量可以流到压头300，并且该热流可以例如用于冷却并且由此使可挠曲凸缘160在上部主体200与压头300之间被压缩时在其挠曲位置硬化。
在图2所展示的实施例中，单个压头300可被构造成同时撞击制品的基本上所有周边凸缘120。例如，图2中描绘的压头300被设计成撞击并施加压缩力到单个周边凸缘120，该单个周边凸缘完全围绕具有圆角的矩形托盘型容器形状的制品的周边延伸。
在图5所展示的替代性实施例中，在没有本文所述类型的上部主体200的情况下，制品的可挠曲凸缘160被加热以软化并碰撞压头300。没有上部主体200可能导致可挠曲凸缘160的软化部分变形或挠曲，至少在其他部分(例如，延伸部50或制品100的主体10的与可挠曲凸缘160相邻的部分)的刚性不足以防止这种变形或挠曲的情况下。然而，如果存在这种刚性，或者如果最终产品中容许这种变形或挠曲，则可以在没有上部主体200的情况下使用本文所述的方法。
实例
现在参考以下实例描述本披露的主题。提供该实施例是仅为了说明的目的，并且主题不限于该实施例，而是涵盖由于本文提供的传授内容而显而易见的所有变型。
实例1
图6A和图6B展示了热塑性托盘，该热塑性托盘由热塑性材料的平坦片材热成形，然后从片材上切下。在这些图中的每个图中都示出了由切割过程形成的尖锐边缘，其中有手指正在触摸尖锐边缘。在对这些托盘进行本文所述的平滑化处理之后，托盘的外观大致如图3所示，其中尖锐的边缘已被“翻卷”，使得其面向托盘的主体和平滑部分，通过折曲可挠曲凸缘的至少弯曲区域并将其加热和冷却来形成托盘的平滑外周边，该平滑外周边不会影响附接到托盘边沿上的薄塑料膜或紧紧缠绕在整个托盘周围的薄塑料膜。
本文所引用的每个专利、专利申请和出版物的披露通过援引以其全文并入本文。
虽然已经参考具体实施例披露了该主题，但显而易见的是，本领域的其他技术人员可以设计出其他实施例和变型，而不脱离本文所述主题的真实精神和范围。所附权利要求包括所有这些实施例和等同变型。

Claims (20)

1.一种制造具有平滑边缘的制品的方法，该方法包括
由具有周边边缘的热塑性片材来形成制品，所述制品具有：
主体，以及
在周边边缘处的可挠曲凸缘，该可挠曲凸缘包括
包括所述周边边缘的周边凸缘；
弯曲区域，所述弯曲区域将所述可挠曲凸缘连接到所述制品的其余部分，所述弯曲区域具有平滑曲线的构造，以及
弯头，所述弯头连接所述周边凸缘和所述弯曲区域，从而所述周边凸缘沿周向延伸超过所述弯曲区域；
将所述制品插入至由上部主体限定的腔体的内部，由此内部表面撞击在该周边凸缘上并且使该可挠曲凸缘沿反周向挠曲，由此所述可挠曲凸缘在所述弯曲区域处挠曲；
对挠曲的该弯曲区域施加足够的热量以软化热塑性材料；并且
此后，冷却挠曲的该弯曲区域，由此使所述弯曲区域即使在所述上部主体和该制品分开后，仍然保持在挠曲的位置，从而得到具有平滑边缘的制品。
2.根据权利要求1所述的方法，其中，所述弯曲区域具有至少0.5毫米的曲率半径。
3.根据权利要求1所述的方法，其中，所述弯曲区域在所述弯曲区域的上方弯曲90度。
4.根据权利要求3所述的方法，其中，在所述弯曲区域和所述制品的其余部分之间设置有平坦的延伸部。
5.根据权利要求4所述的方法，其中，所述延伸部具有的尺寸足以提供用于使所述可挠曲凸缘沿反周边挠曲至使所述周边凸缘与所述延伸部接触的程度的空间。
6.根据权利要求4所述的方法，其中，在所述弯曲区域和所述弯头之间设置有平坦的间隔件。
7.根据权利要求6所述的方法，其中，所述间隔件的长度足以促进所述可挠曲凸缘的反周向挠曲至使所述周边凸缘与所述延伸部接触的程度。
8.根据权利要求1所述的方法，其中，所述弯头以直角将所述周边凸缘连接至所述弯曲区域。
9.根据权利要求6或7所述的方法，其中，所述弯头以直角将所述周边凸缘连接至所述间隔件。
10.根据权利要求1所述的方法，其中，在冷却挠曲的弯曲区域之后，所述周边边缘在所述制品的周边内。
11.根据权利要求1所述的方法，其中，在冷却挠曲的弯曲区域之后，所述周边边缘在所述弯曲区域和如果存在的所述延伸部下折起。
12.根据权利要求6所述的方法，其中，在冷却挠曲的弯曲区域之前，向所述周边凸缘、所述弯头、所述延伸部以及所述间隔件中的至少一个施加足够的热量以软化热塑性材料。
13.根据权利要求1所述的方法，其中，所述热塑性材料选自由聚乙烯、聚丙烯、聚对苯二甲酸乙二醇酯和聚氯乙烯所组成的组。
14.根据权利要求1所述的方法，其中，所述可挠曲凸缘形成在所述片材的所有周边边缘周围，并且其中，当所述制品插入所述腔体中时，所述腔体的内部同时撞击在所述制品的所有周边周围的该可挠曲凸缘上并且使所述周边凸缘挠曲，由此，所述方法得到了在整个周边光滑的制品。
15.根据权利要求1所述的方法，所述方法进一步包括：
在将所述制品插入至所述腔体的内部之后，压头撞击所述周边凸缘以进一步使所述周边凸缘沿反周向挠曲。
16.根据权利要求15所述的方法，其中，使完全在所述制品的周边延伸的压头撞击所述周边凸缘。
17.根据权利要求1所述的方法，其中，将非热塑性材料层压至所述热塑性片材。
18.根据权利要求17所述的方法，其中，所述非热塑性材料为金属箔和纸板之一。
19.根据权利要求1所述的方法，其中，所述热塑性片材包括可剥离层。
20.根据权利要求1所述的方法，其中，所述主体限定凹形隔室，并且所述制品具有环绕所述隔室的基本平面的密封表面，所述方法进一步包括：
在冷却挠曲的弯曲部件之后，将顶部片材完全密封到该密封表面以形成密封的隔室。
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