Systems and methods for containers with locking lug and recess

1. A method of forming a thermoformed locking assembly including a locking lug having a lug undercut defining a cantilevered lug ledge having a lug engaging surface and a locking recess having a recess undercut defining an opposing recess ledge having a recess engaging surface and a lug stop opposite the recess undercut, the method comprising:

providing a mold having a mold surface with a moveable locking lug mold portion and a moveable locking recess mold portion, each of the moveable locking lug mold portion and the moveable locking recess mold portion being moveable between a mold condition aligned with the mold surface and a retracted condition below the mold surface,

the moveable locking lug mold portion having an upper surface with a cavity defined therein corresponding in shape to at least a portion of the locking lug, and a lug undercut mold member slidably mounted on an angled surface of the moveable locking lug mold portion with the lug undercut mold member having a flange corresponding to the lug undercut, and

the moveable locking recess mold portion having a protrusion extending above the mold surface when the moveable locking recess mold portion is in the mold condition and corresponding in shape to at least a portion of the locking recess, and a recess undercut mold member slidably mounted on an angled surface of the moveable locking recess portion with the recess undercut mold member having a flange corresponding to the recess undercut;

positioning at least one web of thermoformable material having a first web portion on the mold surface with the moveable locking lug mold portion and a second web portion on the mold surface with the moveable locking recess mold portion each in the mold condition;

thermoforming the web to form an article including a locking lug having an undercut defining a cantilevered lug ledge having a lug engaging surface formed by the moveable locking lug mold portion and a locking recess having an undercut defining an opposing recess ledge having a recess engaging surface and a lug stop opposite the recess undercut formed by the moveable locking recess mold portion; and

retracting the moveable locking lug mold portion and the moveable locking recess mold portion to the retracted condition, wherein while retracting the lug undercut mold member slides along the angled surface of the moveable locking lug mold portion to release the lug undercut and the recess undercut mold member slides along the angled surface of the moveable locking recess mold portion to release the recess undercut.

2. The method of forming a thermoformed locking assembly of claim 1 , wherein the locking lug of the article formed is L-shaped in cross section.

3. The method of forming a thermoformed locking assembly of claim 1 , wherein the lug engagement surface of the article formed has a depth of between approximately 0.043 inches and 0.063 inches.

4. The method of forming a thermoformed locking assembly of claim 1 , wherein the lug undercut mold member is biased towards an initial position, the lug undercut mold member slides along the angled surface of the moveable locking lug mold portion against the bias until the lug undercut is released returning the lug undercut mold member to the initial position.

5. The method of forming a thermoformed locking assembly of claim 1 , wherein the recess undercut mold member is biased towards an initial position, the recess undercut mold member slides along the angled surface of the moveable locking recess mold portion against the bias until the recess undercut is released returning the recess undercut mold member to the initial position.

6. The method of forming a thermoformed container of claim 1 , wherein the mold includes a male lock assembly pocket and a female lock assembly pocket, configured to secure the web of thermoformable material to the mold surface.

7. A method of forming a thermoformed locking assembly including a locking lug having a lug undercut defining a cantilevered lug ledge having a lug engaging surface and a locking recess having a recess undercut defining an opposing recess ledge having a recess engaging surface and a lug stop opposite the recess undercut, the method comprising:

providing a mold having a mold surface with a moveable locking lug mold portion and a moveable locking recess mold portion, each of the moveable locking lug mold portion and the moveable locking recess mold portion being moveable between a mold condition aligned with the mold surface and a retracted condition below the mold surface,

the moveable locking lug mold portion having an upper surface with a cavity defined therein corresponding in shape to at least a portion of the locking lug, and a lug undercut mold member slidably mounted on an angled surface of the moveable locking lug mold portion with the lug undercut mold member having a flange corresponding to the lug undercut, and

the moveable locking recess mold portion having a protrusion extending above the mold surface when the moveable locking recess mold portion is in the mold condition and corresponding in shape to at least a portion of the locking recess, and a recess undercut mold member slidably mounted on an angled surface of the moveable locking recess portion with the recess undercut mold member having a flange corresponding to the recess undercut;

positioning at least one web of thermoformable material having a first web portion on the mold surface with the moveable locking lug mold portion and a second web portion on the mold surface with the moveable locking recess mold portion each in the mold condition; and

thermoforming the web to form an article including a locking lug having an undercut defining a cantilevered lug ledge having a lug engaging surface formed by the moveable locking lug mold portion and a locking recess having an undercut defining an opposing recess ledge having a recess engaging surface and a lug stop opposite the recess undercut formed by the moveable locking recess mold portion.