Multi-cellular container with cut-score
A multi-cellular polypropylene container with a cut-scored region connecting the cells of the container is described. By varying the cut-score depths depending on the orientation of the plastic material, greater consistency in the tearability of the individual cells is achieved. One or more star-cut patterns may be provided between the cells. The star-cut patterns have curved edges that lead to the separation region. The curved edges provide a generally smooth surface that does not cut or snag the user.
1. A method of manufacturing a multi-cellular container from a plastic sheet, comprising:
forming a plurality of cells connected together by a separation region, wherein an individual cell may be removed by tearing the separation region between the individual cell and the plurality of cells; and
providing cut-scores between the plurality of cells, wherein the cut-scores parallel to an index direction of the plastic sheet are deeper than the cut-scores perpendicular to the index direction.
2. The method of manufacturing a multi-cellular container according to claim 1 , further comprising forming star-cut patterns between the plurality of cells.
3. The method of manufacturing a multi-cellular container according to claim 2 , further comprising forming the star-cut patterns with curved and generally smooth edges that lead to the separation region.
4. The method of manufacturing a multi-cellular container according to claim 3 , wherein the curved and generally smooth edges provides corners for the cells having a radius.
5. The method of manufacturing a multi-cellular container according to claim 1 , further comprising forming star-cut patterns between the plurality of cells without sharp corners.
6. The method of manufacturing a multi-cellular container according to claim 1 , wherein the cut-scores and a star-cut pattern between the plurality of cells are cut before a perimeter of the multi-cellular container is cut.
7. The method of manufacturing a multi-cellular container according to claim 1 , wherein the cut-scores and a star-cut pattern between the plurality of cells are cut by one trim press and a perimeter of the multi-cellular container is cut by another trim press.
8. The method of manufacturing a multi-cellular container according to claim 1 , wherein the cut-scores and a star-cut pattern between the plurality of cells are cut in one step and a perimeter of the multi-cellular container is cut in another step.
9. The method of manufacturing a multi-cellular container according to claim 1 , wherein the cut scores alternate with a cut-through.
10. The method of manufacturing a multi-cellular container according to claim 1 , wherein the cut-scores between the individual cells includes a cut-through at the beginning of the cut-scores.
11. The method of manufacturing a multi-cellular container according to claim 1 , further comprising forming the multi-cellular container with four cells.
12. The method of manufacturing a multi-cellular container according to claim 1 , wherein an individual cell removed from the plurality of cells has a perimeter formed from the separation region, wherein the perimeter has a generally smooth edge.
13. A method of manufacturing a multi-cellular container, comprising:
forming a plurality of cells from a sheet of plastic, wherein the cells are connected together by a separation region, wherein an individual cell may be removed by tearing the separation region between the individual cell and the plurality of cells;
providing cut-scores in the separation region, wherein the cut-scores parallel to an index direction of the plastic material are deeper than the cut scores perpendicular to the index direction.
14. The method of manufacturing a multi-cellular container according to claim 13 , further comprising thermoforming the plurality of cells from a sheet of polypropylene, wherein the cells are depressions having a bottom and sides, the sides are angled or curved relative to the bottom, the sides transition into a generally planar boundary that forms a rim for each cell, and the boundary comprises the separation region.
15. The method of manufacturing a multi-cellular container according to claim 13 , further comprising forming alternating cut-throughs with the cut-scores in the separation region.
16. A method of manufacturing a multi-cellular container, comprising:
forming a plurality of cells from a sheet of plastic, wherein the cells are connected together by a separation region, wherein an individual cell may be removed by tearing the separation region between the individual cell and the plurality of cells;
cutting cut-scores in the separation region with one trim press, wherein the cut-scores parallel to an index direction of the sheet of plastic are deeper than the cut-scores perpendicular to the index direction;
cutting a star-cut pattern between the plurality of cells with the one trim press; and
cutting a perimeter of the multi-cellular container with another trim press.
17. The method of manufacturing a multi-cellular container according to claim 16 , wherein the cutting of the cut-scores and the cutting of the star-cut pattern between the plurality of cells occurs in one step and the cutting of the perimeter of the multi-cellular container occurs in another step.
18. The method of manufacturing a multi-cellular container according to claim 16 , further comprising using a vertical trim press to cut the star-cut pattern, the cut scores, and an inner portion of a curved edge that forms rounded corners for the cells, and further comprising using a horizontal trim press to cut an outer portion of the curved edge and outer edges of the multi-cellular container.