WO2011106887A1 - Molded container with integral split lid - Google Patents

Abstract

A unitary molded container comprising both a container body, and a container lid, in which the container lid is split so that the container lid is comprised of a least two top panels. The split lid design permits easier filling of the container. Further, when closed, the two top panels overlap at least partially, so as to provide a sealing surface on the top of the unitary container which sealing surface can be sealed, using labels, tape, ribbon or the like so as to provide evidence of tampering. The container can be manufactured using theremoforming techniques from a sheet of plastic material in order to reduce the cost of the container.

Description

Molded Container with Integral Split Lid

Field of the Invention:

This invention relates to the field of containers, and in particular relates to molded unitary containers which are intended to contain and preferably display one or more items. More particularly, the invention is directed to such containers which include a split lid assembly to facilitate filling of the container, as well as preferably providing, upon easy visual inspection, a readily useable and easily observed method to determine whether or not the container has been tampered with.

Background of the Invention:

There are many circumstances in many disparate fields of endeavor where a producer or supplier wishes to bring to the consumer some discrete product items of some sort or another, in a rigid or semi-rigid plastic package. In many cases, these plastic packages are made of a clear plastic, so that the containers may display a huge variety of various discrete product items ranging from food items such as salad greens and the like, to hardware items such as nuts and bolts, to medications, and even to sterile implements and the like which may be used in surgical procedures. In each case, however, the container will typically have in it a plurality of discrete product items - that is, each product item is distinguishable from another product item in the same container. In production line situations, it is preferred that the container be capable of being rapidly filled, and filled in such a manner that the product is quickly, easily and reliably inserted into the container, prior to closing of the container.

Further, most commonly, it is intended that the container will be opened only by the ultimate consumer of the product items therein where the consumer wants to be able to obtain the container with those discrete product items therein and preferably with the assurance that the container has not been tampered with. For example, a retail grocery consumer purchasing a package of salad greens wants to be assured that the individual salad green items have been washed and packaged in keeping with the standards established by the supplier, so that there is reasonable assurance to the consumer that the salad greens have not been contaminated. The supplier, however, wishes to rapidly fill each container with the appropriate amount of lettuce, in a manner that all of the lettuce is held within the container, and does not expand over the side of the container, prior to closing of the container lid. Moreover, this loading of the container is preferably done in such a fashion that the lettuce itself is not damaged by the loading procedure, and in particular, the act of inserting the lettuce into the container, and holding it in place while the prior art lids are closed.

Likewise, if the container is intended to provide a given number of nuts and bolts to the consumer, for example, the consumer wishes to have the assurance that the correct number of nuts and bolts are loaded, and that the nuts and bolts match each other as to gauge, size, material, etc. In a fully loaded container of the prior art, having a single lid, nuts, bolts or the like could be pushed from the container, by the simple action of closing the lid.

Further, the user may wish to have the supplier provide some method to ensure that the product within the container has not been tampered with, and therefore, require some mechanism to avoid un-authorized opening of the container. In the prior art, the sides of the lid can be "sealed" to the container body by use of labels, tape or ribbon, but this system has processing difficulties due to the fact that the sealing procedure acts on the edges of the container.

Providing evidence of tampering can be especially important in some industries such as the aerospace industry where special purpose fastening devices are provided for manufacture or repair of an aircraft, space craft, etc. In food applications, the need to avoid tampering is self- evident. Additionally, in hospitals and nursing homes and the like, it may be very important for any specific patient to receive a prescribed quantity and combination of medications that are specific to that patient; and in keeping with the present invention the nursing staff administering such medications can be assured that such will be the case because the dispensing pharmacist would have checked and double checked the medication dose before closing and sealing the container.

Many prior art containers are known which include a unitary container body and lid, but these have a lid which is attached to one edge of the container body. Using one hinge, the lid closes to cover the container body, and the lid can be sealed to the container using labels, tapes or ribbons, in order to provide reassurance as to quality and an indication of tampering. However, these prior art containers are typically made from process such as injection molding, or the like, which provides a relatively thick plastic layer. The present inventor has unexpectedly discovered that using well-known thermoforming techniques, and an appropriate grade of relatively thin, sheet plastic material, an inexpensive mass-produced container of any desired size can be produced. Such containers can be rapidly filled with less risk of loss of material, and the containers can be conveniently used to contain and display discrete product items, and to deliver those discrete product items to the consumer.

Moreover, the lid of the container of the present invention can be rapidly and easily sealed so as to assure the consumer that, in the interval between the production of the packaged product and the consumption of the discrete product items in the package, there has been no tampering therewith Summary of the Invention

Accordingly, it is a principal advantage of the present invention to provide a unitary molded container comprising both a container body, and a container lid, in which the container lid is split so that the container lid is comprised of a least two top panels. When closed, the at least two top panels preferably at least partially overlap so as to provide a sealing surface on the top of the unitary container which sealing surface can be sealed, using labels, tape, ribbon or the like.

The advantages set out hereinabove, as well as other objects and goals inherent thereto, are at least partially or fully provided by the unitary molded container of the present invention, as set out herein below.

Accordingly, in one aspect, the present invention provides a molded, preferably tamper evident, container for delivery of one or more discrete product items to a consumer thereof, comprising:

a unitary molded container body having at least two side panels, at least two top panels, and at least one discrete chamber;

wherein each of said side panels is preferably of equal height;

wherein said at least one discrete chamber has a bottom panel;

wherein each of said side panels is terminated at its lower edge by said bottom panel, and at its upper end by a preferably outwardly extending lip;

wherein each of said at least two top panels is adjoined to a respective side panel at said lip, by a flexible, integral hinge; and

wherein the width of said at least two top panels is sufficient to meet, when closed, over said container, so as to substantially close said container.

A label, tape or ribbon can also be provided so as to be secured to at least a portion of each top panel; and it is preferred that the material of the label, tape or ribbon be tearable or frangible. The label, tape or ribbon is preferably secured to at least a portion of each top panel which it contacts by appropriate adhesives or by being shrink wrapped or shrink fitted thereto. As such, in a further embodiment, the present invention additionally provides a molded tamper evident container which is a unitary body, and which when closed and sealed in keeping with the present invention is such that any tampering with the container so as to gain access to the discrete product items therein will result in evidence of such tampering.

Preferably therefore, a label, tape or ribbon is secured to at least a portion of each of said at least two top panels, and said ribbon or label is tearable or frangible so that any damage to said label, tape or ribbon is evidence of tampering therewith by any other person prior to breaking or tearing thereof by the consumer of said discrete product items.

Accordingly, when there is any damage to the label, tape or ribbon prior to that which will occur when the consumer of the discrete product items in the container unseals and opens the container, then that prior damage is evidence of tampering with the container and/or the discrete product items therein.

The container body typically has at least one discrete chamber. However, the container body can be divided into two or more chambers, as desired. Moreover, while the container body is typically square or rectangular in shape, other shapes such as oval, heart-shaped, or the like, can also be used, as indicated hereinbelow.

The size of the container can also vary depending on the size of the thermoforming equipment. Commonly, the container body will typically be from 2.5cm to 50 cm in width, but widths of up to 1 meter or more, are also possible.

Commonly, the height of the container body will be 0.5 to 25 cm, and more preferably, 1 cm to 15 cm, or more.

Variations of the above are provided for hereafter.

The top (or lid) panel is preferably split into two halves, and preferably having essentially the same dimensions so that each top panel half will cover essentially half of the container openings. When forming the container and top panels within the thermoformed plastic sheet material, there is a potential part weight savings by having the lid portions smaller and on both sides of the container. Those skilled in the art of tooling manufacturing and or thermoforming process control can drag material during the thermoforming process from the sheet adjacent to a deep draw section, such as the main cavity of the container. By having lid sections on both sides of the deep cavity section the material in the lid sections can be minimized compared to prior art techniques of having the top panel produced off to one side of the container, only.

Further, the top panel can be divided into three or more panel sections. In this embodiment, preferably all of the separate top panel sections are essentially equal in size, and preferably, all of the separate top panels overlap at at least one point. Alternatively, one or more larger panel sections can overlap with several other smaller sections that might not overlap with one another.

Further however, the top panels do not need to overlap, but can instead, merely meet or rest adjacent to one another, when closed. The label, tape or ribbon used for evidence of tampering, will preferably cover at least a portion of the top panels, whether they overlap, meet, or rest adjacent to one another.

In another aspect, the present invention also provides a process for the production of containers as described herein, wherein said containers are formed using a thermoforming process.

Brief Description of the Drawings

Embodiments of this invention will now be described by way of example in association with the accompanying drawings in which:

Figure 1 shows a prior art container, having a single top panel and a plurality of discrete chambers;

Figure 2 shows the embodiment of Figure 1 , but in a closed position;

Figure 3 is a perspective view of an embodiment of the present invention having two top panels in their open position;

Figure 4 is similar to Figure 3, but showing the container in a closed position;

Figure 5 is similar to Figure 4, but having a different sealing arrangement;

Figure 6 is a perspective view of another embodiment of the present invention;

Figure 7 is a perspective view of the embodiment of Figure 6, showing the manner in which the top panels will close;

Figure 8 is a perspective view of yet another embodiment of the present invention;

Figure 9 is a view similar to Figure 5, but showing a further variation of the present invention; and

Figure 10 is a view similar to Figure 5, but showing a still further variation of the present invention.

Detailed Description of the Preferred Embodiments

The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which presently preferred embodiments of the invention will now be illustrated, by way of example only. In the drawings, like reference numerals depict like elements. Also, it is expressly understood that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. Also, unless otherwise specifically noted, all of the features described herein may be combined with any of the above aspects, in any combination.

Referring first to Figures 1 and 2, a prior art container 90 having a container body 92 incorporating two discrete chambers 91 and 93 and a single top panel 94, is shown. Top panel 94 is joined to a side panel by a unitary flexible hinge 96. Lift tabs 95 and 97 are integrally molded onto the container body and top panel respectively, so that when the container is closed as seen in Figure 2, easier opening of the container 90 is possible. Because of the interaction of protrusions 89 and their mating recesses 99, the container top panel 94, is held in place, when top panel 94 is moved to the closed position.

Also, as seen in Figure 2, a ribbon 98 extends from the back to the front of container 90 across top panel 94, and is held in place by adhesive. However, the nature of ribbon 98 is that it is tearable or frangible so that opening of container 90 will tear, or in some way damage, ribbon 98. As such, the consumer is able to determine whether the goods in the container may have been tampered with.

Referring now to Figure 3, a container according to the present invention is described. In Figure 3, a unitary container unit is shown generally at 10. That is to say, the entire container 10 is thermoformed using conventional thermoforming molding techniques from a single sheet of plastic material so as to be monolithic in nature.

This can include thermoforming techniques known to the skilled artisan, and can include vacuum or pressure forming techniques from a larger sheet of plastic material. This is in distinct contrast to other prior art techniques for production of plastic materials, such as injection molding techniques.

In this embodiment, it will be seen that the container 10 comprises a molded container body 1 1 , and has two top top panels, 21 and 23. For any container there is at least one discrete chamber 25; and in this case, container 10 is seen to have two discrete chambers 25 and 27 within container body 1 1 . The unitary molded body which comprises the container 10 as seen in Figure 3 as a plurality of side panels 28, 29. In this embodiment, it will be seen that the side panels each have equal height and that that height defines the height of the container.

While it is preferred that the side panels have an equal height, it will be understood that the side panels can also be of differing heights in other embodiments.

The chambers 25 and 27 each have a bottom panel which is shown at 31.

It will be noted that each of the side panels 27, 29 terminates at its upper end by an outwardly extending lip 33. Of particular importance is the fact that each of the two top panels 21 , 23 is adjoined to the respective side panels 29 by a unitary flexible hinge 32, which takes the form of a living hinge and is formed at the same time as the entire container is thermoformed.

The only additional feature which is added to the unitary molded body, and which comprises part of the present invention, is a label, tape or ribbon which is applied after the container has been filled with the intended discrete product items. By filling a container which is in keeping with the present invention, it is meant only that the requisite amount of discrete product items are placed into the container, whether that amount is determined by volume or by particle count.

Referring now to Figures 4 and 5, a representative mode of sealing the container 10 is shown in two different manners. In Figure 4, a ribbon 34 is shown extending from one end 35 to the other and 37 of the top panels 21 , 23. Clearly, the ribbon 34 covers that portion of each of the top panels 21 , 23 where they either meet or overlap. In Figure 5, a label 36 is shown which does not extend over the ends of the top panels as does the ribbon 34 in Figure 4. Rather, the label 36 may extend only partially along the seam 39 which is formed when the top panels 21 , 23 meet or overlap; but it will be seen that in either case the container 10 is sealed. The nature of the ribbon 34 or label 36 is such that the material from which it is manufactured is either tearable or frangible, so that any attempt to remove or displace the ribbon 34 or label 36 after they have been secured in place will result in damage to the ribbon or label. That damage, in turn, will be evidence of some kind of tampering with the container 10 in or the discrete product items therein, whether intended or inadvertent.

In any event, the contents of the container may have been compromised, and a decision will then have to be made by the supplier, retailer, or consumer, as to whether the container will be allowed to continue in the supply line in which it is found, or whether it would have to be removed, replaced, or disposed of.

It has been found that when handling such food products as salad greens, it is convenient for the container to comprise at least two discrete chambers. It will be understood that such food items as salad greens do not have a high packing density, especially when first placed into a container, but during shipment the individual salad green leaves etc. may settle, become broken, or they may wither due to dehydration. Also, such containers may be shipped on ends, so that the salad green contents of the container may tend to settle at one end of the container, giving the impression that the container has not been properly filled to the correct volume. The presence of a divider 38 tends to preclude that effect from happening. It has also been noted that when such containers are filled with salad greens in an industrial environment, spillage or excess fill of the salad greens tends to be towards the sides of the container and not to the ends, so that when the top panels 21 , 23 are closed there may be an additional salad green item or two charged into the container, but there would be no wastage.

In other words, as top panels 21 and 23 are moved to a closed position, they push excess materials towards the centre of container 10. In contrast to the prior art container shown in Figure 1 , closure of top panel 94 pushes material towards the outer edges of container 90.

In Figure 3, it should also be noted that the height of the divider 38 is not greater than the height of any of the side panels. Moreover, it is clear that the opposed side panels from which the divider 38 extends are effectively bifurcated by the presence of the divider 38. In any event, when present, the height of any divider is preferably at least 50% of the height of the side panels. This permits some communication between discrete chambers. It will be seen hereafter that in other embodiments of the present invention, the dividers which define discrete chambers may be of any suitable height, so as to preclude communication of discrete product items from one chamber to another. As such, the divider height can vary from 10% to essentially 100% of the side panel height.

Referring now to Figures 6 and 7, a significantly different appearance of container 40 is shown. Container 40 includes a molded unitary body; it has at least two top panels 43, 45; it has discrete chambers 47, 49; each discrete chamber has a bottom panel 51 ; each of the side panels 48 in each compartment is of equal height; the top panels 43, 45 are joined to the respective side panels by unitary flexible hinges 42, 44; and as can be seen in Figure 7, a label 46 can be placed on the upper surfaces of the top panels 43, 45 so as to provide evidence of tampering should the label 46 be damaged in one way or another.

It will be seen in Figures 6 and 7 that the divider between discrete chambers 47, 49 comprises that structure between the discrete chambers 47, 49 that is of the same height as the outside side panels. This precludes communication between the discrete chambers 47, 49 of any discrete product items that may be found therein. Accordingly, different kinds of candy may be merchandised; or mating nuts and bolts may be packaged; or specific combinations of medications in prescribed amounts may be delivered to a patient, and so on.

Briefly referring to Figure 8, another form of container 60 is shown; and it will be understood that this container 60 meets all of the same criteria as the container 40 described above, and also the same as the container 10. In particular, the container 60 is a molded unitary body; and in this case, there are four discrete chambers and four top panels 61 , 63, 65, 67. A label 62 will be applied when the top panels are moved to their closed position, and it is evident that the label 62 will cover at least a portion of each of the top panels 61 , 63, 65, 67.

Several other features that have been illustrated in any or all of Figures 3 to 8 are now discussed. For example, a pair of lift tabs 41 is shown on the top panel 21 ; and it will be evident that when the top panels 21 , 23 are closed so that top panel 21 overlies top panel 23, and after the ribbon 34 or label 36 has been removed, then the lift tabs 41 will permit easy opening of the container 10. Lift tabs 41 could also be provided on the outside edges, or any other suitable location, on top panel 21.

It will also be seen in Figures 3 to 5 that one or more protrusions 53 may be formed which will mate with recesses 55; and that if properly dimensioned, protrusions 57 and recesses 59 will also mate one with another so as to assure more complete closure of the container. The same holds true with protrusions 57 and recesses 59 as they are seen in Figures 6 and 7; except that in this case, the recesses 59 are formed in a top wall 64 which extends between discrete chambers 47 and 49. The same feature is also evident in Figure 8.

Referring now to Figures 9 and 10 a further embodiment of the present invention is now discussed. Here, at least a portion of the outwardly extending lip 33, and of the top panels 21 , 23 or 43, 45, extends further outwardly away from the discrete chambers within the containers 70 or 80. In this case, as seen in Figure 9, an outwardly extending tear tab 72 is formed at each end of the container 70. After the container 70 has been filled and closed, portions 74 of each of the tear tabs 72 is plastic welded, staked or glued so that they may not be separated. In order to open the container 70, the tear tabs 72 are torn away from the container 70 along the tear line 76 which may be formed in any convenient manner known to those skilled in the art. A similar situation exists with respect to container 80 in Figure 10, where portions 82, 84 of the respective outwardly extending lip 33 in the top panel 45 are molded integrally with the remainder of the container when it is thermoformed. The same conditions would apply to the other discrete chamber and its respective top panel. A portion 86 is designated on each of the extension portions 82, 84 where plastic welding, staking or glueing will occur when the container 80 has been closed. Once again, a suitable tear line 87 will be formed in the manner known to those skilled in the art.

Other modifications and alterations may be used in the design and manufacture of the apparatus of the present invention without departing from the spirit and scope of the

accompanying claims.

Thus, it is apparent that there has been provided, in accordance with the present invention, a unitary, molded container made from a thermoforming process, which fully satisfies the goals, objects, and advantages set forth hereinbefore. Therefore, having described specific embodiments of the present invention, it will be understood that alternatives, modifications and variations thereof may be suggested to those skilled in the art, and that it is intended that the present specification embrace all such alternatives, modifications and variations as fall within the scope of the appended claims. Additionally, for clarity and unless otherwise stated, the word "comprise" and variations of the word such as "comprising" and "comprises", when used in the description and claims of the present specification, is not intended to exclude other additives, components, integers or steps. Further, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

Moreover, the words "substantially" or "essentially", when used with an adjective or adverb is intended to enhance the scope of the particular characteristic; e.g., substantially planar is intended to mean planar, nearly planar and/or exhibiting characteristics associated with a planar element.

Further, use of the terms "he", "him", or "his", is not intended to be specifically directed to persons of the masculine gender, and could easily be read as "she", "her", or "hers", respectively.

Also, while this discussion has addressed prior art known to the inventor, it is not an admission that all art discussed is citable against the present application.

Claims

We claim:

1. A molded container for delivery of one or more discrete product items to a consumer, comprising:

a unitary molded container body having side panels, at least two top panels, and at least one discrete chamber;

wherein said at least one discrete chamber has a bottom panel;

wherein each of said side panels is terminated at its lower edge by said bottom panel, and at its upper end by a preferably outwardly extending lip;

wherein each of said at least two top panels is adjoined to a respective side panel at said lip, by a flexible, integral hinge; and

wherein the width of said at least two top panels is sufficient to meet, when closed, over said container, so as to substantially close said container.

2. A container as claimed in claim 1 , comprising:

a unitary molded body having at least two side panels, at least two top panels, and at least one discrete chamber;

wherein each of said side panels is of equal height;

wherein each of said side panels is preferably terminated at its upper end by an outwardly extending lip; and

wherein a label, tape or ribbon is preferably secured to at least a portion of each of said at least two top panels, and said label, tape or ribbon being tearable or frangible; and

wherein the securement of said label, tape or ribbon to at least a portion of each of said at least two top panels is by adhesive or shrink fit;

whereby any damage to said ribbon or label is evidence of tampering therewith by any other person prior to breaking or tearing thereof by the consumer of said discrete product items.

3. A container as claimed in claim 1 , wherein said unitary molded body is formed so as to have at least two discrete chambers having a divider therebetween, wherein the height of said divider between any adjacent pair of discrete chambers is not greater than the height of any of said side panels.

4. A container as claimed in claim 1 , wherein the height of each said divider is at least 50% of the height of said side panels, and is less than the height of said side panels; and H 156

WO 2011/106887 PCT/CA2011/000240 wherein the opposed side panels between which each said divider extends are bifurcated by said divider.

5. A container as claimed in claim 1 , wherein at least one lift tab is formed in said at least one top panel.

5 6. A container as claimed in claim 1 , wherein at least one dimple is formed in an outwardly extending lip from at least one side panel, and a mating protrusion is formed on the underside of at least one top panel so as to mate with said dimple when said at least one top panel is in its closed position over at least a portion of said at least one discrete chamber.

7. A container as claimed in claim 1 , wherein said at least two top panels are slightly 10 overlapped one over the other when they are in their closed position.

8. A container as claimed in claim 7, wherein said ribbon or label overlies at least a portion of the overlapped region of said at least two top panels.

9 A container as claimed in claim 7, wherein at least one lift tab is formed in one of said top panels so as to overlie the other of said top panels when the top panels are in their closed 15 position.

10. A container as claimed in claim 1 , wherein a portion of said outwardly extending lip of at least one side panel and a portion of the mating one of said top panels are welded or secured together when the container is filled and closed, so as to form an outwardly extending tear tab for at least partially opening a sealed and untampered with container;

20 and wherein said tear tab is formed so as to be tearable or frangible when the container is closed and sealed.

1 1. A container as claimed in claim 2, wherein said ribbon or label extends over at least one outwardly extending lip at least one side panel.

12. A container as claimed in claim 2, wherein said ribbon or label does not extend over any 25 outwardly extending lip of any side panel.

13. A container as claimed in claim 3, wherein said at least two discrete chambers are separated at the top elevations thereof by a top wall extending between adjacent discrete chambers.

14. A container as claimed in claim 13, wherein at least one recess is formed in a top wall between adjacent discrete chambers, and a mating protrusion is formed on the underside of the respective at least one top panel so as to mate with said recess when said at least one top panel is in its closed position.

15. A container as claimed in claim 1 , wherein said container is formed using a

thermoforming process.

16. A molded tamper evident container for delivery of discrete product items to the consumer thereof, comprising:

a unitary molded body having side panels, at least one top panel, and at least one discrete chamber; over lies

wherein each of said side panels is of equal height;

wherein said at least one discrete chamber has a bottom panel;

wherein each of said side panels is terminated at its upper end by an outwardly extending lip;

wherein said at least one top panel is adjoined to a respective outwardly extending lip of the respective side panel by a unitary flexible hinge;

wherein at least one label, tape or ribbon is placed across said at least one top panel so as to reach from one side panel to a non-adjacent side panel, so that said ribbon is a secured to at least a region of said top panel adjacent to the side panel from which said ribbon extends, and to at least a region of the respective side panel to which said ribbon extends; and

wherein said label, tape or ribbon is frangible or tearable, so that any damage to said ribbon anywhere along its length is evidence of tampering therewith by any other person prior to breaking or tearing of said ribbon by the consumer of said discrete product items.

17. A molded tamper evident container as claimed in claim 16, wherein at least one lift tab is formed in said at least one top panel.

18. A molded tamper evident container as claimed in claim 16, wherein the container is rectangular, and there are two top panels extending from opposed flexible hinges associated with the respective outwardly extending opposed side panels; and

wherein said two top panels are dimensioned so as to at least slightly overlap when in 5 their closed position.

19. A molded tamper evident container as claimed in claim 16, wherein at least one lift tab is formed in one of said top panels so as to overlie the other of said top panels when the top panels are in their closed position.

20. A molded tamper evident container as claimed in claim 6, wherein said unitary molded 10 body is formed so as to have at least two discrete chambers having a divider therebetween, wherein the height of said divider between any adjacent pair of discrete chambers is not greater than the height of any of said side panels.

21 . A molded tamper evident container as claimed in claim 20, wherein the height of each said divider is at least 50% of the height of said side panels, and is less than the height of said

15 side panels; and

wherein the opposed side panels between which each said divider extends are bifurcated by said divider.

22. A molded tamper evident container as claimed in claim 16, wherein said container is formed using a thermoforming process.