A method of making a shaped abrasion-resistant multilayer optical film includes providing a curable composition comprising, based on the total weight of components a) to d) components: a) 87 to 96 weight percent of urethane (meth)acrylate compound having an average (meth)acrylate functionality of 2 to 4.8; b) 2 to 12.5 weight percent of (meth)acrylate monomer having a (meth)acrylate functionality of 1 to 2, wherein the (meth)acrylate monomer does not comprise a urethane (meth)acrylate compound; optionally c) 0.5 to 2 weight percent of silicone (meth)acrylate; and d) optional effective amount of photoinitiator. The curable composition is coated onto an MOF. Optionally, the curable composition to is at least partially dried. Next, the curable composition or the at least partially dried curable composition is at least partially cured to provide an abrasion-resistant multilayer optical film. Lastly, the abrasion-resistant multilayer optical film is thermoformed using a female mold having a mold surface. At least a portion of the mold surface has a radius of curvature of 58 to 76 mm and a maximum depth of 13 to 20 mm.

A thermoforming device includes: an upper hot plate including a first heating surface configured to heat a sheet from above; a lower hot plate including a second heating surface configured to heat the sheet from below; and a substrate-supplying unit including a base configured to hold a molded substrate, and configured to attach the molded substrate to and detach the molded substrate from the base and to dispose the molded substrate at a molding position below the first heating surface with the sheet interposed therebetween, in which the upper hot plate and the lower hot plate are configured to heat the sheet simultaneously from an upper surface and a lower surface of the sheet, the lower hot plate is provided to be movable in a horizontal direction with respect to a position below the upper hot plate, and the thermoforming device die-molds or adheres, onto the molded substrate held by the base, the sheet softened by being heated by the upper hot plate and the lower hot plate.

A thermoforming device includes: an upper hot plate including a first heating surface configured to heat a sheet from above; a lower hot plate including a second heating surface configured to heat the sheet from below; and a substrate-supplying unit including a base configured to hold a molded substrate, and configured to attach the molded substrate to and detach the molded substrate from the base and to dispose the molded substrate at a molding position below the first heating surface with the sheet interposed therebetween, in which the upper hot plate and the lower hot plate are configured to heat the sheet simultaneously from an upper surface and a lower surface of the sheet, the lower hot plate is provided to be movable in a horizontal direction with respect to a position below the upper hot plate, and the thermoforming device die-molds or adheres, onto the molded substrate held by the base, the sheet softened by being heated by the upper hot plate and the lower hot plate.

The disclosure relates to forming shaped thermoplastic articles having smooth peripheries. Many thermoplastic articles have sharp edges formed upon molding or cutting the article from a feedstock sheet. Such sharp edges can damage thin plastic films or flesh which they contact, and smoothing the edges is desirable. Described herein are methods of forming a smooth periphery for such sharp-edged articles by rolling over the sharp edge. The smoothing operation is performed by forming a deflectable flange including a bend region separated from the potentially sharp peripheral edge by a spacer, deflecting a portion of the deflectable flange, and softening at least one bent portion of the deflectable flange to yield a smooth periphery upon cooling. The deflection can include curling the spacer at or near the peripheral edge.

A method of manufacturing a PTP sheet for pharmaceutical drug packaging from which a solid pharmaceutical drug is easily taken out and in which a pocket portion is hard to be accidentally damaged. The PTP sheet has a first sheet from which a pocket portion capable of housing a solid pharmaceutical drug protrudes to the side of an upper surface and a second sheet which is stuck to a lower surface of the first sheet and which closes an opening of the pocket portion. The pocket portion has a peripheral wall portion having a peripheral surface continuous with the upper surface and a top portion having a top surface continuous with the peripheral surface of the peripheral wall portion. A wall thickness of the peripheral wall portion is smaller than a wall thickness of the top portion.

A tray sealer that includes a control unit and a sealing station is presented. The sealing station comprises a tool upper part, a clamping frame and a tool lower part. The interior of the tool upper part comprises a dome-shaped die for deforming a top film. The dome-shaped die comprises at least a first channel and the tool upper part comprises a second channel. The dome-shaped die may have an inner contact surface. The clamping frame may clamp the top film in position on the tool upper part in a gas-tight manner so as to define an upper chamber within the tool upper part. In one embodiment, a vacuum sensor is operably connected to the control unit and is disposed between the dome-shaped die and a vacuum generator. The control unit may detect a tear in the film using a pressure profile generated by the vacuum sensor.

An article of luggage is provided for comprising a first layer of hard shell and a second layer of hard shell material with one or more ornamental substrate disposed between at least the first layer of hard shell material and at least the second layer of hard shell material. A section of hard shell material may be formed by pressing and/or heating at least the first layer of hard shell material, the second layer of hard shell material, and the ornamental substrate together.

A dental aligner and methods and systems for manufacturing the dental aligner. A boundary contour is defined in a two-dimensional space based on an edge of a model aligner in a ruler disc. The boundary contour may be measured on a grid in which the model aligner is formed. The information pertaining to the boundary contour in the model is transferred to a flat workpiece. The boundary contour may follow the patient's gingival margin. A trench is formed in the flat workpiece based on the boundary contour measured in the model aligner. The flat workpiece including the trench is deformed. Deforming the trench forms at least a portion of the edge of the dental aligner and may include a trim boundary. The aligner may be separated from the workpiece at the trim boundary. The model aligner and dental aligner may vacuum thermoformed from the same mold.

A dental aligner and methods and systems for manufacturing the dental aligner. A boundary contour is defined in a two-dimensional space based on an edge of a model aligner in a ruler disc. The boundary contour may be measured on a grid in which the model aligner is formed. The information pertaining to the boundary contour in the model is transferred to a flat workpiece. The boundary contour may follow the patient's gingival margin. A trench is formed in the flat workpiece based on the boundary contour measured in the model aligner. The flat workpiece including the trench is deformed. Deforming the trench forms at least a portion of the edge of the dental aligner and may include a trim boundary. The aligner may be separated from the workpiece at the trim boundary. The model aligner and dental aligner may vacuum thermoformed from the same mold.

The invention disclosed herein is an automotive acoustic panel including a porous sound-absorption material made from a polymer and an expanded perlite. One or more silane compounds may be coupled or coated onto the expanded perlite while a coupling agent and a chemical foaming agent may additionally be added to the automotive acoustic panel.