Method and apparatus for producing labeled, plastic foam containers, and product of same

Abstract

A method and apparatus for producing labeled, plastic foam containers, such as a labeled EPS cup uses a heated pocket to thermally bond a label to a plastic cup. Also described is a labeled plastic foam container, such as a labeled EPS cup, having high quality printing capabilities, sufficient stiffness, acceptable insulation and barrier properties and reduced production cost.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation of Application PCT / IB2004 / 003517, filed Oct. 1, 2004, which application claims the benefit under 35 USC 119(e) of U.S. application Ser. No. 60 / 507,944, filed Oct. 3, 2003, U.S. application Ser. No. 60 / 510,519, filed Oct. 14, 2003. The respective disclosures of each of these related application are incorporated herein by reference in their entireties.FIELD OF THE INVENTION [0002] This invention relates to a method and apparatus for producing labeled, plastic foam containers, such as, for example, a labeled expanded polystyrene cup. It further relates to a labeled, plastic foam container, such as a labeled expanded polystyrene cup. BACKGROUND OF THE INVENTION [0003] Plastic foam containers, such as cups and other receptacles are widely used. Such containers can be made from different materials, including expanded polystyrene (EPS). Plastic foam containers, such as those made of EPS, are relatively inexpe...

AI Technical Summary

Benefits of technology

[0015] According to another aspect of the invention, a labeled plastic foam container has an inner plastic foam portion having a density of less than 0.8 g / cm3, and an outer sleeve that adheres to an outer surface of said inner plastic foam portion. The outer sleeve has an outwardly facing surface to which is applied print or graphical designs, the outer sleeve providing stiffness to the inner portion. The label may be applied made according to a method or machine of the invention, prior to labeling, has relatively low density and stiffness, but after application of the label, has an overall stiffness and density that is comparable to similarly sized conventional foam containers.

[0017] The stiffness obtained by the combination of plastic foam and label materials permits the use of substantially less EPS resin in comparison with a standard plastic foam container of comparable (or even less) volume capacity. The particular combination of a lower resin content, such as EPS resin, combined with a sleeve providing improved rigidity results in a container having a significantly lower cost than prior containers made out of paper and / or plastic. The outer sleeve dramatically improves printability in comparison to standard foam containers. This may result in particular by using a pre-printed label. Further, the container according to the invention further provides comparable or improved stiffness, barrier properties and insulation in comparison with comparable sized-containers.

Problems solved by technology

Plastic foam containers, however, typically have poor printing capabilities.

That is, it is difficult to apply print or graphical designs directly to the surface of plastic foam containers, such as EPS containers.

Traditional labeling devices suffer from certain limitations.

For example, it is often complicated to apply labels to foam containers with conical surfaces, such as cups.

It is particularly difficult to cover substantially the entire outer surface of such a container, such as the entire outer wall of a cup.

It is also difficult to achieve proper and consistent bonding between the label and the cup.

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