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  Method and apparatus for producing labeled, plastic foam containers, and product of sameUSPTO Application #: 20060005917Title: 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. (end of abstract) Agent: Foley And Lardner LLP Suite 500 - Washington, DC, US Inventor: Benito Alvarez USPTO Applicaton #: 20060005917 - Class: 156215000 (USPTO) Related Patent Categories: Adhesive Bonding And Miscellaneous Chemical Manufacture, Methods, Surface Bonding And/or Assembly Therefor, With Permanent Bending Or Reshaping Or Surface Deformation Of Self Sustaining Lamina, By Bending, Drawing Or Stretch Forming Sheet To Assume Shape Of Configured Lamina While In Contact Therewith, Flexible Sheet To Cylinder Lamina The Patent Description & Claims data below is from USPTO Patent Application 20060005917. Brief Patent Description - Full Patent Description - Patent Application Claims
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 inexpensive and have excellent insulating properties for holding both hot and cold fluids. 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. [0004] In order to improve aesthetics and other properties, it is desirable to apply a label to a plastic foam container. 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. [0005] It is therefore desirable to provide a process for forming a labeled plastic foam container in which: (1) labels are applied at sufficiently high speed; and (2) good bonding is obtained between the container and the label. In the latter case improving the bonding between the foam container and the label includes avoiding poor bonding, for example, from formation of air bubbles or loose edges; avoiding loose labels wrapped to the labeled foam container; and avoiding deformation on the geometries of the labeled foam container. SUMMARY OF THE INVENTION [0006] According to one aspect of the invention, a method for labeling a plastic foam container, includes: providing an unlabeled plastic foam container, made of, for example, EPS; positioning the plastic foam container onto a mandrel; applying a label to an exterior surface of the plastic foam container as the plastic foam container is positioned on the mandrel; positioning a cavity that corresponds substantially in shape to the outer surface of the plastic foam container relative to the mandrel onto which the container is positioned so as to substantially surround the exterior surface to which the label is applied; heating the plastic foam container at the exterior surface to which the label is applied with the cavity being at a sufficient temperature and for a time sufficient to bond the label to exterior surface of the container to provide a resulting labeled, plastic foam container; and removing the resulting labeled, plastic foam container from the mandrel. In a preferred embodiment, the plastic foam container is a plastic foam cup. [0007] Preferably, the cavity is heated to a temperature in a range of about 135.degree. C. to about 150.degree. C. Heating may be accomplished by providing heating elements within the cavity. Alternatively, steam may be applied to the exterior of the cavity and/or input into the cavity. [0008] According another feature of the invention, the cavity is used to apply pressure to the exterior surface to which the label is applied. [0009] According to yet another feature of the invention, the cavity is formed within a metal cylinder that is positioned to move relative to the mandrel onto which the foam plastic container is positioned. [0010] According to still another feature of the invention, the mandrel is provided on a rotating turret that moves the mandrel successively to: a first station at which the plastic foam container is placed on the mandrel; a second station at which the label is applied to the plastic foam container; and a third station at which the cavity is positioned to surround exterior surface of the plastic foam container to which the label is applied. [0011] According to another feature of the invention, the label is affixed with at least one of a thermal agent, a hot melt, and/or a plastic coating. The plastic coating may comprise one or more of polyethylene, polypropylene, and any other suitable polymer or co-polymer or mixtures thereof. [0012] According to another aspect of the invention, a machine for labeling plastic, foam containers comprises: a rotatable turret having a plurality of mandrels attached thereto. The turret is driven to rotate the mandrills to a plurality of stations, wherein the mandrels are configured to receive a plastic foam container, preferably from a cup feeder provided at a first station. The mandrels may be further configured to affix a label to a plastic foam container on one of the mandrels, preferably from a sleeve transfer device at a second station. The mandrels may be further configured to be received within a cavity that is so configured to be positioned over the outer surface of a plastic foam container that is placed on one of the mandrels, so as to substantially surround the exterior surface to which the label is applied at a third station. [0013] According to another aspect of the invention, the method and apparatus according to the invention are used to manufacture labeled, plastic foam containers, wherein the label has good printing characteristics. Preferably, the label is formed of at least one of paper, aluminum or plastic film, and mixtures thereof. The person having ordinary skill in the art would understand the types of suitable materials for use in the label for the labeled foam containers according to the present invention. [0014] According to a feature of the invention, a plastic foam container 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. Preferably, the plastic foam container, prior to application of the label, has a density of less than 0.8 g/cm.sup.3. More preferably, the plastic foam container, prior to application of the label, has a density in the range of about 0.041 to 0.076 g/cm.sup.3. Preferably, the resulting labeled, plastic foam container has an overall density in the range of 0.05720-0.1888 g/cm.sup.3. [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/cm.sup.3, 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. [0016] According to a feature of the invention, the inner plastic foam portion defines a cup shape with a lip portion, bottom portion, and sidewall. Preferably, the inner plastic foam portion comprises EPS. [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. [0018] Other features and advantages of the invention will be apparent from the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS [0019] In the drawings: Continue reading... 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