Abstract A two-piece plastic container is fabricated by selecting a sheet of expanded plastic material having an integral skin, the skin having a density approaching that of the basic unfoamed plastic, while the intermediate body of foamed plastic has a relatively low density of the order of 11-14 lbs./cu.ft. and a cell size of from about 0.2 to about 0.3 mm., the overall thickness of the sheet being about 0.030 inch to about 0.050 inch. Blanks are cut from the aforesaid sheet, treated with a solvent along the margins at the bottom and end, and folded around a mandrel to bring opposite ends into overlapping position with the solvent therebetween whereupon the overlapped ends are pressed together to form a seam. A bottom member is solvent sealed to the bottom edge of the side wall blank.
The method as set forth in claim 1, in which the plastic material is foamed polystyrene, the sheet thereof having a thickness of from about 0.030 inch to about 0.050 inch, said impervious skins of said sheet having a Density on the order of about 66 lbs./cu.ft., and said blank is folded while at a temperature of between 60* and 80* F.
Claim 2
Dependent Claim
46 words
The method as set forth in claim 2 which further comprises forming said bottom member by preheating a sheet of high impact polystyrene having a thickness of the order 0.010 inch to a temperature of about 120* F. and punching and forming said bottom member therefrom.
Claim 3
Dependent Claim
31 words
The method as set forth in claim 1, in which said foamed plastic material comprises crystalline (homopolymer) polystyrene containing from about 1 percent to about 2.5 percent residual pentane foaming agent.
Claim 4
Dependent Claim
64 words
The method as set forth in claim 1 in which the solvent is a chlorinated solvent and is applied to said blank by an etched gravure roll on which the etching is about 0.006 inch deep with a line screen of about 40 lines per inch and said container side seam is completed within about one second after the solvent seal pattern is applied.
Claim 5
Dependent Claim
89 words
The method as set forth in claim 1 which further comprises the steps of supporting the assembled body comprising the side wall member and bottom member in a container holder, preconditioning the top edge of said assembled body by subjecting it to a medium velocity flow of air heated to about 500* F. and thereafter to a non-contacting plug heated to a temperature of about 525* F. and, after thus preconditioning said edge, partially forming a beaded lip and thereafter completing the lip to its final shape and dimensions.