Abstract: A labeled expanded resin container that includes pre-expanded resin beads molded in a shape having a sidewall with an outer surface and a base; and a label formed from a label material capable of maintaining an electrostatic charge disposed over at least a portion of the outer surface of the sidewall of the container. The container has a rim strength that is at least 50% greater than the rim strength of a container that does not contain a label, where the containers are otherwise made using the same equipment. After a liquid at 50° F. (10° C.) is placed in the container and the container is exposed to conditions of 86° F. (30° C.) and 60% relative humidity for 30 minutes, less than 2 ml of moisture condenses on the outer surface of the container.

Abstract: A device and method for producing labeled expanded resin containers; the method including applying a label sheet, formed from a label material capable of maintaining an electrostatic charge, to an inner wall of female portions of two-part molds, positioning one or more male portions of the two-part molds in contact with the corresponding female portions to form one or more mold cavities; adding expandable resin beads or pre-expanded resin beads to the mold cavities; applying a sufficient amount of heat for a sufficient length of time to the mold cavities to effect expansion of the expandable resin beads or pre-expanded resin beads to form labeled containers; cooling the labeled containers; and removing the labeled containers from the mold cavities. The labels on the external wall of the labeled containers present a smooth circumferential surface.

Abstract: A system, apparatus, and method for coating and curing disposable containers, e.g. cups that are made from thermoplastic particles, e.g. expandable polystyrene particles (EPS), and that are coated with a coating, e.g. latex coating. The system comprises a preparation station, a coating station, a curing station, and a container handling station. An apparatus comprising a rotatable wheel is used to position the containers into the several stations. The rotatable wheel contains a plurality of container holding means that consists of vacuum means selectively operable for retaining and releasing the containers relative to the stations and a rotatable platform for selectively rotating the containers to evenly apply and/or dry the coating on the containers and to increase the production rate for coating and/or curing the containers.

Abstract: A mold assembly for forming a container made of expandable thermoplastic particles, e.g. expandable polystyrene particles, comprises an inner mold and an outer mold, which when assembled form a mold cavity for receiving the thermoplastic particles. Steam and cooling fluid are supplied to passageways in the inner mold and outer mold. Temperature sensing devices, e.g. thermocouples, permanently mounted to the inside wall of the inner mold and to the outside wall of the outer mold, detect the temperature of the mold assembly. Pressure transducers in communication with the steam and cooling fluid being supplied into the passageways detect the pressure of the steam and water supplied to the passageways. These devices are continuously operative throughout the supply of steam and cooling fluid in the molding cycle to adjust the pressure and/or cycle time of the steam and to adjust the cycle time of the cooling fluid to optimally fuse together and cool the particles in the mold assembly.

Abstract: Expandable or pre-expanded thermoplastic particles, e.g. polystyrene particles, used to form foam containers e.g. cups, bowls, are coated with a coating composition comprising a liquid part consisting of a) liquid polyethylene glycol with an average molecular weight of 200 to 800; and a solid part comprising components selected from the group consisting of b) polyolefin wax, e.g. polyethylene wax, c) a metal salt of higher fatty acids, e.g. zinc stearate or calcium stearate; d) polyethylene glycol with an average molecular weight of 900 to 10,000; and e) a fatty bisamide or fatty amide, e.g. ethylene bis-stearamide; and combinations of b) through e). The coating composition prevents or resists leakage of liquids and foods with oil and/or fatty components and improves the rim strength and ATF properties of foam containers.

Abstract: A foam thermoplastic container e.g. cup, bowl molded from expandable thermoplastic particles e.g. expandable polystyrene, has a film made of a thermoplastic resin e.g. solid polystyrene, rubber-modified polystyrene, PET, polyethylene, polypropylene, fused to its inner sidewall surface by heat and pressure to create a barrier to resist the leakage of liquid and food with oil and/or fatty components and to increase the rim strength of the container. The thermoplastic resin film can be fused to the outer surface of the container for printing purposes and/or to create a barrier and/or can be fused to the base surfaces of the container. The molding machine used to form the foam container is used to fuse the film to the container.

Abstract: A molded thermoplastic container e.g. cup, bowl made from expandable thermoplastic particles e.g. expandable polystyrene, has a latex coating, e.g. latex of methyl methacrylate and styrene copolymer, latex of methyl acrylate and styrene copolymer, latex of acrylic acid and styrene copolymer, and latex of butadiene and styrene copolymer, applied to at least its inner surface via dipping, brushing or spraying processes for improved leakage and/or stain resistance and/or storage longevity. The coating may be applied to the outer surface of the container for leak resistance and printing purposes. A related method for forming the container, an article of manufacture, and an improved method for storing liquid and food substances are also disclosed.