Methods and means for manufacturing foam plastic containers and sidewall blanks for same

Claim 3

The method defined in claim 1, wherein said blank includes printed graphics on one face thereof and including the step of orienting said blank such that said graphics appear on the outer circumference of said cylindrical blank.

Claim 6

The method defined in claim 3, wherein said blank includes printed graphics on one face thereof including the step of orienting said blank such that said graphics appear on the outer circumferences of said cylindrical blank.

Claim 9

The method of claim 5, wherein said shrinking of said cylindrical blank comprises continuously transporting said second mandrels through a zone of elevated temperature sufficient to shrink said blanks to the configuration of said mandrels during the time of transport through said zone.

Claim 12

The method defined in claim 7 including the further step of forming annular rim configurations at the ends of said sidewalls to define mouths for said containers.

Claim 13

Means for forming a cylindrical blank from a rectangular blank of foam plastic sheet material comprising: conveyor means feeding said rectangular blank along a predetermined path transversely of its length at a predetermined continuous rate; cylindrical mandrel means positioned parallel with said predetermined path adjacent said conveyor means; folding means adjacent said mandrel means over a portion of the length of the latter engaging and progressively folding said blank about said mandrel means while feeding said blank along said path to overlap the ends thereof on said mandrel in the provision of a lapped seam; heating means adjacent said path for progressively applying heat to the ends of said blank to prepare said blank for heat sealing of said lapped seam; and sealing means adjacent said mandrel downstream of said folding means for pressing said heated ends of said blank together to heat seal said lapped seam.

Claim 14

Means for forming a cylindrical blank from a rectangular blank of foam plastic sheet material comprising: conveyor means feeding said rectangular blank along a predetermined path transversely of its length at a predetermined continuous rate; cylindrical mandrel means positioned parallel with said predetermined path adjacent said conveyor means; folding means adjacent said mandrel means over a portion of the length of the latter engaging and progressively folding said blank about said mandrel means while feeding said blank along said path to overlap the ends thereof on said mandrel in the provision of a lapped seam; heating means adjacent said path for progressively applying heat to the ends of said blank to prepare said blank for heat sealing of said lapped seam; and sealing means adjacent said mandrel downstream of said folding means for pressing said heated ends of said blank together to heat seal said lapped seam.

Claim 15

The invention of claim 9 wherein said rectangular blank is stretch oriented in its longitudinal direction in the provision of a heat shrinkable foam blank; and wherein said orientation in said cylindrical blank is circumferentially disposed.

Claim 16

The invention of claim 9, wherein said rectangular blank is printed on one side thereof with a desired pattern; and wherein the other side thereof is placed adjacent the cylindrical mandrel when said blank is engaged by said conveyor means.

Claim 17

The invention defined in claim 9, wherein said rectangular blank is stretch oriented in its longitudinal direction in the provision of a heat shrinkable foam blank; wherein said orientation in said cylindrical blank is circumferentially disposed; and wherein said rectangular blank is printed on one side thereof with a desired pattern; and wherein the other side thereof is placed adjacent the cylindrical mandrel when said blank is engaged by said conveyor means.

Claim 20

The invention defined in claim 13, including the further step of forming an interlock between said annular rim and said cap to maintain the latter on said container.

Claim 23

The invention defined in claim 15, including the further step of forming an interlock between said annular rim and said cap to maintain the latter on said container.

Claim 24

Means forming two-piece containers from rectangular sidewall blanks and disc-shaped bottom blanks of thermoplastic sheet material comprising: conveyor means feeding a plurality of longitudinally stretch oriented rectangular blanks along a predetermined path transversely of the longitudinal dimension thereof; cylindrical mandrel means positioned parallel with said predetermined path adjacent said conveyor means; folding means adjacent said mandrel means over a portion of the length of the latter engaging and progressively folding said blank about said mandrel means while feeding said blank along said path to overlap the ends thereof on said mandrel in the provision of a lapped seam; heating means adjacent said path for progressively applying heat to the ends of said blank to prepare said blank for heat sealing of said lapped seam; and sealing means adjacent sadi mandrel downstream of said folding means for pressing said heated ends of said blank together to heat seal said lapped seam to provide a cylindrical blank on said mandrel; a plurality of finishing mandrels; conveyor means sequentially indexing said finishing mandrels into coaxial position with one end of said cylindrical mandrel means; ejection means ejecting said cylindrical blanks from said cylindrical mandrel onto said finishing mandrels in synchronism with the said indexing of the latter with the former; supply means providing a plurality of disc-shaped bottom blanks for said containers sequentially indexed with said finishing mandrels to supply bottom blanks thereto; said finishing mandrels each comprising at least a sidewall and bottom portion for receiving said cylindrical and bottom blanks, respectively; means retaining said bottom blanks on said bottom portion of said finishing mandrels; a heat tunnel heated to a temperature sufficient to shrink said cylindrical blanks into conformal engagement with said sidewall portion and over the peripheries of said bottom blanks to form said two piece continers; said conveyor means carrying said finishing mandrels bearing said cylindrical blanks and said bottom blanks through said heat tunnel; bottom ironing means downstream of said heat tunnel means compressing said overlapped portions of said sidewall and bottom blank to seal the bottom of said two piece container; and discharge means ejecting said container from said finishing mandrels downstream of said bottom ironing means.

Claim 25

Means forming two-piece containers from rectangular sidewall blanks and disc-shaped bottom blanks of thermoplastic sheet material comprising: conveyor means feeding a plurality of longitudinally stretch oriented rectangular blanks along a predetermined path transversely of the longitudinal dimension thereof; cylindrical mandrel means positioned parallel with said predetermined path adjacent said conveyor means; folding means adjacent said mandrel means over a portion of the length of the latter engaging and progressively folding said blank about said mandrel means while feeding said blank along said path to overlap the ends thereof on said mandrel in the provision of a lapped seam; heating means adjacent said path for progressively applying heat to the ends of said blank to prepare said blank for heat sealing of said lapped seam; and sealing means adjacent sadi mandrel downstream of said folding means for pressing said heated ends of said blank together to heat seal said lapped seam to provide a cylindrical blank on said mandrel; a plurality of finishing mandrels; conveyor means sequentially indexing said finishing mandrels into coaxial position with one end of said cylindrical mandrel means; ejection means ejecting said cylindrical blanks from said cylindrical mandrel onto said finishing mandrels in synchronism with the said indexing of the latter with the former; supply means providing a plurality of disc-shaped bottom blanks for said containers sequentially indexed with said finishing mandrels to supply bottom blanks thereto; said finishing mandrels each comprising at least a sidewall and bottom portion for receiving said cylindrical and bottom blanks, respectively; means retaining said bottom blanks on said bottom portion of said finishing mandrels; a heat tunnel heated to a temperature sufficient to shrink said cylindrical blanks into conformal engagement with said sidewall portion and over the peripheries of said bottom blanks to form said two piece continers; said conveyor means carrying said finishing mandrels bearing said cylindrical blanks and said bottom blanks through said heat tunnel; bottom ironing means downstream of said heat tunnel means compressing said overlapped portions of said sidewall and bottom blank to seal the bottom of said two piece container; and discharge means ejecting said container from said finishing mandrels downstream of said bottom ironing means.

Claim 26

The invention defined in claim 17, wherein said forming means further includes; top curl forming means receiving said ejected containers from said discharge means, forming a top curl configuration thereon and ejecting said finished containers therefrom.

Claim 27

The invention defined in claim 17, wherein said forming means further comprises: filling means for said containers; capping means for said containers; and second conveyor means receiving said ejected containers from said discharge means and conveying same through said filling and capping means; all of said means being coordinated to provide continuous in-line forming, filling and closing of containers to preclude storage of the latter.

Claim 28

The invention defined in claim 17, wherein said conveyor means comprises: an endless chain; socket means driving and guiding said chain; one said sprocket means having its axis of rotation substantially coincident with said one end of said cylindrical mandrel; and support arms holding said finishing mandrels on said chain; said support arms extending radially inward of said one sprocket means such that said finishing mandrel assumes and remains in a coaxial position with respect to said cylindrical mandrel and said sprocket means for a predetermined period of time to receive said cylindrical blanks thereon.

Claim 29

The invention defined in claim 17, wherein said supply means comprises: a roll of strip stock; rotary die means sequentially cutting bottom blanks from said roll of strip stock; and rotary transfer means comprising turret means having peripherally spaced disc retaining means mutually indexed with said finishing mandrel means to transfer said bottom blanks from the former to the said bottom portion of the latter.

Claim 30

The invention defined in claim 17, wherein said means retaining said bottom blanks on said bottom portion of said finishing mandrels comprises: vacuum ports formed in said mandrels extending through the surface of said bottom portion; hose means connected with said vacuum ports; a vacuum manifold means connected with said hose means; a source of vacuum; and porting means in said manifold means selectively interconnecting said source to said hose means to retain said bottom blanks on said finishing mandrels for a predetermined period of time.

Claim 31

The invention defined in claim 22, wherein said discharge means comprises: a source of positive pressure; and second porting means in said manifold means selectively interconnecting said source of positive pressure to said hose means to transmit pressure through said vacuum ports in said finishing mandrels to eject finished containers therefrom.

Claim 32

The invention defined in claim 17, wherein said bottom ironing means comprises rotary turret means adjacent said conveyor means; ironing plate means peripherally mounted on said turret means for radial displacement thereon; means indexing said ironing plates one with each said finishing mandrels; and cam means driving said plate means into compressive engagement with said overlapped portions of said bottom sidewall and bottom blank.

Claim 33

The invention defined in claim 17, wherein said conveyor means comprises: an endless chain; sprocket means driving and guiding said chain; one said sproket means having its axis of rotation substantially coincident with said one end of said cylindrical mandrel; and support arms holding said finishing mandrels on said chain; said support arms extending radially inward of said one sprocket means such that said finishing mandrel assumes and remains in a coaxial position with respect to said cylindrical mandrel and said sprocket means for a predetermined period of time to receive said cylindrical blanks thereon; wherein said supply means comprises: a roll of strip stock; rotary die means sequentially cutting bottom blanks from said roll of strip stock; and rotary transfer means comprising turret means having peripherally spaced disc retaining means mutually indexed with said finishing mandrel means to transfer said bottom blanks from the former to the said bottom portion of the latter.

Claim 34

The invention defined in claim 17, wherein said conveyor means comprises: an endless chain; sprocket means driving and guiding said chain; one said sprocket means having its axis of rotation substantially coincident with said one end of said cylindrical mandrel; and support arms holding said finishing mandrels on said chain; said support arms extending radially inward of said one sprocket means such that said finishing mandrel assumes and remains in a coaxial position with respect to said cylindrical mandrel and said sprocket means for a predetermined period of time to receive said cylindrical blanks thereon; and wherein said means retaining said bottom blanks on said bottom portion of said finishing mandrels comprises: vacuum formed in said mandrels extending through the surface of said bottom portion; hose means connected with said vacuum ports; a vacuum manifold means connected with said hose means; a source of vacuum; and porting means in said manifold means selectively interconnecting said source to said hose means to retain said bottom blanks on said finishing mandrels for a predetermined period of time.

Claim 35

The invention defined in claim 26, wherein said discharge means comprises: a source of positive presssure; and second porting means in said manifold means selectively interconnecting said source of positive pressure to said hose means to transmit pressure through said vacuum ports in said finishing mandrels to eject finished containers therefrom.

Claim 36

The invention defined in claim 17, wherein said supply means comprises: a roll of strip stock; rotary die means sequentially cutting bottom blanks from said roll of strip stock; and rotary transfer means comprising turret means having peripherally spaced disc retaining means mutually indexed with said finishing mandrel means to transfer said bottom blanks from the former to the said bottom portion of the latter; and wherein said means retaining said bottom blanks on said bottom portion of said finishing mandrels comprises: vacuum ports formed in said mandrels extending through the surface of said bottom portion; hose means connected with said vacuum ports; a vacuum manifold means connected with said hose means; a source of vacuum; and porting means in said manifold means selectively interconnecting said source to said hose means to retain said bottom blanks on said finishing mandrels for a predetermined period of time.

Claim 37

The invention defined in claim 28, wherein said discharge means comprises: a source of positive pressure; and second porting means in said manifold means selectively interconnecting said source of positive pressure to said hose means to transmit pressure through said vacuum ports in said finishing mandrels to eject finished containers therefrom.

Claim 38

The invention defined in claim 17, wherein said bottom ironing means comprises rotary turret means adjacent said conveyor means; ironing plate means peripherally mounted on said turret means for radial displacement thereon; means indexing said ironing plates one with each said finishing mandrels; and cam means driving said plate means into compressive engagement with said overlapped portions of said bottom sidewall and bottom blank; and wherein said means retaining said bottom blanks on said bottom portion of said finishing mandrels comprises: vacuum ports formed in said mandrels extending through the surface of said bottom portion; hose means connected with said vacuum ports; a vacuum manifold means connected with said hose means; a source of vacuum; and porting means in said manifold means selectively interconnecting said source to said hose means to retain said bottom blanks on said finishing mandrels for a predetermined period of time.

Claim 39

The invention defined in claim 29, wherein said discharge means comprises: a source of positive pressure; and second porting means in said manifold means selectively interconnecting said source of positive pressure to said hose means to transmit pressure through said vacuum ports in said finishing mandrels to eject finished containers therefrom.

Claim 40

The invention defined in claim 17, wherein said conveyor means comprises: an endless chain; sprocket means driving and guiding said chain; one said sprocket means having its axis of rotation substantially coincident with said one end of said cylindrical mandrel; and support arms holding said finishing mandrel on said chain; said support arms extending radially inward of said one sprocket means such that said finishing mandrel assumes and remains in a coaxial position with respect to said cylindrical mandrel and said sprocket means for a predetermined period of time to receive said cylindrical blanks thereon; wherein said supply means comprises: a roll of strip stock; rotary die means sequentially cutting bottom blanks from said roll of strip stock; and rotary transfer means comprising turret means having peripherally spaced disc retaining means mutually indexed with said finishing mandrel means to transfer said bottom blanks from the former to the said bottom portion of the latter; and wherein said means retaining said bottom blanks on said bottom portion of said finishing mandrels comprises: vacuum ports formed in said mandrels extending through the surface of said bottom portion; hose means connected with said vacuum ports; a vacuum manifold means connected with said hose means; a source of vacuum; and porting means in said manifold means selectively interconnecting said source to said hose means to retain said bottom blanks on said finishing mandrels for a predetermined period of time.

Claim 41

The invention defined in claim 31, wherein said discharge means comprises: a source of positive pressure; and second porting means in said manifold means selectively interconnecting said source of positive pressure to said hose means to transmit pressure through said vacuum ports in said finishing mandrels to eject finished containers therefrom.

Claim 42

The invention defined in claim 31, wherein said bottom ironing means comprises rotary turret means adjacent said conveyor means; ironing plate means peripherally mounted on said turret means for radial displacement thereon; means indexing said ironing plates one with each said finishing mandrels; and cam means driving said plate means into compressive engagement with said overlapped portions of said bottom sidewall and bottom blank.

Claim 43

The invention defined in claim 33, wherein said discharge means comprises: a source of positive pressure; and second porting means in said manifold means selectively interconnecting said source of positive presssure to said hose means to transmit pressure through said vacuum ports in said finishing mandrels to eject finished containers therefrom.