Labeled containers, methods and devices for making same

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.

1 - 9 . (canceled) 
   
   
       9 . A method of molding a labeled expanded resin container comprising:
 applying a label sheet to an inner wall of a female portion of a two-part mold by
 positioning one or more mandrels, that hold a label sheet using vacuum applied through suction holes, in the female portion; and 
 releasing the label sheet in the female portion by stopping the vacuum and applying an electrostatic charge to the label sheet via charging pins in the mandrel; 
   positioning a male portion of the two-part mold in contact with the corresponding female portion to form a mold cavity;   adding expandable resin beads or pre-expanded resin beads to the mold cavity;   applying a sufficient amount of heat for a sufficient length of time to the mold cavity to effect expansion of the expandable resin beads or pre-expanded resin beads to form a labeled container;   cooling the labeled container; and   removing the labeled container from the mold cavity.   
   
   
       10 . The method according to  claim 9 , wherein the mandrel is free floating when positioned in a female portion. 
   
   
       11 . The method according to  claim 9 , wherein the applying heat step includes applying a heat cycle in the female portion that is independent from applying a heat cycle in the male portion. 
   
   
       12 . The method according to  claim 9 , wherein the label sheet comprises a material capable of maintaining a surface electrostatic charge. 
   
   
       13 . The method according to  claim 9 , wherein the surface resistivity of the label sheet is greater than 10 10  Ω/sq. 
   
   
       14 . The method according to  claim 9 , wherein the female and male portions of the two-part mold are adapted such that when the female portion is in a removed position the male and female portions are spaced apart and not in contact with each other and such that when the male portion is in a releasing position or extended position, the male portion is spaced apart and not in contact with the female portion. 
   
   
       15 . The method according to  claim 9 , wherein the label sheet is applied to the female portion by
 extracting a label sheet from a magazine containing label sheets stacked in a parallel relationship to the female and male portions of the two-part mold, the magazine being adapted to rotate between a loading position and a feeding position, the labels being extracted from the magazine by way of a suction plate attached to an arm, which is movable between a pick up position and an application position, wherein the suction plate is adapted to contact a surface of a top label in the magazine and is adapted to extract and hold the top label through the application of vacuum;   moving the suction plate with label held thereto from the pick up position to the application position,   positioning the label sheet directly above the mandrel in the readying position, wherein the mandrel in the readying position is aligned with the application position of the suction plate and the mandrel in the insertion position is aligned in a position horizontally opposed to the female portion;   transferring a label sheet from the suction plate to the mandrel by applying a vacuum through the mandrel and discontinuing the vacuum applied to the suction plate;   moving the mandrel with a label sheet attached thereto from the readying position to the insertion position, the female portion being in the removed position;   moving the female portion from the removed position to the transfer position and positioning the label sheets adjacent to the inner wall of the female portion at a predetermined location;   discontinuing the vacuum to the mandrel;   applying an electrostatic charge to the label sheets by generating a sufficient voltage to the electrostatic pins to provide an electrostatic attractive force between the label sheets and the inner wall surface of the female portion,   moving the female portion from the transfer position to the removed position; and   moving the mandrel from the insertion position to the readying position.   
   
   
       16 . The method according to  claim 15 , further comprising wrapping the label sheet around the mandrel using positioning fingers attached to the suction plate arm after transferring the label sheet from the suction plate to the mandrel. 
   
   
       17 . The method according to  claim 9 , wherein the male portion is horizontally positioned in the female portion of the two-part mold to form a mold cavity by
 moving the female portion from the removed position to the molding position; and   moving the male portion from the extended position to the molding position.   
   
   
       18 . The method according to  claim 9 , wherein the labeled container is removed from the mold cavity after cooling by
 applying compressed air from the female portion into the mold cavity and/or   applying vacuum from the male portion sufficient to cause the labeled container to travel with the male portion;   moving the female portion from the molding position to the removed position;   moving the male portion from the molding position to the releasing position;   moving the mandrel from the readying position to the insertion position;   applying a vacuum to the cup remover oriented directly opposed to a base of the labeled container sufficient to cause the labeled container to release from the male portion and remain in contact with and travel with the remover;   moving the mandrel to the readying position; and   removing the vacuum to the cup remover causing the cup to release and fall away from the cup remover.   
   
   
       19 . The method according to  claim 9 , wherein the expandable resin beads or pre-expanded resin beads are added to the mold cavity by way of one or more feed channels in the female portion, wherein a valve is positioned at an end of the feed channels adapted to close and seal the feed channel from the mold cavity during expansion and fusion of the resin beads. 
   
   
       20 . The method according to  claim 9 , wherein the resin beads or pre-expanded resin beads comprise homopolymers of vinyl aromatic monomers; an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers, copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl (meth)acrylates, (meth)acrylonitrile, olefins, and/or maleic anhydride; polyolefins; polycarbonates; polyesters; polyamides; natural rubbers; synthetic rubbers; and combinations thereof. 
   
   
       21 . The method according to  claim 9 , wherein the resin beads or pre-expanded resin beads comprise expandable polystyrene particles. 
   
   
       22 . The method according to  claim 9 , wherein the resin beads or pre-expanded resin beads have an average particle size of from about 10 μm to about 600 μm. 
   
   
       23 . The method according to  claim 9 , including preheating the mold cavity by flushing steam cavities adjacent the outside of the mold cavity within the female portion with steam. 
   
   
       24 . The method according to  claim 23 , including applying steam to the mold cavity from the male portion after preheating. 
   
   
       25 . The method according to  claim 9 , including preheating the mold cavity by flushing steam cavities adjacent the outside of the mold cavity within the male portion with steam. 
   
   
       26 . The method according to  claim 25 , including applying steam to the mold cavity from the male portion after preheating. 
   
   
       27 . The method according to  claim 9 , including preheating the mold cavity by flushing steam cavities adjacent the outside of the mold cavity within the male portion with steam and flushing steam cavities adjacent the outside of the mold cavity within the female portion with steam. 
   
   
       28 . The method according to  claim 27 , including applying steam to the mold cavity from the male portion after preheating. 
   
   
       29 . The method according to  claim 9 , wherein the time required for completing the steps from applying the label sheet to removing the labeled container is less than 30 seconds. 
   
   
       30 . A labeled expanded resin container comprising:
 expandable resin beads or 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.   
   
   
       31 - 73 . (canceled)