Tri-layer food container

摘要

A container for holding food or beverages includes an inner thermoformed sleeve and a molded insulating foam support layer. The inner sleeve and foam support layer each have a circumferential wall extending from a bottom wall. The foam layer is bonded to the thermoformed sleeve on the outside or inside of the sleeve. The container can also include an outer sleeve bonded to an outer surface of the foam support layer. The inner sleeve may be made of thermoformed polystyrene. The outer sleeve may be a paper label.

主权项

1. A method of forming a container comprising:
providing a molded one-piece, insulating, beaded foam support layer including a bottom wall and an upwards extending circumferential sidewall, such that the support layer is seamless, the foam support layer having an inner surface; thermoforming an unfoamed plastic sleeve including a bottom wall and an upwards extending circumferential sidewall, such that the unfoamed plastic sleeve is seamless, the unfoamed plastic sleeve having an outer surface; positioning the unfoamed plastic sleeve inside the foam support layer; bonding the outer surface of the unfoamed plastic sleeve to the inner surface of the foam support layer using a heated mandrel; and bonding an outer paper sleeve to an outer surface of the foam support layer.