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Method for making an insulated container having a shock-resistant bottom

  • US 4,130,615 A
  • Filed: 04/13/1978
  • Issued: 12/19/1978
  • Est. Priority Date: 04/13/1978
  • Status: Expired due to Term
First Claim
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1. A method for making an insulated container having a shock-resistant bottom comprising the steps of:

  • (a) supporting a pliable sheet of a heated plastic-like material near the edges of said material;

    (b) forming a liner having a plurality of substantially aligned ridges of the material of step (a), each of said ridges having a top with two sides joining the top with a floor of the plastic-like material, by contacting the material of step (a) with a mold having a plurality of substantially aligned ridges thereon;

    (c) cooling the liner of step (b);

    (d) applying a quantity of a non-adhering material to the top inside surface of the ridges of step (c);

    (e) substantially drying the non-adhering material;

    (f) forming a lower container body having a bottom, four sides and an open top;

    (g) positioning the lower container body of step (f) in a female fixture whereby the open top of the lower container body is substantially unobstructed;

    (h) applying a multiple component, expanding exothermic foam onto the inside bottom surface of the container body of step (g);

    (i) positioning the ridged liner of step (e) inside the lower container body of step (h) such that the non-adhering material of step (e) is disposed between the expanding foam of step (h) and top inside surface of the ridges; and

    (j) expanding the foam of step (h) such that the expanding exothermic foam heats the non-adhering material and urges and non-adhering material toward the top inside surface of the ridges such that the foam adheres to the floor and the sides of the ridges not in contact with the non-adhering material and to the lower container body thereby producing an insulated container having a bonded inside liner, the bottom of said liner having ridges therealong, the tops of which are reasonably shock-resistant.

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