Insulated shipping container, method of making, and article and machine used in making

Abstract

An insulated shipping container includes a formed body of foamed polymer material. This formed body defines a chamber, an opening from the chamber outwardly to ambient, a transition surface surrounding this opening, and an exterior surface. Preferably, the chamber and exterior surface are both cylindrical prismatic shapes of like configuration so that a uniformly thick wall of insulative foamed polymer material is provided between the chamber and ambient. A single sheet of plastic is integrally bonded to the foamed polymer body such that it faces all of the chamber, the transition surface, and a substantial portion of the exterior surface of the container. In one embodiment of the container the remainder of the exterior surface of the container is faced with a separate sheet of plastic, and the two pieces of plastic cooperate to define an escape slit at which excess foamed polymer material escapes during formation of the container in a fixture. In another embodiment of the container this un-foamed plastic sheet faces all exterior surfaces of the foamed polymer material, including those which bound the chamber.