CONTAINER AND METHOD OF FORMING THE SAME
A one-piece container including a base and a lid. The base is made of a multi-layer sheet that includes an inner foamed layer and outer layers made of polypropylene. The inner foamed layer is made of industrial polypropylene regrind, pre and/or post consumer polypropylene regrind, recycled plastics or a combination of these materials. The lid is made of polypropylene.
1 . A lidded container comprising a base portion comprising foamed polypropylene and a lid portion connected to the base portion via a hinge wherein the base portion has a greater thickness than the lid portion.
2 . The lidded container of claim 1 wherein the base portion comprises outer layers of unfoamed polypropylene and an inner layer of foamed polypropylene.
3 . The lidded container of claim 1 wherein the base portion is opaque and at least part of the lid portion is transparent.
4 . The lidded container of claim 2 , wherein the outer layers of the base portion further comprise a pigment.
5 . The lidded container of claim 4 wherein part of the lid portion is opaque.
6 . A method of manufacturing the lidded container of claim 1 comprising the steps of:
co-extruding a film comprising a portion comprising foamed polypropylene and a portion comprising unfoamed polypropylene;
feeding the film to a thermoforming tool; and
forming the film into a container shape comprising a base portion comprising foamed polypropylene, a lid portion comprising unfoamed polypropylene and a hinge connecting the base portion and the lid portion.