Process and apparatus for manufacturing a foamed resin container with a label

The present invention provides a process and apparatus for readily and continuously producing foamed resin containers with labels by following a process sequence including the steps of supplying a sheet which bears label bodies printed in predetermined positions thereon, positioning a label body, punching the label body, and molding a foamed resin container with the label properly positioned. The invention further provides a process which allows for precise positioning of a label. Therefore, a thin and less stiff synthetic resin sheet can be employed for the label instead of a paper base. In addition, the label can be applied in a predetermined position on the foamed resin container without preliminarily rolling the label into a predetermined tubular shape.

TECHNICAL FIELD 
The present invention relates to a process and apparatus for producing a 
foamed resin container with a label for use as a bowl for instant noodles, 
a drinking cup for juice, hot coffee or the like, a vessel for frozen 
sweets, or a like packaging container. 
BACKGROUND ART 
Conventionally, foamed resin containers have widely been used as vessels 
for instant food, juice or the like. Such a foamed resin container is 
generally produced through a foam molding method in which pre-foamed beads 
obtained by preliminarily foaming foamable resin beads containing a 
polystyrene resin and a volatile blowing agent such as butane, pentane or 
chrolofluorocarbon are loaded in a mold cavity and heated by a heating 
medium such as steam for foaming the foamed resin containers. 
Some of the foamed resin containers are provided with a label which bears 
information such as a trade name and a maker's name and/or a design such 
as a vignette printed thereon, or serves to impart an excellent gas 
barrier property to the foamed resin containers. 
Known as a method for providing such information or the like on the surface 
of a foamed resin container (foamed bead cup), there are a method wherein 
information or the like is directly printed on the surface of a foamed 
resin container, a method wherein a label bearing information or the like 
preliminarily printed thereon is bonded onto a foamed resin container, and 
a so-called shrink-labeling method wherein a heat-shrinkable film bearing 
information or the like preliminarily printed thereon is wrapped around a 
foamed resin container and shrunken by heat. 
In the method of directly printing on the surface of a foamed resin 
container, it is difficult to obtain a sharp printing like gravure or to 
perform a multi-color printing. In the method of bonding onto a foamed 
resin container a label bearing information preliminarily printed thereon, 
a container molding step, a label stamping step, and a label bonding step 
are separately performed. Therefore, it is required that the label be 
positioned in place in the label bonding step, so that the process is 
complicated. In the shrink labeling method using a heat-shrinkable film, 
the heat-shrinkable film softly adheres on the container so that the film 
is liable to slip out of the container if the container has an inclined 
circumferential surface. 
To solve these problems, Japanese Unexamined Patent Publication No. 
4-331132 (1992) discloses a method for in-mold labeling of a foamed resin 
container, which includes steps of rolling into a predetermined tubular 
shape a print paper sheet having a print layer on the outer surface and a 
heat-seal layer on the inner surface of a paper base, setting the print 
sheet in a cavity mold, fixing the print sheet on the inner wall of the 
cavity mold by evacuating the cavity through a multiplicity of gas vent 
holes provided in the cavity mold, matching the cavity mold with a core 
mold, loading foamable resin beads into a gap defined between the print 
paper sheet and the core mold for foam molding, and fuse-bonding the print 
paper sheet onto the resulting foamed resin container by applying heat 
thereto for the foamed resin molding. 
However, the aforesaid method involves complicated process steps because 
the print paper sheet is once punched out into a predetermined 
configuration and then the punched sheet should be rolled into a tubular 
shape. Further, the print paper sheet which has the print layer and the 
heat-seal layer provided, respectively on the opposite surfaces of the 
paper base is inferior in the moisture resistance and gas-barrier 
property. Therefore, the paper sheet absorbs steam applied when the foamed 
resin container is molded, so that the printing is liable to be blurred. 
In addition, because the print layer on the outer surface of the paper 
base is brought in directly contact with the cavity mold, the printing ink 
is liable to be transferred onto the cavity mold from the print paper 
sheet by heat. If the printing ink transfer occurs, the print density on 
the foamed resin container is reduced, resulting in a printing failure. 
The ink transferred onto the cavity mold is further transferred onto the 
next mold product, resulting in successive printing failures. 
Since the print paper sheet should be rolled into a tubular shape before 
the molding, the process steps are complicated, resulting in an increased 
cost. 
To solve these problems of the prior art, it is an object of the present 
invention to provide a novel process and apparatus for producing a labeled 
foamed resin container with which employ a thin and less stiff or floppy 
synthetic resin sheet instead of the paper base and a label obtained by 
preliminarily printing fine letters and a sharp design such as including 
smooth gradation on the resin sheet, and is adapted to apply the floppy 
sheet label in a predetermined position on the foamed resin container by 
integral molding without rolling the label into a tubular shape before 
molding the foamed resin container. 
It is a more specific object of the present invention to provide a process 
and apparatus for producing a foamed resin container with a label, in 
which a sheet which bears printed labels in predetermined portions thereof 
is continuously supplied and a process sequence from the step of punching 
a label from the sheet to the step of molding the foamed resin container 
with a label is readily and continuously performed. 
DISCLOSURE OF INVENTION 
In accordance with one preferred mode of the present invention to achieve 
the aforesaid objects, there is provided a process for producing a foamed 
resin container with a label provided on a circumferential surface thereof 
by integral molding, comprising steps of: 
supplying a continuous sheet which bears label bodies printed thereon to a 
label punching device upon positioning each of the label bodies at a 
punching position; 
cutting off the label body and fixing a resulting label on a label 
reception platform having means for fixing the label beneath the punching 
position; 
moving the label reception platform which bears the label fixed thereon to 
supply the label to a predetermined position with respect to a dummy core 
mold; 
applying pressurized gas jet to the label to wind the label around the 
dummy core mold while fixing the label around the dummy core mold by 
suction through vent holes formed in the dummy core mold; 
matching the dummy core mold which bears the label fixed thereon with a 
cavity mold, and then transferring and fixing the label onto an inner wall 
of the cavity mold in intimate contact therewith by stopping the suction 
from the dummy core mold or by pressurizing through the vent holes of the 
dummy core mold while sucking through vent holes formed in the cavity 
mold; 
separating the dummy core mold from the cavity mold which bears the label 
fixed on the cavity inner wall in intimate contact therewith; and 
locking a core mold with the cavity mold, loading foamable resin beads 
therebetween, and heating the foamable resin beads for foam molding, 
whereby the foamed resin container is molded integrally with the label. 
In accordance with another preferred mode of the present invention, there 
is provided an apparatus for producing a foamed resin container with a 
label provided on a circumferential surface thereof by automatically 
performing a process sequence from a label punching step to an integral 
molding step, comprising: 
a sheet feeding device having a mechanism which is capable of positioning 
each of label bodies printed on a continuous sheet; 
a label punching device which includes a punching mechanism for punching 
the supplied sheet in order to obtain a label in a predetermined 
configuration, and a label reception platform adapted to fix the label 
thereon at a position where the label has been punched and to be movable 
to a predetermined position with respect to a dummy core mold; 
a device for winding up the sheet after the punching of the label; 
a cavity mold provided in association with the dummy core mold so that the 
cavity mold can be matched with the dummy core mold, the dummy core mold 
having vent holes for suction to fix the label around the dummy core mold 
after the label is wound around the dummy core mold by a pressurized gas 
jet mechanism; and 
a core mold provided in association with the cavity mold so that the cavity 
mold can be matched with the core, the core mold having suction holes for 
intimately fixing the label thereon by sucking the label after the label 
is transferred from the dummy core mold onto an inner wall of the cavity 
mold, a feed hole for feeding foamable resin beads, and heater means for 
foam molding, the cavity mold having heater means for the foam molding. 
In accordance with the present invention, a continuous sheet which bears 
label bodies printed in predetermined portions thereof is supplied so that 
each of the label bodies can be properly positioned, and then the label 
body is cut off and transported to the predetermined position with respect 
to the dummy core mold by the label reception platform which has the means 
for fixing the label to that position. Therefore, only one positioning 
operation is required before the label punching, and no subsequent 
positioning operation is required. Further, since the label such as of a 
synthetic resin wound around the dummy core mold is held around the dummy 
core mold by suction through the vent holes, there is no need to 
preliminarily roll the label into a tubular shape. 
Therefore, the foamed resin container with a label provided in a 
predetermined position on the circumferential surface of the container in 
an integral manner can be produced readily and efficiently. Further, the 
step of rolling the label into a tubular shape can be eliminated, so that 
the apparatus can be simplified, requiring no complicated process and no 
special device. 
In the production apparatus, the label punching mechanism includes a 
punching plate for cutting off the label from the sheet which bears the 
label bodies printed thereon and then holding the label, the punching 
plate being formed with an opening having a configuration compatible with 
the label, and the label reception platform is adapted to move up through 
the opening to the upper side of the punching plate and have vent holes 
for pressurization and suction. 
With this arrangement, the label thus cut off and held on the punching 
plate is transported, as it is, to the dummy core mold and therefore, the 
position of the label once determined is not changed. 
In accordance with another preferred mode of the present invention, there 
is provided a process for producing a foamed resin container with a 
synthetic resin label provided on a circumferential surface thereof by 
integral molding, comprising steps of: 
winding the label around a dummy core mold, and retaining the label around 
the dummy core mold by suction through vent holes formed in the dummy core 
mold; 
correcting a possible positional offset of the label by stopping the 
suction from the dummy core mold immediately before the dummy core mold 
retaining the label is matched with a cavity mold, or by matching the 
dummy core mold with the cavity mold; 
transferring the label onto a cavity inner wall of the cavity mold and 
fixing the label thereto in intimate contact therewith by pressurizing the 
label through the vent holes of the dummy core mold; 
separating the dummy core mold from the cavity mold with the label fixed 
onto the cavity inner wall in intimate contact therewith; and 
locking the cavity mold with a core mold with the label fixed onto the 
cavity inner wall in intimate contact therewith, then loading foamable 
resin beads, and heating the foamable resin beads for foam molding, 
whereby the foamed resin container is molded integrally with the label. 
In accordance with the present invention, the suction from the dummy core 
mold is stopped immediately before the dummy core mold holding the label 
thereon is matched with the cavity mold to correct the positional offset 
of the label by the matching of the dummy core mold with the cavity mold. 
Even if the positional offset of the label occurs, the label wound around 
the dummy core mold is once freed and therefore, when the dummy core mold 
is matched with the cavity mold, the positional offset of the label is 
corrected. Then, the label is transferred onto a predetermined position of 
the inner wall of the cavity mold and fixed thereon in intimate contact 
therewith by pressurizing the label through the vent holes of the dummy 
core mold in the subsequent step. 
Thereafter, the cavity mold is locked with the core mold with the label 
fixed onto the cavity inner wall in intimate contact therewith. Then, the 
foamable resin beads are loaded and heated for foam molding, whereby the 
foamed resin container can be molded integrally with the Label. Therefore, 
the foam molding of the foamed resin container and the application of the 
label are simultaneously achieved while the positional offset of the label 
is efficiently prevented without rolling the label into a tubular shape 
before the foam molding. 
Thus, the foamed resin container with the synthetic resin label provided on 
the circumferential surface thereof can be produced efficiently through a 
simplified process by employing a thin and less stiff synthetic resin 
sheet, instead of a paper base, and a label bearing fine letters and a 
sharp design such as including smooth gradation preliminarily printed 
thereon and by providing the label in a predetermined position on the 
foamed resin container in an integral manner while efficiently preventing 
the positional offset of the label. 
The resulting foamed resin container with a label is aesthetic, and the 
label is flush with the circumferential surface of the resulting foamed 
resin container, and is less liable to be peeled off. Therefore, the 
foamed resin container can readily be produced which has a label bearing 
information represented by fine letters and a sharp design such as 
including smooth gradation printed thereon by multicolor printing or the 
like.

BEST MODE FOR CARRYING OUT THE INVENTION 
Preferred embodiments of the present invention will hereinafter be 
described. In the present invention, as shown in FIG. 1, to obtain a label 
L a continuous sheet 1 on which label bodies 11 each bearing information 
represented by letters and vignettes designs or the like are printed are 
punched to cut off each label body 11. Reference numeral 11' denotes 
openings. The label bodies 11 printed on the sheet 1 are arranged at 
predetermined intervals, and each have a fan shape, for example, as shown 
in FIG. 2. Further, a position detection mark 12 is printed between each 
adjacent pair of label bodies 11, 11 on the sheet. The position detection 
mark 12 is detected by detector means 29 such as a photoelectric tube. The 
sheet 1 is quantitatively fed with the label body properly positioned by 
actuating a sheet feed driving motor M1 provided in association with the 
detector means. 
Examples of specific sheets (films) on which the label bodies 11 are to be 
printed include resin films of thermoplastic resins, such as polystyrene, 
polypropylene, high density polyethylene, polyvinyl chloride, polyethylene 
terephthalate, polyamide and polyvinylidene chloride, containing 8% to 65% 
by weight of inorganic fine powder, films obtained by coating these resin 
films with a latex containing an inorganic filler, and films obtained by 
depositing aluminum on these films by evaporation. The base of the sheet 
may be either mono-layered or multi-layered. 
As required, an adhesive layer is provided on the rear surface of the sheet 
(to be brought in contact with a foamed resin container). Exemplary 
materials for the adhesive layer include low density polyethylene, a 
copolymer of vinyl acetate and ethylene, a copolymer of ethylene and 
acrylate or methacrylate, and metal salts of a copolymer of ethylene and 
acrylate or methacrylate, among which a heat-sealable resin having a 
melting point of 85.degree. C. to 135.degree. C. is preferably used. 
If the sheet which bears the label bodies 11 printed thereon is formed of a 
resin of the same type as the material for the foamed resin container or 
if a printing ink to be used is excellent in adhesiveness, the label may 
be fuse-bonded onto the foamed resin container in the molding. Where it is 
difficult to fuse-bond the label to the foamed resin container, however, 
the label L may have an adhesive layer for fuse-bonding on its rear 
surface to assuredly bond the label onto the foamed resin container. The 
adhesive layer may be provided either entirely or partially on the rear 
surface of the label L. The label L may have a thickness of 10 .mu.m to 1 
mm, preferably 50 .mu.m to 100 .mu.m. 
The sheet 1 is fed in such a manner that one label body 11 can be 
positioned in a predetermined position, and then the fan-shaped label body 
11 is cut off from the sheet. The label obtained by the punching is 
denoted at "L" in the drawings. A punching device 2 as shown in FIGS. 1 
and 3 is used for the punching. For punching the sheet 1 to cut off the 
label body 11, after the feeding of the sheet 1, a press-punching drive 
portion 22 is driven against a punching plate 20 formed therein an opening 
21 having a configuration compatible with the label body 11, thereby to 
press-cut the sheet. The punching plate 20 further includes a label 
reception platform 23 having, for example, vent holes 24 which can suck 
one or more labels, as means for fixing the label L to that position. 
The label L is fixed onto the label reception platform 23 beneath the 
punching position by suction through the vent holes 24. After the label L 
is cut off, the sheet 1 is wound up by a sheet wind-up device 3 driven by 
a sheet wind-up driving motor M2. The wind-up device 3 is preferably 
operated in association with the aforesaid label body detection means. 
The label reception platform 23 is movable together with the punching plate 
20 between a position where the label punching device 2 is provided and a 
position where the label L is wound around a dummy core mold 5. Position 
detection means for properly determining the position of the label 
reception platform 23 are provided at the label punching position and at 
the position where the label L is wound around the dummy core mold 5. 
As shown in FIG. 4, the punching plate 20 which bears the label L fixed 
thereon by suction is moved to a predetermined position, and the label 
reception platform 23 is lifted up and set at the position where the label 
L is wound around the dummy core mold 5. The label reception platform 23 
is positioned with respect to the dummy core mold 5 by various detection 
means. 
Although the apparatus shown in FIG. 1 is constructed such that, after one 
label L is cut off, the label reception platform 23 is moved every by one 
label pitch to the next adjacent label L along with the punching plate 20 
for the next label punching, the press-punching drive portion 22 may be 
moved instead by one label pitch. Alternatively, the press-punching drive 
portion 22 may be constructed such that two labels L can be cut off at a 
time, or such that more than two labels L can be cut off at a time. In 
such a case, a plurality of dummy core molds 5 are provided so that a 
plurality of foamed resin containers with labels can be produced by 
multi-shot molding. An embodiment for four-shot molding is shown as the 
multi-shot molding in FIG. 5. 
The resulting label L is wound around the dummy core mold 5 by applying 
pressurized gas jet to the label L as shown in FIGS. 4(1) to 4(3). The 
application of the pressurized gas jet for winding the label L around the 
dummy core mold 5 is achieved by setting the label L with the central 
portion thereof abutting against the dummy core mold 5 as shown in FIG. 
4(1), and closing pressure reduction valves 25 connected to the vent holes 
24 of the label reception platform 23 and, at the same time, opening 
pressurization valves 26 to apply the pressurized gas jet to the label L. 
The right and left sides of the label L may be wound around the dummy core 
mold 5 in a time-staggered manner by applying pressurized gas jet 
alternately to the right side and the left side of the label L, as shown 
in FIGS. 4(2) and 4(3), by separately operating the pressure reduction 
valves 25 and the pressurization valves 26 connected to the left and right 
side vent holes. Thus, the edge portions of the label L can smoothly be 
overlapped, thereby suppressing the wrinkling and folding of the label L. 
Therefore, this arrangement is the most preferable. 
Since the label L can be transported by moving the label reception platform 
23 to the position where the label L is wound around the dummy core mold 5 
after the label body 11 is once positioned for the punching, no subsequent 
positioning operation is required. In addition, there is no need to roll 
the label L into a tubular shape. 
As described above, the pressurized gas jet may be equipped with the label 
reception platform 23. Alternatively, a label winding stand may separately 
be provided which has a pressurized gas jetting mechanism for winding the 
label L around the dummy core mold 5, and an additional step may be 
employed in which the label is transferred from the label reception 
platform 23 to the label winding stand through transfer means by suction. 
The employment of the label winding stand is particularly preferred where 
a plurality of foamed resin containers with labels are to be produced at a 
time. This arrangement is employed, for example, where the label bodies 11 
are printed along a plurality of lines on the film sheet, or where a 
plurality of film sheets each bearing label bodies 11 are fed in parallel. 
FIGS. 5 to 7 show an apparatus which is capable of simultaneously forming 
four labels L and includes a label winding stand having a pressurized gas 
jetting mechanism, in accordance with another embodiment of the present 
invention. 
The apparatus includes a punching plate 31 formed with recesses each having 
a configuration compatible with a label body, and a label winding stand 32 
for sucking up labels L cut off on the punching plate 31 and winding the 
labels L around respective dummy core molds 5. 
The punching plate 31 holds thereon the labels cut off by the driving of 
the press-punching drive portion 22. In this embodiment, a sheet which 
bears labels arranged along two parallel lines is fed. The punching plate 
31 is moved by one label pitch with two labels held thereon, and the next 
two labels are cut off on the punching plate 31. Then, the punching plate 
31 is moved to the lower side of the label winding stand 32 with the four 
labels L in total held thereon. 
The label winding stand 32 includes two support pipes disposed parallel to 
each other and serve for conduits for suction and pressurization, and four 
sucking portions 34 provided on the support pipes 33 and each including a 
pair of air pipes. The sucking portions 34 are each connected to a 
pressure reduction valve and a pressurization valve as in the aforesaid 
embodiment. 
When the labels L are transported or sucked, the two support pipes 33 are 
horizontally parallel with each other. When the labels L are fed to the 
dummy core molds 5, a support portion 35 is rotated by 90 degrees so that 
the support pipes 33 are vertically arranged as shown in FIGS. 6 and 7. 
When the labels are to be wound around the dummy core molds 5, the dummy 
core molds 5 are moved to the upper sides of the respective labels L held 
by the label winding stand 32. The labels L are wound around the dummy 
core molds 5 by application of pressurized gas jet in the same manner as 
in the aforesaid embodiment. 
In another embodiment for winding the labels around the dummy core molds 5, 
the support portion 35 may be moved along with the sucking portions 34 
holding the labels without moving the dummy core molds 5. 
As described above, the labels L retained by the label reception platform 
23 or the label winding stand 32 are wound around the dummy core molds 5 
by applying pressurized gas jet to the labels L. The dummy core molds 5 
each have a plurality of vent holes 52 formed in a circumferential wall 
thereof so that the wound labels L can be sucked and brought in intimate 
contact with the dummy core molds by vacuum. The vent holes 52 may be 
elongate slits or circular openings, for example. The dummy core molds 5 
are slightly larger than core molds 7 (which will be described later) so 
as to be intimately matched with cavity molds 6 substantially without gap 
with the labels L fixed around the dummy core molds 5. As shown in FIGS. 8 
and 9, the dummy core molds 5 each have an air chamber 53 provided 
therein, and a plurality of passages 51 formed in the bottom thereof for 
evacuating (vacuuming) or pressurizing the air chamber 53. The passages 51 
are each provided with a pressure reduction valve 54 or a pressurization 
valve 55 (see FIG. 11) and connected to a pressure equipment not shown. 
Thus, when the pressure reduction valves 54 of the dummy core molds are 
opened, the air chambers 53 of the dummy core molds 5 are evacuated 
through the passages 51, thereby sucking the labels L through the passages 
51. When the pressurization valves 55 are opened, the air chambers 53 in 
the dummy core molds 5 are pressurized through the passages 51. The 
aforesaid vent holes 52 communicate with the air chamber 53, and an 
atmospheric release valve 56 is provided which serves to instantaneously 
bring the evacuated or pressurized air chamber 53 back to the atmospheric 
pressure. 
With the labels L thus wound around the dummy core molds 5, the pressure 
inside the air chambers 53 is reduced to, for example, 200 mmHg to 740 
mmHg, whereby the labels L can be fixed on the circumferential surfaces of 
the dummy core molds 5. The pressure inside the air chambers 53 may 
properly be controlled depending on the thickness (or weight) of the label 
L. 
After the labels have been suck-fixed on the dummy core molds 5, an 
assembly including the dummy core molds 5 is inverted or moved in such a 
manner that the dummy core molds 5 are brought closer to the cavity molds 
6 (hereinafter referred to as "cavity molds") or, alternatively, the 
cavity molds 6 may be brought closer to the dummy core molds 5 so that the 
dummy core molds 5 can be matched with the cavity molds 6. In the 
subsequent step, the dummy core molds 5 are inserted into the cavity molds 
6 to be matched therewith as shown in FIG. 9. Thereafter, suction (for 
pressure reduction) through vent holes 65 of the cavity molds 6 is started 
and, at the same time, pressurization through the passages 5L of the dummy 
core molds 5 is started or the suction through the passages 51 of the 
dummy core molds 5 is stopped, whereby the labels L are released from the 
dummy core molds 5 and fixed on cavity inner walls of the cavity molds 6 
in intimate contact therewith. 
Referring FIG. 10, the cavity molds 6 each include annular grooves 66 
formed in the cavity inner wall to be respectively fitted along upper and 
lower edges of the label L transferred and fixed onto the cavity inner 
wall, longitudinal grooves (not shown) formed in the cavity inner wall to 
be respectively fitted along left and right edges of the label L, and vent 
holes 65 for evacuating gaps defined between the label L fitted on the 
cavity inner wall and the annular grooves 66 and gaps defined between the 
label L and the longitudinal grooves. The cavity mold 6 has a steam 
chamber 62 therein so that the cavity mold 6 can indirectly be heated by 
introducing steam into the steam chamber 62. The cavity mold 6 further 
includes a loading device (not shown) for loading a material into a cavity 
8 through a material supplying port 61, a steam and cooling water feeding 
port 63, a drain 64, an air supplying port (not shown) for supplying air 
to transfer a mold product onto a core mold 7. 
The annular grooves 66 are respectively formed as corresponding to lines 
spaced 0.1 mm to 2 mm, preferably 0.2 mm to 0.5 mm, apart from the upper 
(or lower) edge of the label L, and each have a width of 0.1 mm to 1 mm 
and depth of 0.1 mm to 1 mm. The longitudinal grooves are respectively 
formed as corresponding to lines spaced 0 mm to 3 mm, apart from the left 
and right edges of the label L, and each have a width of 0.1 to 1 mm and a 
depth of 0.1 mm to 1 mm. 
Where the label L is to be provided to entirely cover the circumferential 
surface of the foamed resin container, the left and right edges of the 
label L are preferably overlapped to a certain degree with the label fixed 
on the cavity inner wall in intimate contact therewith. However, provision 
of a greater overlap margin increases the wastage of the label L and is 
hence uneconomical. Accordingly, the overlap margin is preferably 0 mm to 
10 mm. 
The label L can precisely be positioned without any offset in the following 
manner. The label 1, wound around the dummy core mold 5 is liable to be 
offset as shown in FIG. 11, and the following method can effectively 
prevent the offset of the label L. 
Immediately before the dummy core mold 5 retaining the label L fixed 
thereon is matched with the cavity mold 6, the suction from the dummy core 
mold 5 is stopped and, at the same time, the evacuated air chamber 53 is 
preferably brought back to the atmospheric pressure through the 
atmospheric release valve 56. Thus, the positional offset of the label L 
can be corrected for locating the label L in a predetermined position by 
matching the dummy core mold 5 with the cavity mold 6 while stopping the 
suction of the label L from the dummy core mold 5. 
More specifically, where a construction is employed in which the dummy core 
mold 5 is located below the cavity mold 6 and the dummy core mold 5 
located on the lower side is adapted to be moved up, the label L is freed 
by stopping the suction from the dummy core mold 5 and preferably bringing 
the air chamber 53 instantaneously back to the atmospheric pressure 
through the atmospheric release valve 56 immediately before the mold 
matching. At this time, the label L naturally moves down by gravity, and 
is supported on a flange 59 formed along a lower circumferential edge of 
the dummy core mold 5 for the positioning thereof. The upper edge of the 
label L abuts against the top inner wall of the cavity mold 6. Thus, the 
positional offset of the label L can be corrected. 
Where a mold assembly is employed which is designed such that the dummy 
core mold 5 is located above the cavity mold 6 and the dummy core mold 5 
is moved down, the suction from the dummy core mold 5 is stopped 
immediately before the mold matching to correct the positional offset of 
the label L by utilizing the innermost face of the cavity of the cavity 
mold 6. 
With the offset of the label L thus corrected, the dummy core mold 5 is 
inserted into the cavity mold 6, and then the air chamber 53 is 
pressurized. Thus, the label L is pressed against the inner wall of the 
cavity mold 6 by air jet through the vent holes 52. Thus, the label L is 
released from the dummy core mold 5, transferred onto the cavity inner 
wall of the cavity mold 6 and fixed thereon in intimate contact therewith. 
The molding of the foamed resin container with a label can be achieved in 
the same manner as in the aforesaid embodiment. In this embodiment, the 
label L can be positioned more precisely. 
Thereafter, the dummy core mold 5 is withdrawn from the cavity mold 6 with 
the label L fixed on the cavity inner wall in intimate contact therewith, 
and the core mold 7 is locked with the cavity mold 6. The mold locking is 
achieved, for example, with the use of a press for beads foam molding. The 
press includes a platform 60 provided on the upper side and a movable 
platform 70 provided on the lower side and adapted to be moved up and down 
by a ram 75. The cavity mold 6 is fixed to the platform 60, while the core 
mold 7 is fixed to the movable platform 70. By locking the cavity mold 6 
with the core mold 7, a cavity 8 is defined therebetween which has a 
configuration compatible with the container to be produced. 
The core mold 7 has a steam chamber 71 provided therein, a steam and 
cooling water feeding port 72, a drain 73 and an air vent (not shown). The 
core mold 7 further includes, though not shown, pressure reduction valves 
(regulators) and electromagnetic valves including a load air valve, a 
steam valve, a direct heating valve for the cavity 8, a drain valve, a 
cooling water valve and an air outlet valve, and control panel for 
controlling these valves. 
The material for the foamed resin container shown in FIG. 13 is, for 
example, polystyrene beads containing a blowing agent and having a 
diameter of 0.25 mm. The polystyrene beads are preformed twelve times in 
bulkiness (to a diameter of 0.57 mm). The foamed resin container is 
produced from the prefoamed resin beads with a foaming ratio of 12 by an 
in-mold bead foam molding. The foamed resin container has a configuration, 
as shown in FIG. 13, with a top diameter of 96 mm, a bottom diameter of 68 
mm, a height of 107 mm and a side wall thickness of 2 mm. 
The foamable thermoplastic resin to be used as the material for the foamed 
resin container is not particularly limited as long as the resin can 
contain a blowing agent and is suitable for the in-mold bead foam molding. 
Examples thereof include polystyrene resins such as polystyrene, 
high-impact polystyrene, styrene-maleic anhydride copolymer and 
styrene-acrylonitrile copolymer, polyolefin resins such as polyethylene, 
polypropylene and ethylene-vinyl acetate copolymer, and mixtures thereof. 
The molding of the foamed resin container with a label is achieved in the 
following manner. Vacuum valves of the cavity mold 6 are opened to 
evacuate the gaps defined between the label L and the suction grooves 66 
through the vent holes 65, and then the dummy core mold 5 is withdrawn 
from the cavity mold with the label L fixed onto the inner wall of the 
cavity mold 6 in intimate contact therewith. The cavity mold 6 is matched 
and locked with the core mold 7. Then, the load air valve is opened to 
load the prefoamed bead; into the cavity 8. Thereafter, steam is 
introduced into the steam chamber 62 of the cavity mold 6 and the steam 
chamber 71 of the core mold 7 for heating thereof. At this time, the drain 
valve is opened to drain condensed. 
In turn, the direct heating valve is opened for direct heating of the 
cavity 8. When the prefoamed beads are fuse-bonded with each other, the 
cooling water valve is opened to cool the entire mold. After the cooling, 
the air outlet valve is opened for disloading of air, and the foamed resin 
container C with a label is transferred onto the core mold 7. Then, the 
movable platform 70 is lowered by the ram 75 to open the mold, and the 
foamed resin container C with a label is taken out. 
In this embodiment, the label L comprises a 30-.mu.m thick polypropylene 
film bearing a printing on its rear surface and a 30-.mu.m thick adhesive 
layer of a vinyl acetate-ethylene copolymer formed on the rear print 
surface of the polypropylene film, and has a total thickness of 60 .mu.m. 
In accordance with the present invention, the foamed resin container with a 
label can efficiently be molded in an integral manner with a smaller 
number of process steps, and the label L is prevented from being offset 
with respect to the container and from being readily peeled off. In 
addition, the container can readily be produced which is provided with a 
label L bearing information represented by fine letters and a sharp design 
such as including smooth gradation printed thereon by multi-color printing 
or the like. The label L thus provided is aesthetic without any bubble 
trapped between the label L and the foamed resin container and any 
wrinkle. The configuration of the foamed resin container with a label is 
not limited to the one shown in the drawings, but the present invention is 
applicable to foamed resin containers having any of various 
configurations. 
Where the label L to be used bears a printing on its adhesive surface to be 
brought in contact with the foamed resin container, ink applied on its 
print layer is not transferred onto the cavity mold 6 by application of 
heat, so that the printing failure due to the transfer can be prevented. 
In such a case, the label L comprises a transparent resin sheet, a print 
layer and, as required, an adhesive layer. Since a resin is used instead 
of paper as the material for the label L, the label L is less liable to 
absorb moisture when the molding of the foamed resin container employs 
steam heating. 
Where the label L is formed of a material having an excellent gas barrier 
property and applied on the entire circumferential surface of the foamed 
resin container by integral molding, the foamed resin container provides 
for excellent moisture-proof and gas-barrier effects, so that the 
container can be used as a food container suitable for long-term storage. 
The label L may be provided not entirely but partially on the 
circumferential surface of the container. For example, the label L may be 
configured such that smaller the length thereof is smaller than the height 
of the trunk of the mold product. Where the label L is provided to cover 
only the middle portion of the trunk of the mold product, swelling of the 
trunk of the mold product can be prevented which may result from moisture 
absorption by a content such as noodles contained in the mold product. 
Where the label L is provided to cover only the upper portion of the trunk 
of the mold product, the top of the mold product can be reinforced. Thus, 
a less expensive mold product can be obtained. 
As previously described, the present invention provides a process and 
apparatus for producing a foamed resin container with a label, which 
employs a thin and less stiff resin sheet instead of a paper base, and is 
adapted to stamp a label body printed on the sheet and apply the label 
body as the label in a predetermined position on the foamed resin 
container by integral molding without preliminarily rolling the label into 
a tubular shape. Therefore, ready and continuous production of foamed 
resin containers with labels can be achieved by following a process 
sequence including the steps of supplying a sheet which bears label bodies 
printed in predetermined positions thereon, positioning a label body, 
punching the label body, and molding a container with the label properly 
positioned. 
In accordance with the present invention, a continuous sheet which bears 
label bodies printed in predetermined positions thereon is supplied, then 
label bodies are cut off and fixed on the label reception platform to that 
position, and the label reception platform and the dummy core molds are 
transported to predetermined positions. Accordingly, only one positioning 
operation is required before the label punching, and no subsequent 
positioning operation is required. Therefore, the foamed resin container 
with a label provided in a predetermined position on the circumferential 
surface thereof in an integral manner can be produced readily and 
efficiently. Further, the step of rolling the label to be applied on the 
container into a tubular shape can be eliminated, so that the apparatus 
can be simplified, requiring no complicated process and no special device. 
The process for correcting possible positional offset of the label includes 
the steps of stopping the suction from the dummy core mold immediately 
before the dummy core mold holding the label thereon is matched with the 
cavity mold, and matching the dummy core mold with the cavity mold. In 
this process, even if the positional offset of the label occurs when the 
label is wound around the dummy core mold, the label is temporarily freed 
and the positional offset of the label is corrected during the mold 
matching operation. In the subsequent step, the label is transferred onto 
the inner wall of the cavity mold and fixed thereon in intimate contact 
therewith by pressurizing the label through the vent holes of the dummy 
core mold. Thus, the label can be applied precisely in a predetermined 
position on the cavity mold. 
The resulting foamed resin container is free from wrinkles and bubbles 
trapped between the label and the foamed resin container. Further, the 
foamed resin container is aesthetic, and the label is flush with the 
circumferential surface of the foamed resin container, and is less liable 
to be peeled off. Therefore, the foamed resin container can readily be 
produced which has a label bearing information represented by fine letters 
and a sharp design such as including smooth gradation printed thereon by 
multi-color printing or the like.