Patent ID: 8677600

Claim:
A method of forming a container with a foam block insert, comprising: providing a container having a major axis approximately parallel to its bottom and a minor axis at approximately a right angle to its major axis; creating a first male mold having an outer periphery cooperatively shaped to fit inside the container; creating a second female mold from the first male mold, the second female mold having an opening with inner dimensions corresponding to the outer periphery of the first male mold; dispensing a foam into the opening of the second female mold; curing the dispensed foam to form a foam block insert with outer dimensions corresponding to the opening of the second female mold, the cured foam block insert having a major axis approximately parallel to its bottom and a minor axis at approximately a right angle to its major axis; removing the cured foam block insert from the second female mold; and inserting the cured foam block insert into the container.