| abstract |
A medical waste container includes a reduced-weight section having a high density outer skin layer, a high density inner skin layer, and a cellular core layer between the outer skin layer and inner skin layer. A method for manufacturing a medical waste container includes the steps of combining a thermoplastic polymer with a endothermic chemical blowing agent, heating the polymer and blowing agent to form a melted mixture, maintaining the mixture under conditions that prevent or substantially prevent activation of the blowing agent, injecting the mixture into a mold having a mold chamber and chamber walls, the mold being at a pressure that is sufficiently low to activate the blowing agent and initiate cell formation in the mold chamber, and cooling the melted mixture in the mold to form skin layers in the mixture where the mixture contacts the chamber walls. |