Beverage and food containers and substrates

A substrate sheet material for use in fabricating beverage and food containers, said substrate sheet material comprising:

• (a) a substrate layer of paperboard about 0.15 millimeter to about 0.75 millimeter thick and having a basis weight of about 50 pounds per 3000 square feet to about 250 pounds per 3000 square feet;
• and
• (b) a non-syntactic expanded foam layer comprising expanded products of polymeric microcapsules expanded in accord with an earlier-applied heating process, and affixed to the substrate paperboard layer, said expanded foam layer having been applied as a coating of heat expandable microcapsules on said paperboard substrate layer, sufficiently continuous as applied to substantially cover any uncoated areas of said substrate paperboard layer within overall boundaries defined by said expanded foam layer, when said microcapsules were expanded to form said expanded foam layer, so as to prevent a user's finger from descending into such uncoated area and touching said substrate layer.

A substrate sheet material for use in fabricating beverage and food containers, said substrate sheet material comprising:

• (a) a substrate layer of substantially dry paperboard about 0.15 millimeter to about 0.75 millimeter thick and having a basis weight of about 50 pounds per 3000 square feet to about 250 pounds per 3000 square feet;
• and
• (b) an expanded foam layer comprising expanded products of polymeric microcapsules expanded in accord with an earlier-applied heating process, and affixed to the substrate paperboard layer, said expanded foam layer having been applied as a coating of heat expandable microcapsules on said paperboard substrate layer, said expanded foam layer having a pre-expanded wet coating thickness of about 1 micron to about 76 microns and, when expanded, being sufficiently continuous as applied to substantially cover any uncoated areas of said substrate paperboard layer within overall boundaries defined by said expanded foam layer, so as to prevent a user's finger from descending into such uncoated area and touching said substrate layer when holding a container made from such substrate sheet material.

A substrate sheet material for use in fabricating beverage and food containers, said substrate sheet material comprising:

• (a) a substrate layer of paperboard about 0.15 millimeter to about 0.75 millimeter thick and having a basis weight of about 50 pounds per 3000 square feet to about 250 pounds per 3000 square feet;
• (b) an expanded foam layer comprising expanded products of polymeric microcapsules expanded in accord with an earlier-applied heating process, and affixed to the substrate paperboard layer, said expanded foam layer having been applied as a coating of heat expandable microcapsules on said paperboard substrate layer and, when expanded, being sufficiently continuous as applied to substantially cover any uncoated areas of said substrate paperboard layer within overall boundaries defined by said expanded foam layer, when said microcapsules were expanded to form said expanded foam layer, so as to prevent a user's finger from descending into such uncoated area and touching said substrate layer when holding a container made from such substrate sheet material
• the dried and expanded foam coating comprising about 60 weight percent to about 90 weight percent microcapsules and about 40 weight percent to about 10 weight percent binder.