Method for in-die lamination of plural layers of material and paper-containing product made thereby
AssigneeDixie Consumer Products LLC
InventorsMark B. Littlejohn, Timothy P. Hartjes
Life of this patent
Estimating the term…
Abstract
A method for making a multilayered paper-containing product, for example a paper plate or tray, includes assembling two or more sheets of paper-containing material cut into blanks. The blanks are pressed together and shaped in a die, usually with a bonding agent being used to secure the blanks. Pleats are formed in the curved portion of the shaped product. However, the pleats on each blank are formed independently so that the folded region formed in the pleats are arranged in a staggered array and are not interleaved with the pleats of the other blank.
Claims19
A method for making a multilayered paper-containing product comprising the steps of:
- a) providing at least a top blank of paper-containing material having a curved portion and a bottom blank of paper-containing material having a curved portion;
- b) assembling said top and bottom blanks in a superposed arrangement;
- c) independently forming pleats in the curved portions of the top and bottom blanks such that a plurality of the folded regions in the pleats in the top blank are arrayed in staggered arrangement with the folded regions in the pleats in the bottom blank;
- and,
- d) securing the top and bottom blanks in a fixed position relative to each other after the pleats are formed so as to form an integral shape-sustaining paper-containing product.
A laminated paper-containing product comprising:
- a) a top blank of a paper-containing material which includes a curved portion having a plurality of pleats;
- b) a bottom blank of paper-containing material which includes a curved portion having a plurality of pleats, wherein the folded regions in the pleats of the bottom blank are in staggered array with the folded regions in the pleats of the top blank;
- and
- c) means for securing the top blank to the bottom blank.
A pressed paperboard food service container having a substantially flat bottom surface, an upwardly curving first annular concave region surrounding said flat bottom surface, an upwardly extending sidewall section adjoining said first annular concave region, an outward flaring convex annular region and a rim region, said pressed paperboard container comprising:
- first and second layers of paper-containing material, at least one of said first and second layers having sufficient Rigidity so as to be shape-sustaining, wherein said pressed paperboard container exhibits a W/S ratio of less than 0.42.
Dependencies are inferred from the claim text.