Patterned metal foil laminate and method for making same
First Claim
1. A method of forming a patterned metal foil/substrate laminate comprising the steps of:
- (a) laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate in a pattern which defines areas where adhesive is present and areas where no adhesive is present;
(b) cutting said metal foil in a pattern which corresponds to the boundaries of the adhesive-containing areas; and
(c) removing the areas of metal foil which are not adhesively adhered to said substrate.
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Accused Products
Abstract
A patterned metal foil/substrate laminate wherein the pattern is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between the metal foil and substrate in a predetermined pattern which defines areas where adhesive is present and areas where no adhesive is present, cutting the metal foil, as by rotary die cutting or laser cutting, in a pattern which corresponds to the boundaries of the adhesive-containing areas and removing the areas of metal foil which are not adhesively adhered to the substrate. Particularly where the laminate is intended for microwave packaging, the laminate further includes a sheet of barrier layer material, preferably polymer film, laminated to the patterned metal foil layer. The polymer film layer-containing laminate can be formed into a container for packaging food intended for heating in a microwave oven, the container having at least one section, corresponding to the areas of the laminate from which metal foil was removed, that is substantially transparent to microwave energy and at least one section, corresponding to the foil-containing areas of the laminate, that is opaque to microwave energy for shielding food adjacent to the opaque section. Preferably, the metal foil is aluminum foil, desirably unannealed aluminum foil, and the substrate is selected from paper, coated or uncoated paperboard and polymer film.
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Citations
46 Claims
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1. A method of forming a patterned metal foil/substrate laminate comprising the steps of:
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(a) laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate in a pattern which defines areas where adhesive is present and areas where no adhesive is present; (b) cutting said metal foil in a pattern which corresponds to the boundaries of the adhesive-containing areas; and (c) removing the areas of metal foil which are not adhesively adhered to said substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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28. A method of forming a container for packaging food intended for heating in a microwave oven, the container having at least one section that is opaque to microwave energy for shielding food adjacent to the opaque section, and at least one section that is substantially transparent to microwave energy, said method comprising the steps of:
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(a) laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate in a pattern which defines areas where adhesive is present and areas where no adhesive is present; (b) cutting said metal foil in a pattern which corresponds to the boundaries of the adhesive-containing areas; (c) removing the areas of metal foil which are not adhesively adhered to said substrate; (d) laminating a sheet of barrier layer material to the patterned metal foil layer; and (e) forming said barrier layer/patterned metal foil/substrate laminate into said container with said barrier layer adjacent to the food in the container, the areas of the laminate from which metal foil was removed forming the sections of the container that are transparent to microwave energy and the foil-containing areas of the laminate forming the sections of the container that are opaque to microwave radiation. - View Dependent Claims (29, 30, 31, 32, 33, 34, 35, 36)
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- 37. A patterned metal foil/substrate laminate wherein said pattern is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate in a pattern which defines areas where adhesive is present and areas where no adhesive is present, cutting said metal foil in a pattern which corresponds to the boundaries of the adhesive-containing areas and removing the areas of metal foil which are not adhesively adhered to said substrate.
- 43. A container for packaging food intended for heating in a microwave oven, said container having at least one section that is opaque to microwave energy for shielding food adjacent to the opaque section, and at least one section that is substantially transparent to microwave energy, said container formed from a barrier layer/patterned metal foil/substrate laminate with said barrier layer adjacent to the food in the container, wherein said barrier layer/patterned metal foil/substrate laminate is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate in a pattern which defines areas where adhesive is present and areas where no adhesive is present, cutting said metal foil in a pattern which corresponds to the boundaries of the adhesive-containing areas, removing the areas of metal foil which are not adhesively adhered to said substrate and laminating a sheet of barrier layer material to the patterned metal foil layer, whereby the areas of the laminate from which metal foil was removed form the sections of the container that are transparent to microwave energy and the foil-containing areas of the laminate form the sections of the container that are opaque to microwave radiation.
Specification