Disposable food container with a linear sidewall profile and an arcuate outer flange

• US 6,715,630 B2
• Filed: 01/21/2003
• Issued: 04/06/2004
• Est. Priority Date: 01/23/2002
• Status: Active Grant

• Current Assignee: GPCP IP Holdings LLC
• Original Assignee: Fort James Corporation (KOCH Industries Incorporated)
• Inventors: Zelinski, Thomas W., Van Handel, Gerald J., Dees, Jerome G., Littlejohn, Mark B.
• Primary Examiner(s): MOY, JOSEPH MAN
• Application Number:
  US10/348,278
• Publication Number:
  US 20030173366A1
• Time in Patent Office: 441 Days
• Field of Search: 229/406, 229/407, 229/400, 220/573, 220/657
• US Class Current: 220/573
• CPC Class Codes: A47G 19/03 for using only once, e.g. made of paper
• CPC Class Codes: B31B 50/592 using punches or dies
• CPC Class Codes: D21H 27/40 at least one of the sheets being non-planar, e.g. crêped crêping or corrugating paper B31F

Abstract

The present invention is directed to rigid disposable food containers provided with a relatively steep sidewall with a generally linear profile and an outwardly flared arcuate flange portion. The containers are further characterized by a flange outer vertical drop wherein the ratio of the length of the vertical drop to the characteristic diameter of the container is greater than about 0.01. By virtue of unique geometry, the containers of the invention exhibit improved rigidity and/or rim stiffness yet have favorable runnability in pressware manufacturing systems characteristic of plates of lower strength.

Claims

1. A disposable food container configured for rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion;

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion having an angle of inclination with respect to the vertical from said generally planar bottom portion; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate outer flange portion being between about 0.0175 and about 0.1 times the characteristic diameter of said disposable food container;

and an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by a flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.01.

2. The disposable food container according to claim 1, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 10°

to about 50°

.

3. The disposable food container according to claim 2, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 10°

to about 40°

.

4. The disposable food container according to claim 1, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.013.

5. The disposable food container according to claim 4, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.015.

6. The disposable food container according to claim 1, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said food container is greater than about 0.025.

7. The disposable food container according to claim 6, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.035 to about 0.07.

8. The disposable food container according to claim 1, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is greater than about 0.025.

9. The disposable food container according to claim 8, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is greater than about 0.03.

10. The disposable food container according to claim 1, wherein said arcuate outer flange portion is characterized by having a single radius of curvature.

11. The disposable food container according to claim 1, wherein the outer periphery of the profile of said container terminates with an outer edge of said arcuate outer flange portion.

12. A disposable food container configured for rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion,

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion, and having an angle of inclination of from about 10 degrees to about 50 degrees with respect to the vertical from said generally planar bottom portion wherein the ratio of the length of the generally linear inclined profile to the characteristic diameter of the disposable food container is greater than about 0.025; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate outer flange portion being between about 0.035 and about 0.07 times the characteristic diameter of said disposable food container; and

an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by an flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.013.

13. The disposable food container according to claim 12 wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.015.

14. The disposable food container according to claim 13, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.0175.

15. The disposable food container according to claim 12, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable article is greater than about 0.03.

16. The disposable food container according to 12, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.035 to about 0.06.

17. The disposable food container according to 16, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.04 to about 0.055.

18. The disposable food container according to claim 12, wherein the generally linear, inclined sidewall profile between said first annular transition portion and said second annular transition portion has an angle of inclination of from about 15°

to about 40°

with respect to the vertical from said generally planar bottom portion.

19. The disposable food container according to claim 18, wherein the generally linear, inclined sidewall profile between said first annular transition portion and said second annular transition portion has an angle of inclination of from about 25°

to about 35°

with respect to the vertical from said generally planar bottom portion.

20. The disposable food container according to claim 12, wherein said convex upper surface of the arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 30°

to about 80°

.

21. The disposable food container according to claim 20, wherein said convex upper surface of said arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 50°

to about 75°

.

22. The disposable food container according to claim 21, wherein the convex upper surface of the arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 55°

to about 65°

.

23. The disposable food container according to claim 12, wherein said first annular transition portion defines an upwardly concave upper surface defining an inner radius of curvature, wherein the ratio of said inner radius of curvature to the characteristic diameter of said disposable food container is from about 0.014 to about 0.14.

24. The disposable food container according to claim 23, wherein the ratio of the inner radius of curvature to the characteristic diameter of the disposable food container is from about 0.035 to about 0.07.

25. The disposable food container according to claim 12, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is from about 0.025 to about 0.06.

26. The disposable food container according to claim 12, wherein said food container is a plate or a deep dish container and wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.025 to about 0.15.

27. The disposable food container according to claim 12, wherein said food container is a bowl and wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.1 to about 0.3.

28. The disposable bowl according to claim 27, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.15 to about 0.25.

29. The disposable food container according to claim 12, wherein said second annular transition portion defines a convex upper surface defining an intermediate radius of curvature, wherein the ratio of said intermediate radius of curvature to the characteristic diameter of said disposable food container is from about 0.014 to about 0.07.

30. The disposable food container according to claim 12, wherein the ratio of the height of said container to said characteristic diameter is from about 0.06 to about 0.3.

31. The disposable food container according to claim 30, wherein said container is a plate and wherein the ratio of the height of said container to the characteristic diameter is from about 0.06 to about 0.12.

32. The disposable food container according to claim 30, wherein said container is a bowl or deep dish container and wherein the ratio of the height of said container to the characteristic diameter is from about 0.1 to about 0.3.

33. The disposable food container according to claim 12, including an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion over a radial span, wherein the ratio of said radial span to the characteristic diameter of said food container is from about 0.01 to about 0.09.

34. The disposable food container according to claim 12 formed of paper.

35. The disposable food container according to claim 34, press-formed from a paperboard blank.

36. The disposable food container according to claim 35, wherein at least one surface of said paperboard blank is provided with a substantially liquid-impervious coating comprising an inorganic pigment or filler and a water-based, press applied overcoat.

37. The disposable food container according to claim 35, wherein at least one surface of said paperboard blank is provided with a styrene-butadiene polymer coating.

38. The disposable food container according to claim 37, wherein styrene-butadiene polymer is a carboxylated styrene-butadiene polymer.

39. The disposable food container according to claim 12, formed of a thermoplastic composition.

40. The disposable food container according to claim 39, fabricated from a thermoplastic material by way of a technique selected from the group consisting of injection molding, injection blow molding, injection stretch blow molding and composite injection molding.

41. The disposable food container according to claim 39, formed from a foamed polymeric material.

42. The disposable food container according to claim 39, formed from sheet stock of thermoplastic material.

43. The disposable food container according to claim 39, thermoformed, thermoformed by the application of vacuum or thermoformed by a combination of vacuum and pressure.

44. The disposable food container according to claim 43, thermoformed by the application of vacuum.

45. The disposable food container according to claim 42, wherein said thermoplastic material is a foamed or solid polymeric material selected from the group consisting of:

polyamides, polyacrylates, polysulfones, polyetherketones, polycarbonates, acrylics, polyphenylene sulfides, acetals, cellulosic polymers, polyetherimides, polyphenylene ethers or oxides, styrene-maleic anhydride copolymers, styrene-acrylonitrile copolymers, polyvinylchlorides and mixtures thereof.

46. The disposable food container of claim 42, wherein said thermoplastic material comprises a foamed or solid polymeric material selected from the group consisting of:

polyesters, polystyrenes, polypropylenes, polyethylenes and mixtures thereof.

47. The disposable food container according to claim 46, thermoformed from mineral-filled polypropylene sheet stock.

48. The disposable food container according to claim 47, wherein said mineral filler is predominantly mica.

49. The disposable food container according to claim 47, having a wall thickness from about 10 to about 80 mils and consisting essentially of from about 40 to about 90 percent by weight of a polypropylene polymer, from about 10 to about 60 percent by weight of a mineral filler, from about 1 to about 15 percent by weight polyethylene, up to about 5 weight percent titanium dioxide and optionally including a basic organic or basic inorganic compound comprising the reaction product of an alkali metal or alkaline earth element with carbonates, phosphates, carboxylic acids as well as alkali metal and alkaline earth element oxides, hydroxides, or silicates and basic metal oxides, including mixtures of silicon dioxide with one or more of the following oxides:

magnesium oxide, calcium oxide, barium oxide, and mixtures thereof.

50. The disposable food container according to claim 39, having a wall caliper of from about 10 to about 50 mils.

51. The disposable food container according to claim 50, having a wall caliper of from about 15 to about 25 mils.

52. The disposable food container according to claim 39, formed of a styrene polymer composition.

53. The disposable food container according to claim 52, formed of polystyrene.

54. The disposable food container according to claim 39, formed from a mineral-filled thermoplastic composition.

55. A disposable food container press-formed from a generally planar paperboard blank and being configured for rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion,

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion, and having an angle of inclination with respect to the vertical from said generally planar bottom portion; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate outer flange portion being between about 0.0175 and about 0.1 times the characteristic diameter of said disposable food container;

and an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by a flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.01;

wherein at least one of the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion is provided with a plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae.

56. The disposable food container according to claim 55, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of to paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the sidewall portion of the container.

57. The disposable food container according to claim 55, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the second annular transition portion of the container.

58. The disposable food container according to claim 55, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the arcuate outer flange portion of the container.

59. The disposable food container according to claim 55, having an inner flange portion between the second annular transition portion and the outer arcuate flange portion wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the inner flange portion of the container.

60. The disposable food container according to claim 55, wherein the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion all include a plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extending around an annular region corresponding to at least a part of the respective profile of the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion of the container.

61. The disposable food container according to claim 55, having a plurality of circumferentially spaced, radially extending pleats disposed in an annular arrangement which pleats include a substantially integrated fibrous structure formed from a plurality of rebonded paperboard lamellae generally extending over the length of the pleat.

62. The disposable food container according to claim 55, provided with a plurality of circumferentially spaced, radially extending pleats the majority of which include a substantially integrated fibrous structure formed from a plurality of rebonded paperboard lamellae extending over at least a portion of their length.

63. The disposable food container according to claim 62, wherein the plurality of substantially integrated fibrous structures formed from rebonded paperboard define an annular rebonded paperboard array extending radially in an annular region corresponding to at least a part of the profile of the sidewall portion, the second annular transition portion, the outer arcuate flange portion or the optional inner flange portion of the container.

64. The disposable food container according to claim 55, wherein said circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent layers are of generally the same thickness as adjacent areas of the food container.

65. The disposable food container according to claim 55, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 10°

to about 50°

.

66. The disposable food container according to claim 65, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 10°

to about 40°

.

67. The disposable food container according to claim 55, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.013.

68. The disposable food container according to claim 67, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.015.

69. The disposable food container according to claim 55, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said food container is greater than about 0.025.

70. The disposable food container according to claim 69, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.035 to about 0.07.

71. The disposable food container according to claim 55, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is greater than about 0.025.

72. The disposable food container according to claim 71, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is greater than about 0.03.

73. The disposable food container according to claim 55, wherein said arcuate outer flange portion is characterized by having a single radius of curvature.

74. The disposable food container according to claim 55, wherein the outer periphery of the profile of said container terminates with an outer edge of said arcuate outer flange portion.

75. A disposable food container press-formed from a generally planar paperboard blank and being configured for rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion,

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion, and having an angle of inclination of from about 10 degrees to about 40 degrees with respect to the vertical from said generally planar bottom portion wherein the ratio of the length of the generally linear inclined profile to the characteristic diameter of the disposable food container is greater than about 0.025; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate outer flange portion being between about 0.035 and about 0.07 times the characteristic diameter of said disposable food container; and

an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by a flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.013;

wherein at least one of the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion is provided with a plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae.

76. The disposable food container according to claim 75, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the sidewall portion of the container.

77. The disposable food container according to claim 75, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the second annular transition portion of the container.

78. The disposable food container according to claim 75, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the arcuate outer flange portion of the container.

79. The disposable food container according to claim 75, having an inner flange portion between the second annular transition portion and the outer arcuate flange portion wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the inner flange portion of the container.

80. The disposable food container according to claim 75, wherein the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion all include a plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extending around an annular region corresponding to at least a part of the respective profile of the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion of the container.

81. The disposable food container according to claim 75, having a plurality of circumferentially spaced, radially extending pleats disposed in an annular arrangement which pleats include a substantially integrated fibrous structure formed form a plurality of rebonded paperboard lamellae generally extending over the length of the pleat.

82. The disposable food container according to claim 75, provided with a plurality of circumferentially spaced, radially extending pleats the majority of which include a substantially integrated fibrous structure formed from a plurality of rebonded paperboard lamellae extending over at least a portion of their length.

83. The disposable food container according to claim 82, wherein the plurality of substantially integrated fibrous structures formed from rebonded paperboard define an annular rebonded paperboard array extending radially in an annular region corresponding to at least a part of the profile of the sidewall portion, the second annular transition portion, the outer arcuate flange portion or the optional inner flange portion of the container.

84. The disposable food container according to claim 75, wherein said circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae are of generally the same thickness as adjacent areas of the food container.

85. The disposable food container according to claim 75, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.015.

86. The disposable food container according to claim 85, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.0175.

87. The disposable food container according to claim 75, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable article is greater than about 0.03.

88. The disposable food container according to claim 75, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.035 to about 0.06.

89. The disposable food container according to claim 88, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.04 to about 0.055.

90. The disposable food container according to claim 75, wherein the generally linear, inclined sidewall profile between said first annular transition portion and said second annular transition portion has an angle of inclination of from about 15°

to about 40°

with respect to the vertical from said generally planar bottom portion.

91. The disposable food container according to claim 90, wherein the generally linear, inclined sidewall profile between said first annular transition portion and said second annular transition portion has an angle of inclination of from about 25°

to about 35°

with respect to the vertical from said generally planar bottom portion.

92. The disposable food container according to claim 75, wherein said convex upper surface of the arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 30°

to about 80°

.

93. The disposable food container according to claim 92, wherein said convex upper surface of said arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 50°

to about 75°

.

94. The disposable food container according to claim 93, wherein the convex upper surface of the arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 55°

to about 65°

.

95. The disposable food container according to claim 75, wherein said first annular transition portion defines an upwardly concave upper surface defining an inner radius of curvature, wherein the ratio of said inner radius of curvature to the characteristic diameter of said disposable food container is from about 0.014 to about 0.14.

96. The disposable food container according to claim 95, wherein the ratio of the inner radius of curvature to the characteristic diameter of the disposable food container is from about 0.035 to about 0.07.

97. The disposable food container according to claim 75, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is from about 0.025 to about 0.06.

98. The disposable food container according to claim 75, wherein said food container is a plate or a deep dish container and wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.025 to about 0.15.

99. The disposable food container according to claim 75, wherein said food container is a bowl and wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.1 to about 0.3.

100. The disposable bowl according to claim 99, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.15 to about 0.25.

101. The disposable food container according to claim 75, wherein said second annular transition portion defines a convex upper surface defining an intermediate radius of curvature, wherein the ratio of said intermediate radius of curvature to the characteristic diameter of said disposable food container is from about 0.014 to about 0.07.

102. The disposable food container according to claim 75, wherein the ratio of the height of said container to said characteristic diameter is from about 0.06 to about 0.3.

103. The disposable food container according to claim 102, wherein said container is a plate and wherein the ratio of the height of said container to the characteristic diameter is from about 0.06 to about 0.12.

104. The disposable food container according to claim 102, wherein said container is a bowl or deep dish container and wherein the ratio of the height of said container to the characteristic diameter is from about 0.1 to about 0.3.

105. The disposable food container according to claim 75, including an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion over a radial span, wherein the ratio of said radial span to the characteristic diameter of said food container is from about 0.01 to about 0.09.

106. The disposable food container according to claim 75, in the form of a disposable plate having a caliper of at least about 10 mils.

107. The disposable food container according to claim 106, in the form of a disposable plate having a caliper of at least about 12 mils.

108. The disposable food container according to claim 107, in the form of a disposable plate having a caliper of at least about 15 mils and being provided with a coating comprising a clay filler.

109. The disposable paper plate according to claim 75, having a caliper of from about 10 to about 25 mils.

110. The disposable paper plate according to claim 109, having a caliper of from about 12 to about 22.5 mils.

111. A disposable food container press-formed from a radially scored, generally planar paperboard blank, the container being configured for rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar-bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion,

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion, and having an angle of inclination with respect to the vertical from said generally planar bottom portion; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate outer flange portion being between about 0.0175 and about 0.1 times the characteristic diameter of said disposable food container;

and an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by a flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.01; and

wherein at least one of the sidewall portion, the second annular transition portion, the arcuate outer flange portion or, if present, the optional inner flange portion are provided with a plurality of circumferentially spaced radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae, said rebonded paperboard lamellae regions extending over a profile distance corresponding to at least a portion of the length of the scores of the paperboard blank from which said container is formed.

112. The disposable food container according to claim 111, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the sidewall portion of the container.

113. The disposable food container according to claim 111, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the second annular transition portion of the container.

114. The disposable food container according to claim 111, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the arcuate outer flange portion of the container.

115. The disposable food container according to claim 111, having an inner flange portion between the second annular transition portion and the outer arcuate flange portion wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the inner flange portion of the container.

116. The disposable food container according to claim 111, wherein the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion all include a plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extending around an annular region corresponding to at least a part of the respective profile of the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion of the container.

117. The disposable food container according to claim 111, having a plurality of circumferentially spaced, radially extending pleats disposed in an annular arrangement which pleats include a substantially integrated fibrous structure formed form a plurality of rebonded paperboard lamellae generally extending over the length of the pleat.

118. The disposable food container according to claim 111, provided with a plurality of circumferentially spaced, radially extending pleats the majority of which include a substantially integrated fibrous structure formed from a plurality of rebonded paperboard lamellae extending over at least a portion of their length.

119. The disposable food container according to claim 111, wherein the plurality of substantially integrated fibrous structures formed from rebonded paperboard define an annular rebonded paperboard array extending radially in an annular region corresponding to at least a part of the profile of the sidewall portion, the second annular transition portion, the outer arcuate flange portion or the optional inner flange portion of the container.

120. The disposable food container according to claim 111, wherein said circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent layers are of generally the same thickness as adjacent areas of the food container.

121. The disposable food container according to claim 111, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 10°

to about 50°

.

122. The disposable food container according to claim 121, wherein said inclined sidewall profile has an angle of inclination with respect to the vertical from said generally planar bottom portion of from about 10°

to about 40°

.

123. The disposable food container according to claim 111, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.013.

124. The disposable food container according to claim 123, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.015.

125. The disposable food container according to claim 111, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said food container is greater than about 0.025.

126. The disposable food container according to claim 125, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.035 to about 0.07.

127. The disposable food container according to claim 111, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is greater than about 0.025.

128. The disposable food container according to claim 127, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is greater than about 0.03.

129. The disposable food container according to claim 111, wherein said arcuate outer flange portion is characterized by having a single radius of curvature.

130. The disposable food container according to claim 111, wherein the outer periphery of the profile of said container terminates with an outer edge of said arcuate outer flange portion.

131. A disposable food container press-formed from a radially scored, generally planar paperboard blank the container being configured for rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion,

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion, and having an angle of inclination of from about 10 degrees to about 50 degrees with respect to the vertical from said generally planar bottom portion wherein the ratio of the length of the generally linear inclined profile to the characteristic diameter of the disposable food container is greater than about 0.025; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate outer flange portion being between about 0.035 and about 0.07 times the characteristic diameter of said disposable food container; and

an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by a flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.013;

wherein at least one of the sidewall portion, the second annular transition portion, the arcuate outer flange portion or, if present, the optional inner flange portion are provided with a plurality of circumferentially spaced radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae, said rebonded paperboard lamellae regions extending over a profile distance corresponding to at least a portion of the length of the scores of the paperboard blank from which said container is formed.

132. The disposable food container according to claim 131, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the sidewall portion of the container.

133. The disposable food container according to claim 131, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the second annular transition portion of the container.

134. The disposable food container according to claim 131, wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the arcuate outer flange portion of the container.

135. The disposable food container according to claim 131, having an inner flange portion between the second annular transition portion and the outer arcuate flange portion wherein the plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extend around an annular region corresponding to at least part of the profile of the inner flange portion of the container.

136. The disposable food container according to claim 131, wherein the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion all include a plurality of circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent lamellae extending around an annular region corresponding to at least a part of the respective profile of the sidewall portion, the second annular transition portion, the arcuate outer flange portion and, if present, the optional inner flange portion of the container.

137. The disposable food container according to claim 131, having a plurality of circumferentially spaced, radially extending pleats disposed in an annular arrangement which pleats include a substantially integrated fibrous structure formed form a plurality of rebonded paperboard lamellae generally extending over the length of the pleat.

138. The disposable food container according to claim 131, provided with a plurality of circumferentially spaced, radially extending pleats the majority of which include a substantially integrated fibrous structure formed from a plurality of rebonded paperboard lamellae extending over at least a portion of their length.

139. The disposable food container according to claim 138, wherein the plurality of substantially integrated fibrous structures formed from rebonded paperboard define an annular rebonded paperboard array extending radially in an annular region corresponding to at least a part of the profile of the sidewall portion, the second annular transition portion, the outer arcuate flange portion or the optional inner flange portion of the container.

140. The disposable food container according to claim 131, wherein said circumferentially spaced, radially extending regions formed from a plurality of paperboard lamellae rebonded into substantially integrated fibrous structures generally inseparable into their constituent layers are of generally the same thickness as adjacent areas of the food container.

141. The disposable food container according to claim 131, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.015.

142. The disposable food container according to claim 141, wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.0175.

143. The disposable food container according to claim 131, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable article is greater than about 0.03.

144. The disposable food container according to claim 131, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.035 to about 0.06.

145. The disposable food container according to claim 144, wherein the ratio of the radius of curvature of said arcuate outer flange portion to the characteristic diameter of said disposable food container is from about 0.04 to about 0.055.

146. The disposable food container according to claim 131, wherein the generally linear, inclined sidewall profile between said first annular transition portion and said second annular transition portion has an angle of inclination of from about 15°

to about 40°

with respect to the vertical from said generally planar bottom portion.

147. The disposable food container according to claim 146, wherein the generally linear, inclined sidewall profile between said first annular transition portion and said second annular transition portion has an angle of inclination of from about 25°

to about 35°

with respect to the vertical from said generally planar bottom portion.

148. The disposable food container according to claim 131, wherein said convex upper surface of the arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 30°

to about 80°

.

149. The disposable food container according to claim 148, wherein said convex upper surface of said arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 50°

to about 75°

.

150. The disposable food container according to claim 149, wherein the convex upper surface of the arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 55°

to about 65°

.

151. The disposable food container according to claim 131, wherein said first annular transition portion defines an upwardly concave upper surface defining an inner radius of curvature, wherein the ratio of said inner radius of curvature to the characteristic diameter of said disposable food container is from about 0.014 to about 0.14.

152. The disposable food container according to claim 151, wherein the ratio of the inner radius of curvature to the characteristic diameter of the disposable food container is from about 0.035 to about 0.07.

153. The disposable food container according to claim 131, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the disposable food container is from about 0.025 to about 0.06.

154. The disposable food container according to claim 131, wherein said food container is a plate or a deep dish container and wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.025 to about 0.15.

155. The disposable food container according to claim 131, wherein said food container is a bowl and wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.1 to about 0.3.

156. The disposable bowl according to claim 155, wherein the ratio of the length of the generally linear inclined sidewall profile to the characteristic diameter of the food container is from about 0.15 to about 0.25.

157. The disposable food container according to claim 131, wherein said second annular transition portion defines a convex upper surface defining an intermediate radius of curvature, wherein the ratio of said intermediate radius of curvature to the characteristic diameter of said disposable food container is from about 0.014 to about 0.07.

158. The disposable food container according to claim 131, wherein the ratio of the height of said container to said characteristic diameter is from about 0.06 to about 0.3.

159. The disposable food container according to claim 158, wherein said container is a plate and wherein the ratio of the height of said container to the characteristic diameter is from about 0.06 to about 0.12.

160. The disposable food container according to claim 158, wherein said container is a bowl or deep dish container and wherein the ratio of the height of said container to the characteristic diameter is from about 0.1 to about 0.3.

161. The disposable food container according to claim 131, including an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion over a radial span, wherein the ratio of said radial span to the characteristic diameter of said food container is from about 0.01 to about 0.09.

162. The disposable food container according to claim 131, wherein said regions formed from a plurality of paperboard lamellae rebonded into substantially integrated structures extend over a profile distance corresponding to at least about 50 percent of the length of the scores in the paperboard blank from which the container is formed.

163. The disposable food container according to claim 162, wherein said regions formed from a plurality of paperboard lamellae rebonded into substantially integrated structures extend over a profile distance corresponding to at least about 75 percent of the length of the scores in the paperboard blank from which the container is formed.

164. The disposable food container according to claim 131, wherein said convex upper surface of said arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 55°

to about 75°

.

165. The disposable food container according to claim 164, wherein said convex upper surface of said arcuate outer flange portion is configured so that it defines its radius of curvature over an included angle of from about 55°

to about 65°

.

166. The disposable food container according to claim 131, wherein said radially scored paperboard blank has from about 20 to about 150 radial scores.

167. The disposable food container according to claim 131, wherein the scores of said radially scored paperboard blank have a width of from about 0.01 inches to about 0.05 inches.

168. The disposable food container according to claim 167, wherein the scores of said radially scored paperboard blank have a width of about 0.03 inches.

169. The disposable food container according to claim 131, wherein said paperboard blank is provided with a substantially liquid-impervious coating comprising an inorganic pigment or filler and a water-based, press-applied overcoat.

170. The disposable food container according to claim 169, wherein said inorganic filler comprises kaolin.

171. A disposable food container configured for rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion,

said sidewall portion defining a generally linear, inclined profile over a length between said first annular transition portion and said second annular transition portion, and having an angle of inclination of from about 10 degrees to about 50 degrees with respect to the vertical from said generally planar bottom portion; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the product of the curvature of said arcuate outer flange portion and the characteristic diameter of said disposable food container being between about 10 and about 50;

and an inner transition flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by a flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the container is greater than about 0.01.

172. The disposable food container according to claim 171, wherein the product of the curvature of said arcuate outer flange portion and the characteristic diameter of said disposable food container is from about 15 to about 30.

173. The disposable food container according to claim 172, wherein the product of the curvature of said arcuate outer flange portion and the characteristic diameter of said disposable food container is from about 20 to about 30.

174. The disposable food container according to claim 173, wherein the product of the curvature of said arcuate outer flange portion and the characteristic diameter of said disposable food container is from about 22.5 to about 25.

175. The disposable food container according to claim 171, wherein said arcuate outer flange portion is of generally constant curvature.

176. A paperboard laminate configured as a food container exhibiting rigidity and rim stiffness having a characteristic diameter comprising:

a generally planar bottom portion;

a first annular transition portion extending upwardly and outwardly from said generally planar bottom portion;

a sidewall portion extending upwardly and outwardly from said first annular transition portion;

a second annular transition portion extending outwardly from said sidewall portion,

said sidewall portion defining a generally linear, inclined sidewall profile over a length between said first annular transition portion and said second annular transition portion, and having an angle of inclination with respect to the vertical from said generally planar bottom portion; and

an arcuate outer flange portion having a convex upper surface extending outwardly with respect to said second annular transition portion, the radius of curvature of said arcuate outer flange portion being between about 0.0175 and about 0.1 times the characteristic diameter of said disposable food container;

and an inner flange portion extending between said second annular transition portion and said arcuate outer flange portion having a ratio of a radial span to the characteristic diameter of from about 0 to about 0.1, said disposable food container being further characterized by a flange outer vertical drop wherein the ratio of the length of the flange outer vertical drop to the characteristic diameter of the laminate container is greater than about 0.01.

177. The laminate according to claim 176, including at least two paperboard layers.

178. The laminate according to claim 176, wherein said laminate includes an embossed paperboard layer.

179. The laminate according to claim 178, wherein the paperboard laminate includes at least two paperboard layers each of which layers has a basis weight of from about 20 lbs. to about 400 lbs. per 3000 square foot ream.

180. The laminate according to claim 179, wherein the paperboard laminate includes at least two paperboard layers each of which layers has a basis weight of from about 80 lbs. to about 220 lbs. per 3000 square foot ream.

181. The laminate according to claim 178, wherein the container includes two embossed paperboard layers and one planar paperboard layer.

182. The laminate according to claim 181, wherein each of the paperboard layers has a basis weight of from about 20 lbs. to about 400 lbs. per 3000 square foot ream.