Metallized cutlery and tableware and method therefor

• US 8,621,755 B2
• Filed: 04/09/2012
• Issued: 01/07/2014
• Est. Priority Date: 08/24/2001
• Status: Expired due to Fees

• Current Assignee: Waddington North America Incorporated (NVLX Holdings LLC)
• Original Assignee: Waddington North America Incorporated (NVLX Holdings LLC)
• Inventors: Gordon, David, Ellsworth, Thomas E, Chan, Raymond, Gallop, William A, Mithal, Ashish K
• Primary Examiner(s): FLORES SANCHEZ, OMAR
• Application Number:
  US13/442,093
• Publication Number:
  US 20120192435A1
• Time in Patent Office: 638 Days
• Field of Search: 303/22, 303/24, 303/40, 30142-150
• US Class Current: 30/322
• CPC Class Codes: A47G 19/03 for using only once, e.g. made of paper
• CPC Class Codes: A47G 19/2205 Drinking glasses or vessels A47G19/23 takes precedence
• CPC Class Codes: A47G 21/00 Table-ware crumb trays A47L13/52; table knives B26B
• CPC Class Codes: A47G 21/16 Table-cloth or napkin holders
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: C09D 1/00 Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: C23C 14/205 by cathodic sputtering
• CPC Class Codes: Y10T 428/24917 including metal layer
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31692 Next to addition polymer from unsaturated monomers

Abstract

A plastic cutlery item molded from a plastic material, such as polystyrene, having a metallic coating that imparts to this cutlery item the appearance of metal cutlery or silverware. In one embodiment the plastic cutlery or tableware items are molded using injection molding techniques, and subjected to a vacuum metallizing process in an individualized non-contiguous manner, where a thin metallic layer is deposited on at least one of their surfaces. The resultant items simulate the appearance of metal cutlery or tableware. In one embodiment of the invention the plastic cutlery or tableware articles are molded from a clear polystyrene resin and are coated with a thin stainless steel layer through vacuum sputtering deposition on only one of the sides. The abrasion resistance of the metallic coating can be enhanced by subjecting the articles to a post-metallizing holding period or by applying a clear protective overcoat.

Claims

1. A metallized plastic food-service item, comprising:

a plastic cutlery article for handling and consuming food, said plastic cutlery article comprising a first portion and a second portion;

a thin metallic coating deposited on said first portion of said plastic cutlery article by a vacuum deposition process, wherein said thin metallic coating is of a sufficient thickness to impart a reflective metal appearance to said first portion of said plastic cutlery article, said thickness being less than 2000 nanometers; and

said second portion of said cutlery article being characterized by absence of said thin metallic coating, and said second portion of said plastic cutlery article retaining its plastic appearance.

2. The metallized plastic food-service item according to claim 1, wherein said second portion of said plastic cutlery article comprises a handle portion of said plastic cutlery article.

3. The metallized plastic food-service item according to claim 1, wherein said first portion of said plastic cutlery article comprises a head portion of said plastic cutlery article.

4. The metallized plastic food-service item according to claim 1, wherein said plastic cutlery article is adapted for placement on a table surface with said first portion displaying said reflective metal appearance and said second portion displaying said plastic appearance.

5. The metallized plastic food-service item according to claim 1, wherein said plastic cutlery article is one of a fork, a knife, and a spoon.

6. The metallized plastic food-service item according to claim 1, wherein said plastic cutlery article is produced by injection molding.

7. The metallized plastic food-service item according to claim 1, wherein at least a portion of said plastic cutlery article is molded from a light-transmitting plastic material.

8. The metallized plastic food-service item according to claim 1, wherein at least a portion of said plastic cutlery article is molded from a colored plastic material.

9. The metallized plastic food-service item according to claim 1, wherein said first portion is made from a light transmitting plastic material, and said second portion of said plastic cutlery article is made from a colored plastic material.

10. The metallized plastic food-service item according to claim 1, wherein said thin metallic coating is less than 1000 nanometers in thickness.

11. The metallized plastic food-service item according to claim 1, wherein said thin metallic coating is less than 200 nanometers in thickness.

12. The metallized plastic food-service item according to claim 1, wherein said vacuum deposition process is a sputtering deposition process.

13. The metallized plastic food-service according to claim 1, wherein said thin metallic coating is stainless steel.

14. The metallized plastic food service item according to claim 1, wherein said plastic cutlery article is adapted for disposable use.

15. The metallized plastic food service item according to claim 1, wherein said plastic cutlery article is at least partially composed of polystyrene.