Metallized cutlery and tableware and method therefor

Inactive Publication Date: 2006-08-31
WADDINGTON NORTH AMERICA
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0035] A further object of the invention is to provide metallized cutlery articles with design features or areas that have contrasting reflective properties in comparison to the rest of the article, and therefore become sharply defined and visibly distinct and further add to the commercial appeal of the metallized articles. For instance, the surface of the plastic article may include alternating smooth and textured areas, or alternating engraved and non-engraved areas, or patterns thereof that, upon metallization, are adapted to standout and highlight the reflective contrast between the smooth and textured areas or between the engraved and non-engraved areas of the plastic article.
[0036] An additional object of the present invention is to provide a method for improving the adhesion between the metallic coating layer and the plastic substrate by subjecting the metallized plastic cutlery items to a post-metallizing curing step.
[0037] Another object of the present invention is to provide a method for improving the adhesion between the metallic coating layer and the plastic substrate by pre-treating the plastic cutlery

Problems solved by technology

In addition, permanent flatware also has to be replaced due to inadvertent disposal or loss.
The presence of non-disposable metal cutlery along with other disposable food-service articles such as plates, cups and the like presents an unusual problem for restaurants and caterers.
The problem stems from the loss of valuable metal cutlery into trash or refuse-containers along with disposable tableware and food remnants particularly during peak business hours and rush situations.
As a result, the food establishment has to constantly replace expensive metal flatware.
U.S. Pat. No. 3,926,792, to Buford, filed on Aug. 23, 1973, in Column 1, lines 12 to 30 states:—“The food industry has long been plagued with the costly and time-consuming problem of separating valuable reusable items, such as metal tableware from solid waste, such as food, paper and other disposable items.
This problem is prevalent in any food service facility, such as restaurants, cafeterias, schools, prisons, and so on, in which plates must be scraped and/or tableware separated from garbage by hand sorting or by scavenging, and especially in the airline industry where there is no opportunity for sorting in flight.
Even when manual sorting or scavenging is carried out, it has been found that a large amount of tableware is lost.
It is obvious that continued replacement of tableware is not only expensive, but economically wasteful.
Some restaurants have found that most missing tableware is lost, rather than taken by customers, and that such losses run as high as $1,300 on a traditionally heavy day.”
U.S. Pat. No. 4,367,138, to Kustas, filed on Jun. 8, 1981, in Column 1, lines 11-16 states:—“ . . . . As is well-known in the restaurant business, the loss of silverware or stainless steel flatware is a very serious problem which costs restaurant owners large sums of money every year.
The problem stems from careless kitchen help and the manner in which food and debris is removed from used dishes.”
Studies made in restaurant kitchens in hotels associated with several intercontinental hotel chains show that not only an occasional item of cutlery is lost in this way, but even the cutlery used by all the guests at a table may be accidentally tipped into the waste container together with waste food, particularly when the restaurant is busy and the waiter rushed.
Another problem that food caterers encounter is the ability to clean metal flatware utensils at certain locations and outdoor catering events.
In preparation for such circumstances caterers tend to carry a large inventory of expensive metal cutlery.
However, the use of disposable plastic cutlery affects the image of the airline, especially in premium seating and higher priced flights.
Thus, a primary obstacle for use of disposable plastic cutlery in upscale situations is the perception and the image associated with disposable plastic cutlery rather than its performance.
Metallic pigments are known in the art and are commercially available; however, it is the general experience of those skilled in the art that these metallic pigments do not impart an authentic metallic look.
Furthermore, metallic pigments do not provide a plastic cutlery article that emulates the polished silver-like metallic appearance of fine cutlery or silverware.
In fact, almost all commercial plastic tableware or cutlery articles made by utilizing a silver metallic pigment have a dull or grayish appearance.
In addition, some of the formulations for metallic pigments have an odor which is less-than-desirable for a food-service it

Method used

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  • Metallized cutlery and tableware and method therefor
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  • Metallized cutlery and tableware and method therefor

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Example

[0057] One intention of the instant invention, inter alia, was to develop disposable cutlery articles that emulate permanent flatware or metal silverware. The present invention recognizes that—imparting a metallic appearance to disposable plastic cutlery would enhance the perceived value and quality of the cutlery items and bridge the perception gap between plastic cutlery and permanent flatware. Prior to the instant invention there were two main classes of flatware or cutlery—(I) Permanent Flatware or Silverware, characterized by its durability, metallic appearance and upscale image; and, (2) Plastic Cutlery known for its convenience and disposable characteristics but generally regarded as a low-end alternative to permanent flatware and not as aesthetically attractive. The instant invention provides a new category of plastic flatware articles that retain their disposable character yet offer the upscale image, reflective appearance and elegance comparable to their more expensive sil...

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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.

Description

RELATED APPLICATIONS [0001] This application is a continuation-in-part application of U.S. patent application Ser. No. 10 / 228,147, filed Aug. 26, 2002, which, in turn claims the benefit of U.S. Provisional Patent Application Ser. No. 60 / 314,677, filed Aug. 24, 2001; said applications are incorporated herein, in entirety, by reference for all purposes.FIELD OF THE INVENTION [0002] This invention relates generally to the production of food-service articles for household, catering and restaurant use including commercial and institutional tableware. More particularly, this invention relates to plastic cutlery having a reflective or metallic appearance. BACKGROUND OF THE INVENTION [0003] Disposable plastic food-service items are in increasingly widespread use for storing, serving and consuming food, due to their reasonably low-cost and the convenience they provide. Disposable food containers and articles inter alia include non-returnable containers such as yogurt cups and dinner entree p...

Claims

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Application Information

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IPC IPC(8): A47J43/28A47G21/00C23C14/20
CPCA47G21/00Y10T428/265B32B27/06A47G19/2205A47G19/03Y10T428/24917A47G21/16C23C14/205C09D1/00Y10T428/31692Y10T428/31678
Inventor MITHAL, ASHISH K.GORDON, DAVIDELLSWORTH, THOMAS E.CHAN, RAYMONDGALLOP, WILLIAM A.
Owner WADDINGTON NORTH AMERICA
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