An ovenable paper container containing an inner liner, an outer liner, and an intermediate or corrugated paper layer positioned between the inner liner and the outer liner. The ovenable paper container can be used to heat and/or cook food and then be used as a serving container without the danger of
An ovenable paper container containing an inner liner, an outer liner, and an intermediate or corrugated paper layer positioned between the inner liner and the outer liner. The ovenable paper container can be used to heat and/or cook food and then be used as a serving container without the danger of causing burns.
대표청구항▼
1. A method for forming a container designed for use with food products and which can be exposed to temperatures of at least about 200° F., said method comprising the step of a) providing a composite material formed of an inner liner, an outer liner and a corrugated layer positioned between said inn
1. A method for forming a container designed for use with food products and which can be exposed to temperatures of at least about 200° F., said method comprising the step of a) providing a composite material formed of an inner liner, an outer liner and a corrugated layer positioned between said inner and outer liners; said corrugated layer is formed of a plurality of flutes; said outer liner having an upper and a lower surface, said outer liner having a weight of at least about 10 pounds per thousand square feet, said lower surface of said outer liner forming a bottom surface of said container; said inner liner having an upper and a lower surface, said inner liner having a weight of at least about 20 pounds per thousand square feet; said corrugated layer having a weight of at least about 1 pound per thousand square feet, said corrugated layer is at least partially connected to at least one of said upper surfaces of said outer liner and said lower surface of said inner liner by an adhesive, said inner liner including a polymeric coating, said polymeric coating is present on said upper surface of said inner liner, said polymeric coating is formulated to engage a food product that is placed on said container and to inhibit the food product from sticking to said container while the food is heated on said container; and,b) forming said composite material into a container having a base and a container rim by compressing said outer liner, said corrugated layer and said inner liner in a die such that said outer liner, said corrugated layer and said inner liner form a base portion, a transition region and a rim portion; said transition region of said outer liner is positioned between said base portion and said rim portion of said outer layer; said transition region of said corrugated layer is positioned between said base portion and said rim portion of said corrugated layer; said transition region of said inner liner is positioned between said base portion and said rim portion of said inner liner; said rim portion of said outer liner at least partially encircling said base portion of said outer liner; said rim portion of said corrugated layer at least partially encircling said base portion of said corrugated layer; said rim portion of said inner liner at least partially encircling said base portion of said inner liner; said base portion of said inner liner is generally planar; said rim portion of said inner liner extending above said base portion of said inner liner; an upper surface of said rim portion, an upper surface of said base portion and an upper surface of said transition region of said inner liner forming said upper surface of said inner liner, said upper surface of said inner liner is absent a seam; a majority of said upper surface of said rim portion of said inner liner is at a higher elevation than said upper surface of said base portion of said inner liner; at least a portion of said upper surface of said rim portion and said base portion of said inner liner can engage a food product that is placed on said container; a height of a majority of said flutes of said corrugated layer that form said rim portion of said corrugated layer is less than a height of a majority of said flutes of said corrugated layer in said base portion of said corrugated layer, at least one of said flutes located in said transition region of said corrugated layer has a height that is less than a height of a majority of said flutes in said base portion of said corrugated layer, a height of said flutes in said rim portion of said corrugated layer varying along a longitudinal length of said container rim. 2. The method as defined in claim 1, wherein a height of said flutes in said rim portion of said corrugated layer located adjacent to said transition region of said corrugated layer is greater than a height of said flutes in said rim portion of said corrugated layer that are located at an opposite end of said rim portion of said corrugated layer. 3. The method as defined in claim 1, wherein said inner liner has a weight that is greater than a weight of said corrugated layer. 4. The method as defined in claim 1, wherein said polymeric coating has a coating weight of at least about 0.05 pounds per thousand square feet, said container configured to heat or cook foods in temperatures of about 200° F.-600° F. and to resist burning. 5. The method as defined in claim 1, wherein said inner liner including a plurality of openings that fully pass through said inner liner, a majority of said openings do not fully pass through said outer liner, said openings are designed to allow a liquid to pass through said openings in said inner liner and result in the liquid being at least partially entrapped between said inner liner and said outer liner. 6. The method as defined in claim 1, wherein said upper surface of said inner liner is embossed to allow air to circulate underneath food positioned on said upper surface of said inner liner during heating of the food. 7. The method as defined in claim 1, wherein said rim portion of said inner liner extending upwardly from said base portion of said inner liner at an angle of at least about 25°. 8. The method as defined in claim 1, wherein said inner liner has a weight of about 50 to about 100 pounds per thousand square feet, said outer liner has a weight of about 10 to about 70 pounds per thousand square feet, said corrugated layer has a weight of about 10 to about 70 pounds per thousand square feet. 9. The method as defined in claim 1, wherein said inner liner, said outer liner and said corrugated layer are formed of a material selected from the group consisting of paper and paper board. 10. A method for providing a food item in a container that can be baked in said container comprising the steps of: a) providing a container designed to at least partially contain the food item and which said container can be exposed to temperatures of at least about 200° F., said container having a base and a container rim that at least partially encircles said base, said container comprising an inner liner, an outer liner and a corrugated layer positioned between said inner and outer liners; said corrugated layer is formed of a plurality of flutes; said outer liner having an upper and a lower surface, said lower surface of said outer liner forming a bottom surface of said container; said inner liner having an upper and a lower surface, said inner liner is formed of a base portion, a transition region and a rim portion; said outer liner is formed of a base portion, a transition region and a rim portion, said corrugated layer is formed of a base portion, a transition region and a rim portion; said transition region of said inner liner is positioned between said base portion and said rim portion; said transition region of said outer liner is positioned between said base portion and said rim portion; said transition region of said corrugated layer is positioned between said base portion and said rim portion; said rim portion of said inner liner is at least partially encircling said base portion; said rim portion of said outer liner is at least partially encircling said base portion; said rim portion of said corrugated layer is at least partially encircling said base portion; said base portion of said inner liner is generally planar; said rim portion of said inner liner extending above said base portion of said inner liner; an upper surface of said rim portion, an upper surface of said base portion and an upper surface of said transition region of said inner liner forming said upper surface of said inner liner, said upper surface of said inner liner is absent a seam; a majority of said upper surface of said rim portion of said inner liner is at a higher elevation than said upper surface of said base portion of said inner liner; at least a portion of said base portion of said inner liner is designed to engage a food product that is placed on said container; said corrugated layer is at least partially connected to at least one of said upper surfaces of said outer liner and said lower surface of said inner liner by an adhesive; a height of a majority of said flutes of said corrugated layer that form said rim portion of said corrugated layer is less than a height of a majority of said flutes of said corrugated layer in said base portion of said corrugated layer, at least one of said flutes located in said transition region of said corrugated layer has a height that is less than a height of a majority of said flutes in said base portion of said corrugated layer, a height of said flutes in said rim portion of said corrugated layer varying along a longitudinal length of said container rim, said inner liner including a polymeric coating, said polymeric coating is present on said upper surface of said inner liner, said polymeric coating is formulated to engage a food product that is placed on said container and to inhibit the food product from sticking to said container while the food is heated on said container;b) inserting the food item on said upper surface of said inner liner of said container; and,c) baking said food item while in said container. 11. The method as defined in claim 10, wherein a height of said flutes in said rim portion of said corrugated layer located adjacent to said transition region of said corrugated layer is greater than a height of said flutes in said rim portion of said corrugated layer that are located at an opposite end of said rim portion of said corrugated layer. 12. The method as defined in claim 10, wherein said inner liner has a weight that is greater than a weight of said corrugated layer. 13. The method as defined in claim 10, wherein said polymeric coating has a coating weight of at least about 0.05 pounds er thousand square feet, said container configured to heat or cook foods in temperatures of about 200° F.-600° F. and to resist burning. 14. The method as defined in claim 10, wherein said inner liner including a plurality of openings that fully pass through said inner liner, a majority of said openings do not fully pass through said outer liner, said openings are designed to allow a liquid to pass through said openings in said inner liner and result in the liquid being at least partially entrapped between said inner liner and said outer liner. 15. The method as defined in claim 10, wherein said upper surface of said inner liner is embossed to allow air to circulate underneath food positioned on said upper surface of said inner liner during heating of the food. 16. The method as defined in claim 10, wherein said rim portion of said inner liner extending upwardly from said base portion of said inner liner at an angle of at least about 25°. 17. The method as defined in claim 10, wherein said inner liner has a weight of about 50 to about 100 pounds per thousand square feet, said outer liner has a weight of about 10 to about 70 pounds per thousand square feet, said corrugated layer has a weight of about 10 to about 70 pounds per thousand square feet. 18. The method as defined in claim 10, wherein said inner liner, said outer liner and said corrugated layer are formed of a material selected from the group consisting of paper and paper board. 19. A method for providing a food item in a container that can be baked in said container comprising the steps of: a) providing a container designed to at least partially contain the food item, said container having a base and a rim that at least partially encircles said base, said container comprising an inner liner, an outer liner and a corrugated layer that is positioned between said inner and outer liners; said corrugated layer formed of a plurality of flutes, said corrugated layer having a corrugated base portion, a corrugated rim portion and a corrugated transition region; said inner and outer liners are formed of a non-corrugated substrate; said outer liner having an upper and lower surface, said lower surface of said outer liner forming a bottom surface of said container, said outer liner having an outer base portion, an outer rim portion and an outer transition region; said inner liner having a lower surface, said inner liner is formed of an inner base portion, an inner rim portion and an inner transition region; said inner rim portion at least partially encircling said inner base portion, said inner rim portion extending upwardly from a peripheral edge of said inner base portion, said inner transition region positioned between said inner base portion and said inner rim portion; an upper surface of said inner rim portion and an upper surface of said inner base portion and an upper surface of said inner transition region are absent a seam; a majority of said upper surface of said inner rim portion at a higher elevation than said upper surface of said inner base portion; said upper surface said inner base portion is configured to engage a food product that is placed on said container; said corrugated layer at least partially connected to at least one of said upper surface of said outer liner and said lower surface of said inner liner; a height of a majority of said flutes located in said corrugated rim portion is less than a height of a majority of said flutes in said corrugated base portion, a height of a majority of said flutes located in said corrugated rim portion is less than a height of at least one flute in said corrugated transition region, said at least one flute in said corrugated transition region has a height that is less than a height of a majority of said flutes in said corrugated base portion, said inner liner including a polymeric coating, said polymeric coating is present on said upper surface of said inner liner, said polymeric coating is formulated to engage a food product that is placed on said container and to inhibit the food product from sticking to said container while the food is heated on said container;b) inserting the food item on said upper surface of said inner liner of said container; and,c) baking said food item while in said container. 20. The method as defined in claim 19, wherein said inner liner has a different weight than at least one of said corrugated layer and said outer liner. 21. The method as defined in claim 19, wherein said polymeric coating has a coating weight of said polymeric coating is at least about 0.05 pounds per thousand square feet, said container configured to heat or cook foods in temperatures of about 200° F.-600° F. and to resist burning. 22. The method as defined in claim 20, wherein said polymeric coating has a coating weight of at least about 0.05 pounds per thousand square feet, said container configured to heat or cook foods in temperatures of about 200° F.-600° F. and to resist burning. 23. A method for forming a container designed for use with food products, said method comprising the step of a) providing a composite material formed of an inner liner, an outer liner and a corrugated layer positioned between said inner and outer liners; said corrugated layer is formed of a plurality of flutes; said outer liner having an upper and a lower surface, said lower surface of said outer liner forming a bottom surface of said container; said inner liner having an upper and a lower surface; said corrugated layer is at least partially connected to at least one of said upper surfaces of said outer liner and said lower surface of said inner liner by an adhesive, said inner liner including a polymeric coating, said polymeric coating is present on said upper surface of said inner liner, said polymeric coating is formulated to engage a food product that is placed on said container and to inhibit the food product from sticking to said container while the food is heated on said container; and,b) forming said composite material into a container having a base and a container rim by compressing said outer liner, said corrugated layer and said inner liner in a die such that said outer liner, said corrugated layer and said inner liner form a base portion, a transition region and a rim portion; said transition region of said outer liner is positioned between said base portion and said rim portion of said outer layer; said transition region of said corrugated layer is positioned between said base portion and said rim portion of said corrugated layer; said transition region of said inner liner is positioned between said base portion and said rim portion of said inner liner; said rim portion of said outer liner at least partially encircling said base portion of said outer liner; said rim portion of said corrugated layer at least partially encircling said base portion of said corrugated layer; said rim portion of said inner liner at least partially encircling said base portion of said inner liner; said base portion of said inner liner is generally planar; said rim portion of said inner liner extending above said base portion of said inner liner; an upper surface of said rim portion, an upper surface of said base portion and an upper surface of said transition region of said inner liner forming said upper surface of said inner liner, said upper surface of said inner liner is absent a seam; a majority of said upper surface of said rim portion of said inner liner is at a higher elevation than said upper surface of said base portion of said inner liner; at least a portion of said upper surface of said rim portion and said base portion of said inner liner can engage a food product that is placed on said container; a height of a majority of said flutes located in said corrugated rim portion is less than a height of a majority of said flutes in said corrugated base portion, a height of a majority of said flutes located in said corrugated rim portion is less than a height of at least one flute in said corrugated transition region, said at least one flute in said corrugated transition region has a height that is less than a height of a majority of said flutes in said corrugated base portion. 24. The method as defined in claim 23, wherein said inner liner has a different weight than at least one of said corrugated layer and said outer liner. 25. The method as defined in claim 23, wherein said polymeric coating has a coating weight of at least about 0.05 pounds per thousand square feet, said container configured to heat or cook foods in temperatures of about 200° F.-600° F. and to resist burning. 26. The method as defined in claim 24, wherein said polymeric coating has a coating weight of at least about 0.05 pounds per thousand square feet, said container configured to heat or cook foods in temperatures of about 200° F.-600° F. and to resist burning.
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