Insulated and moisture absorbent food container and method of manufacture

Claim 3

The method of claim 1 in which said step of providing said package includes providing a sufficiently thin paperboard that it can be bent from a flat sheet into the shape of a container, and providing a sufficiently thin foam layer that it will bend without excessive fracturing when said underlying paperboard layer is bent.

Claim 4

The method of claim 2 which includes providing said container in the form of a flat blank with score lines and die cuts at appropriate points whereby said blank can be folded into the shape of a container, followed by folding said blank into the shape of a container.

Claim 5

The method of claim 1, 2 or 3 in which said absorbent paperboard layer is adhered to said outer layer of resinous foam insulating material by means of a rubber base adhesive.

Claim 6

The method of claim 1 in which said hot food is pizza and said step of providing said container comprises providing a relatively large container for said pizza and making said paperboard at least 0.015 inches thick.

Claim 7

The method of claim 5 which includes providing said paperboard layer with a thickness of from 0.015 inches to 0.020 inches and providing said foam layer with a thickness of from 0.025 inches to 0.075 inches.

Claim 8

The method of claim 1 in which said hot food is a hot meat sandwich and said step of providing said container comprises providing a relatively small container for said sandwich, and providing said paperboard layer in a thickness of at least 0.010 inches and said foam layer in a thickness of at least 0.010 inches.

Claim 9

The method of claim 7 which includes providing said paperboard layer with a thickness of from about 0.010 inches to about 0.020 inches and providing said foam layer with a thickness of from 0.010 inches to 0.050 inches.

Claim 11

The method of claim 1 wherein said step of providing said container includes providing said foam layer of a foamed polystyrene material.

Claim 12

The method of claim 10 wherein said step of providing said container includes providing said foam layer with a density of 4 to 5 pounds per cubic foot.

Claim 15

The method of claim 12 wherein said step of providing said container includes providing said foam layer of a foamed polystyrene material.

Claim 16

In a hot food package comprising a covered container containing hot food having a first portion thereof of a constituency which while in heated condition gives off condensing moisture and an other portion of a constituency that is capable of absorbing said moisture with a negative affect on texture and appeal of said hot food; the improvement comprising said covered container being constructed of an inner food contacting layer of absorbent paperboard adhered to a outer layer of resinous foam insulating material enclosing said inner layer, wherein said paperboard layer has an absorbent porous exposed inner surface and has sufficient thickness and rigidity to lend body and strength to the container, yet is sufficiently thin that it can be bent from flat sheet into the shape of a container, and wherein said outer foam layer is sufficiently thick to insulate and prevent moisture leakage, yet is sufficiently thin that it will bend without excessive fracturing when said paperboard is bent; said absorbent paperboard absorbing a substantial amount of said moisture given off by said first portion of said food thereby substantially lessening the moisture absorbed by said other portion to prevent the said other portion from becoming soggy, said resinous foam material preventing said moisture absorbed by said paperboard from leaking through said container while at the same time retaining heat in said container.

Claim 17

In a hot food package comprising a covered container containing hot food having a first portion thereof of a constituency which while in heated condition gives off condensing moisture and an other portion of a constituency that is capable of absorbing said moisture with a negative affect on texture and appeal of said hot food; the improvement comprising said covered container being constructed of an inner food contacting layer of absorbent paperboard adhered to a outer layer of resinous foam insulating material enclosing said inner layer, wherein said paperboard layer has an absorbent porous exposed inner surface and has sufficient thickness and rigidity to lend body and strength to the container, yet is sufficiently thin that it can be bent from flat sheet into the shape of a container, and wherein said outer foam layer is sufficiently thick to insulate and prevent moisture leakage, yet is sufficiently thin that it will bend without excessive fracturing when said paperboard is bent; said absorbent paperboard absorbing a substantial amount of said moisture given off by said first portion of said food thereby substantially lessening the moisture absorbed by said other portion to prevent the said other portion from becoming soggy, said resinous foam material preventing said moisture absorbed by said paperboard from leaking through said container while at the same time retaining heat in said container.

Claim 18

The package of claim 14 wherein said foam has a density of between about 4 and about 5 pounds per cubic foot.

Claim 19

The package of claim 14 wherein said paperboard has a hard surface oriented towards the interior of said container.

Claim 20

The package of claims 14, 15, or 16 wherein said foam is polystyrene foam.

Claim 21

The package of claims 14, 15, or 16 in which the package is formed from a die-cut and scored container blank folded into said container and in which said paperboard is scored at various points to facilitate folding said blank into a container with said paperboard oriented towards the interior of said container.

Claim 22

The package of claim 14 in which the hot food is pizza.

Claim 23

The package of claim 14 in which the hot food is a hot meat sandwich.