Disposable fluted paperboard plates and method of making same
View Patent ↗A paperboard plate such as a paper plate includes a generally planar bottom portion, an upwardly and outwardly extending fluted sidewall, wherein the sidewall comprises a plurality of sidewall flutes substantially around the outer perimeter of the plate to define a fluted perimeter. The flutes are suitably present at fewer than 3.5 flutes per inch; the plate has a radial profile with a single transition; and the diameter/flute length ratio is greater than 6. The plates are formed in a punch-through die cutting and forming tool from a plurality of paperboard web layers at increased productivities as compared with conventional heated press-forming.
1. A paperboard plate formed from a paperboard blank, comprising:
a) a generally planar bottom portion;
b) an upwardly and outwardly extending fluted sidewall portion, wherein the sidewall portion comprises a plurality of flutes arranged substantially around an outer perimeter of the bottom portion to define a fluted perimeter, wherein the flutes are present at fewer than about 3.5 flutes per inch of the fluted perimeter;
c) a radial profile having a single transition of about 15° to about 50° disposed between the bottom portion and the sidewall portion;
d) a plate diameter to flute length ratio of greater than about 6, wherein the plate has a basis weight of greater than 75 pounds per ream; and
e) a coating comprising polyethylene disposed on a top side and bottom side of the paperboard blank and wherein the plate comprises the coating on its top side and bottom side.
2. The paperboard plate of claim 1 , wherein the single transition is about 15° to about 45°.
3. The paperboard plate of claim 1 , wherein the fluted perimeter comprises of from about 40 to about 80 flutes, wherein the fluted perimeter comprises a plurality of crests and troughs without any inter-pleating therebetween.
4. The paperboard plate of claim 1 , wherein the coating provides resistance to grease, water, or oil.
5. The paperboard plate of claim 1 , wherein the plate diameter is about 9 inches, and the single transition has a radius of curvature ranging from about 0.1 inches to about 0.015 inches.
6. The paperboard plate of claim 5 , wherein the polymeric coating is present at from about 0.1 to about 2 mil on either or both of a topside or a bottomside of the plate.
7. The paperboard plate of claim 6 , wherein the plate has a basis weight of about 85 pounds per ream to about 115 pounds per ream.
8. The paperboard plate of claim 5 , wherein the plate has a basis weight of about 85 pounds per ream to about 130 pounds per ream.
9. The paperboard plate of claim 1 , wherein the plate diameter is about 9 inches and the plate diameter to flute length ratio is of from about 6.5 to about 9.5.
10. The paperboard plate of claim 1 , wherein the plate has from about 1.5 to about 2.25 flutes per inch of perimeter.
11. The plate of claim 1 , further comprising at least one inflection disposed on the fluted sidewall portion.
12. The plate of claim 11 , wherein each inflection comprises a curve.
13. The paperboard plate of claim 1 , wherein the plate has a basis weight of about 75 pounds per ream to about 140 pounds per ream.
14. The paperboard plate of claim 1 , wherein the plate has a basis weight of about 85 pounds per ream to about 115 pounds per ream.
15. A plate formed from a paperboard blank, comprising:
a central portion;
a sidewall at least partially disposed on the central portion;
a radial profile having a single angular transition disposed between the central portion and the sidewall, wherein:
the angular transition is of about 15° to about 50°;
the sidewall comprises less than about 3.5 flutes per inch,
the plate has a basis weight of greater than 75 pounds per ream,
the plate has a ratio of the central portion diameter to flute length greater than about 6; and
a coating comprising polyethylene disposed on a top side and bottom side of the paperboard blank, and wherein the plate comprises the coating on its top side and bottom side.
16. The plate of claim 15 , wherein the plate diameter is about 9 inches, and the plate has a basis weight of greater than about 75 pounds per ream.
17. The plate of claim 15 , wherein the angular transition is about 15° to about 45°.
18. The plate of claim 15 , wherein the sidewall consists of about 40 to about 80 flutes disposed about a perimeter thereof.
19. The plate of claim 15 , wherein the coating provides resistance to at least one of grease, water, and oil.
20. The plate of claim 19 , wherein the coating provides resistance to each of grease, water, and oil.
21. The paperboard plate of claim 20 , wherein the plate has a basis weight of about 85 pounds per ream to about 115 pounds per ream.
22. The plate of claim 19 , wherein the coating has a thickness of from about 0.1 mil to about 2 mil.
23. The paperboard plate of claim 15 , wherein the plate has a basis weight of about 85 pounds per ream to about 115 pounds per ream.
24. The paperboard plate of claim 19 , wherein the plate has a basis weight of about 85 pounds per ream to about 130 pounds per ream.
25. The plate of claim 15 , wherein the ratio of the central portion diameter to flute length ratio is of from about 6.5 to about 9.5.
26. The plate of claim 15 , wherein the number of flutes per inch of a perimeter of the sidewall is of from about 1.5 to about 2.25.
27. The plate of claim 15 , further comprising at least one inflection disposed on the sidewall.
28. The plate of claim 27 , wherein each inflection comprises a curve.
29. The paperboard plate of claim 15 , wherein the plate has a basis weight of about 75 pounds per ream to about 140 pounds per ream.
30. A plate formed from a paperboard blank, comprising:
a central portion that is substantially flat;
a sidewall extending from a perimeter of the central portion;
a single angular transition of from about 15° to about 60° disposed between the central portion and the sidewall;
at least one inflection disposed on the sidewall;
of from about 40 to about 80 flutes disposed on the side wall at less than about 3.5 flutes per inch; and
a coating comprising polyethylene disposed on a top side and bottom side of the paperboard blank, wherein:
the sidewall has no pleats;
the central portion diameter is about 9 inches;
a ratio of the central portion diameter to flute length is greater than about 6;
the plate has a basis weight of greater than about 75 pounds per ream, and
the plate comprises the coating on its top side and bottom side.
31. The plate of claim 30 , wherein each inflection comprises a curve.
32. The paperboard plate of claim 30 , wherein the plate has a basis weight of about 85 pounds per ream to about 115 pounds per ream.
33. The paperboard plate of claim 30 , wherein the plate has a basis weight of about 75 pounds per ream to about 130 pounds per ream.
34. The paperboard plate of claim 30 , wherein the plate has a basis weight of about 85 pounds per ream to about 130 pounds per ream.