US5800724A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Patterned metal foil laminate and method for making same
Assignee: Graphic Packaging International LLC
•
Filing: 1997-01-16
•
Granted: 1998-09-01
•
Expires: 2017-01-16
Abstract
Abstract A method for making a patterned metal foil/substrate laminate by laminating a sheet of metal foil to a substrate by applying an adhesive between the metal foil and substrate and irradiating the metal foil with a laser beam in a predetermined pattern to vaporize the irradiated portions of the metal foil. Particularly where the laminate is intended for microwave packaging applications, the laminate further includes a sheet of barrier layer material, preferably polymer film, laminated to the patterned metal foil layer. The polymer film layer-containing laminate can be formed into a container for packaging food intended for heating in a microwave oven. A particularly effective pattern comprises a plurality of metal foil islands electrically separated by dielectric substrate gaps. Preferably, the metal foil is aluminum foil, desirably unannealed aluminum foil, and the substrate is selected from paper and coated or uncoated paperboard. The patterned metal foil/substrate laminate is also useful for electrical circuitry, particularly, for example, as the resonant circuit in electronic surveillance tags.
Inventors
- 👤 Charles C. Habeger
- 👤 Kenneth A. Pollart
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 13:42
CPC Classifications
B; B32; B32B; B32B3/00; B32B3/10; B32B3/18; B32B3/22; B32B15/00; B32B15/04; B32B15/08; B32B15/09; B32B15/12; B32B15/20; B32B27/00; B32B27/36; B32B38/00; B32B38/10; B32B7/00; B32B7/04; B32B7/12; B32B7/14; B65; B65D; B65D81/00; B65D81/34; B65D81/3446; G; G08; G08B; G08B13/00; G08B13/22; G08B13/24; G08B13/2402; G08B13/2428; G08B13/2437; G08B13/244; G08B13/2445; H; H05; H05K; H05K3/00; H05K3/02; H05K3/027; B32B2310/00; B32B2310/08; B32B2310/0806; B32B2310/0843; B32B2367/00; B32B2439/00; B32B2439/70; B65D2211/00; B65D2581/00; B65D2581/34; B65D2581/3437; B65D2581/3439; B65D2581/344; B65D2581/3463; B65D2581/3467; B65D2581/3471; B65D2581/3472; B65D2581/3486; B65D2581/3487
Claims Analysis
Total Claims: 57
Claim 1
Independent Claim
58 words
A method of forming a patterned metal foil/substrate laminate comprising the steps of: (a) laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate; and (b) irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil.
Claim 2
Independent Claim
58 words
A method of forming a patterned metal foil/substrate laminate comprising the steps of: (a) laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate; and (b) irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil.
Claim 3
Dependent Claim
28 words
A method as claimed in claim 1 including the further step of laminating a sheet of barrier layer material to the patterned metal foil layer of said laminate.
Claim 4
Dependent Claim
16 words
A method as claimed in claim 2 wherein said barrier layer material is a polymer film.
Claim 5
Dependent Claim
15 words
A method as claimed in claim 3 wherein the polymer film is a polyester film.
Claim 6
Independent Claim
32 words
A method as claimed in claims 3 or 4 wherein said polymer film is metallized on one surface thereof and said metallized surface is adhesively adhered to said patterned metal foil layer.
Claim 7
Dependent Claim
29 words
A method as claimed in claim 2 wherein said sheet of barrier layer material is laminated to the patterned metal foil layer of said laminate by hot nip lamination.
Claim 8
Dependent Claim
28 words
A method as claimed in claim 2 wherein said sheet of barrier layer material is laminated to the patterned metal foil layer of said laminate by extrusion lamination.
Claim 9
Dependent Claim
38 words
A method as claimed in claim 2 wherein said sheet of barrier layer material is laminated to the patterned metal foil layer of said laminate by applying a layer of solventless adhesive to said film prior to lamination.
Claim 10
Dependent Claim
30 words
A method as claimed in claim 2 wherein said sheet of barrier layer material is laminated to the patterned metal foil layer of said laminate by dry mount adhesive lamination.
Claim 11
Dependent Claim
25 words
A method as claimed in claim 2 wherein said sheet of barrier layer material is extrusion coated onto the patterned metal layer of said laminate.
Claim 12
Independent Claim
22 words
A method as claimed in claims 1 or 2 wherein said step of laser beam irradiation is accomplished using a Nd:YAG laser.
Claim 13
Independent Claim
25 words
A method as claimed in claims 1 or 2 wherein said substrate is selected from the group consisting of paper, coated paperboard and uncoated paperboard.
Claim 14
Dependent Claim
14 words
A method as claimed in claim 12 wherein said metal foil is aluminum foil.
Claim 15
Dependent Claim
22 words
A method as claimed in claim 12 wherein said metal foil has a thickness in the range of 0.0002 to 0.002 inches.
Claim 16
Dependent Claim
22 words
A method as claimed in claim 14 wherein said metal foil has a thickness in the range of 0.0002 to 0.0006 inches.
Claim 17
Dependent Claim
22 words
A method as claimed in claim 13 wherein said metal foil has a thickness in the range of 0.0002 to 0.002 inches.
Claim 18
Dependent Claim
22 words
A method as claimed in claim 16 wherein said metal foil has a thickness in the range of 0.0002 to 0.0006 inches.
Claim 19
Dependent Claim
15 words
A method as claimed in claim 13 wherein said metal foil is unannealed aluminum foil.
Claim 20
Dependent Claim
29 words
A method as claimed in claim 18 including the step of corona treating the surface of said unannealed aluminum foil prior to laminating said aluminum foil to said substrate.
Claim 21
Dependent Claim
30 words
A method as claimed in claim 18 including the step of mild flame treating the surface of said unannealed aluminum foil prior to laminating said aluminum foil to said substrate.
Claim 22
Independent Claim
21 words
A method as claimed in claims 1 or 2 wherein the pattern is a plurality of conductive islands separated by gaps.
Claim 23
Dependent Claim
14 words
A method as claimed in claim 1 wherein the pattern is an electrical circuit.
Claim 24
Independent Claim
179 words
A method of forming a container for packaging food intended for heating in a microwave oven, the container having at least one section that is opaque to microwave energy for shielding food adjacent to the opaque section, and at least one section that is substantially transparent to microwave energy, said method comprising the steps of: (a) laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate; (b) irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil; (c) laminating a sheet of barrier layer material to the patterned metal foil layer; and (d) forming said barrier layer/patterned metal foil/substrate laminate into said container with said barrier layer adjacent to the food in the container, the areas of the laminate from which metal foil was removed forming the sections of the container that are substantially transparent to microwave energy and the foil-containing areas of the laminate forming the sections of the container that are opaque to microwave radiation.
Claim 25
Independent Claim
179 words
A method of forming a container for packaging food intended for heating in a microwave oven, the container having at least one section that is opaque to microwave energy for shielding food adjacent to the opaque section, and at least one section that is substantially transparent to microwave energy, said method comprising the steps of: (a) laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate; (b) irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil; (c) laminating a sheet of barrier layer material to the patterned metal foil layer; and (d) forming said barrier layer/patterned metal foil/substrate laminate into said container with said barrier layer adjacent to the food in the container, the areas of the laminate from which metal foil was removed forming the sections of the container that are substantially transparent to microwave energy and the foil-containing areas of the laminate forming the sections of the container that are opaque to microwave radiation.
Claim 26
Dependent Claim
37 words
A method as claimed in claim 23 wherein said metal foil is aluminum foil, said substrate is selected from the group consisting of paper, coated paperboard and uncoated paperboard and said barrier layer material is polymer film.
Claim 27
Dependent Claim
22 words
A method as claimed in claim 24 wherein said metal foil has a thickness in the range of 0.0002 to 0.002 inches.
Claim 28
Dependent Claim
22 words
A method as claimed in claim 24 wherein said metal foil has a thickness in the range of 0.0002 to 0.0006 inches.
Claim 29
Dependent Claim
15 words
A method as claimed in claim 24 wherein said metal foil is unannealed aluminum foil.
Claim 30
Dependent Claim
29 words
A method as claimed in claim 27 including the step of corona treating the surface of said unannealed aluminum foil prior to laminating said aluminum foil to said substrate.
Claim 31
Dependent Claim
30 words
A method as claimed in claim 27 including the step of mild flame treating the surface of said unannealed aluminum foil prior to laminating said aluminum foil to said substrate.
Claim 32
Dependent Claim
37 words
A method as claimed in claim 23 wherein said barrier layer material is polymer film, said polymer film is metallized on one surface thereof and said metallized surface is adhesively adhered to said patterned metal foil layer.
Claim 33
Independent Claim
21 words
A method as claimed in claims 23 or 24 wherein the pattern is a plurality of conductive islands separated by gaps.
Claim 34
Dependent Claim
54 words
A patterned metal foil/substrate laminate wherein said pattern is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate and irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil.
Claim 35
Dependent Claim
54 words
A patterned metal foil/substrate laminate wherein said pattern is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate and irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil.
Claim 36
Dependent Claim
25 words
A patterned metal foil/substrate laminate as claimed in claim 32 further including a sheet of barrier layer material laminated to the patterned metal foil layer.
Claim 37
Dependent Claim
18 words
A patterned metal foil/substrate laminate as claimed in claim 33 wherein said barrier layer material is polymer film.
Claim 38
Dependent Claim
36 words
A patterned metal foil/substrate laminate as claimed in claims 32, 33 or 34 wherein said metal foil is aluminum foil and said substrate is selected from the group consisting of paper, coated paperboard and uncoated paperboard.
Claim 39
Dependent Claim
22 words
A method as claimed in claim 35 wherein said metal foil has a thickness in the range of 0.0002 to 0.002 inches.
Claim 40
Dependent Claim
22 words
A method as claimed in claim 35 wherein said metal foil has a thickness in the range of 0.0002 to 0.0006 inches.
Claim 41
Dependent Claim
18 words
A patterned metal foil/substrate laminate as claimed in claim 35 wherein said metal foil is unannealed aluminum foil.
Claim 42
Dependent Claim
33 words
A patterned metal foil/substrate laminate as claimed in claim 34 wherein said polymer film is metallized on one surface thereof and said metallized surface is adhesively adhered to said patterned metal foil layer.
Claim 43
Independent Claim
21 words
A method as claimed in claims 32 or 33 wherein the pattern is a plurality of conductive islands separated by gaps.
Claim 44
Dependent Claim
176 words
A container for packaging food intended for heating in a microwave oven, said container having at least one section that is opaque to microwave energy for shielding food adjacent to the opaque section, and at least one section that is substantially transparent to microwave energy, said container formed from a barrier layer/patterned metal foil/substrate laminate with said barrier layer adjacent to the food in the container, wherein said barrier layer/patterned metal foil/substrate laminate is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate, irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil and laminating a sheet of barrier layer material to the patterned metal foil layer, whereby the areas of the laminate from which metal foil was removed form the sections of the container that are substantially transparent to microwave energy and the foil-containing areas of the laminate form the sections of the container that are opaque to microwave radiation.
Claim 45
Dependent Claim
176 words
A container for packaging food intended for heating in a microwave oven, said container having at least one section that is opaque to microwave energy for shielding food adjacent to the opaque section, and at least one section that is substantially transparent to microwave energy, said container formed from a barrier layer/patterned metal foil/substrate laminate with said barrier layer adjacent to the food in the container, wherein said barrier layer/patterned metal foil/substrate laminate is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate, irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil and laminating a sheet of barrier layer material to the patterned metal foil layer, whereby the areas of the laminate from which metal foil was removed form the sections of the container that are substantially transparent to microwave energy and the foil-containing areas of the laminate form the sections of the container that are opaque to microwave radiation.
Claim 46
Dependent Claim
37 words
A container as claimed in claim 41 wherein said metal foil is aluminum foil, said substrate is selected from the group consisting of paper, coated paperboard and uncoated paperboard and said barrier layer material is polymer film.
Claim 47
Dependent Claim
22 words
A container as claimed in claim 42 wherein said metal foil has a thickness in the range of 0.0002 to 0.002 inches.
Claim 48
Dependent Claim
22 words
A container as claimed in claim 42 wherein said metal foil has a thickness in the range of 0.0002 to 0.0006 inches.
Claim 49
Dependent Claim
15 words
A container as claimed in claim 42 wherein said metal foil is unannealed aluminum foil.
Claim 50
Dependent Claim
37 words
A container as claimed in claim 41 wherein said barrier layer material is polymer film, said polymer film is metallized on one surface thereof and said metallized surface is adhesively adhered to said patterned metal foil layer.
Claim 51
Dependent Claim
21 words
A container as claimed in claims 41 or 42 wherein the pattern is a plurality of conductive islands separated by gaps.
Claim 52
Dependent Claim
125 words
An electronic surveillance tag for merchandise for initiating an alarm in the event tagged merchandise is removed from a merchandise establishment, said tag comprising a resonant circuit tuned to a given radio frequency for producing a detectable resonant condition for triggering an anti-shoplifting alarm, said resonant circuit formed from a patterned metal foil/substrate laminate, wherein said patterned metal foil/substrate laminate is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate and irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil, whereby unirradiated areas of the laminate formed of metal foil comprise conductive circuit elements for forming the resonant circuit.
Claim 53
Dependent Claim
125 words
An electronic surveillance tag for merchandise for initiating an alarm in the event tagged merchandise is removed from a merchandise establishment, said tag comprising a resonant circuit tuned to a given radio frequency for producing a detectable resonant condition for triggering an anti-shoplifting alarm, said resonant circuit formed from a patterned metal foil/substrate laminate, wherein said patterned metal foil/substrate laminate is formed by laminating a sheet of metal foil to a substrate by applying an adhesive between said metal foil and said substrate and irradiating said metal foil with a laser beam in a pattern for removing by vaporization the irradiated areas of the metal foil, whereby unirradiated areas of the laminate formed of metal foil comprise conductive circuit elements for forming the resonant circuit.
Claim 54
Dependent Claim
32 words
An electronic surveillance tag as claimed in claim 48 wherein said metal foil is aluminum foil and said substrate is selected from the group consisting of paper, coated paperboard and uncoated paperboard.
Claim 55
Dependent Claim
24 words
An electronic surveillance tag as claimed in claim 49 wherein said metal foil has a thickness in the range of 0.0002 to 0.002 inches.
Claim 56
Dependent Claim
24 words
An electronic surveillance tag as claimed in claim 49 wherein said metal foil has a thickness in the range of 0.0002 to 0.0006 inches.
Claim 57
Dependent Claim
17 words
An electronic surveillance tag as claimed in claim 48 wherein said metal foil is unannealed aluminum foil.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2001-08-31 | 2002-03-02 | 2002-09-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2005-08-31 | 2006-03-02 | 2006-09-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2009-08-31 | 2010-03-02 | 2010-09-01 | $7700.00 | Window Closed / Lapsed |