Metallized cutlery and tableware and method therefor

Abstract

A tableware item molded from a plastic material, such as polystyrene has a metallic coating applied to at least one surface by a sputtering deposition process. The sputtered coating is suitable for food contact without an overcoat, and imparts the appearance of a metal tableware item. In embodiments, the tableware item is a cup, a plate, a bowl, a tray, a lid, a glass, a champagne flute, a goblet, a napkin ring, a candle holder, or a centerpiece receptacle. The metallic coating can be silver, steel, stainless steel, chromium, aluminum, copper, or gold. In some embodiments, the metallic coating is not applied to all surfaces of the tableware item. In various embodiments, the tableware article is molded from a clear polystyrene resin and coated with a thin stainless steel layer on only one side. The abrasion resistance of the metallic coating can be enhanced by applying a clear protective overcoat.

What is claimed is: 
     
         1 . A metallized plastic food service item, comprising:
 a plastic tableware article; and   a thin metallic coating deposited on a surface of said plastic tableware article, wherein said thin metallic coating is characterized by its suitability for food contact without an overcoat, wherein said thin metallic coating is of a sufficient thickness to impart a reflective metal-like appearance to the plastic tableware article, to simulate genuine metal tableware, and wherein said thin metallic coating is deposited by a sputter deposition process.   
     
     
         2 . The metallized plastic food service item according to  claim 1 , wherein the food service item is one of a cup, a plate, a bowl, a tray, a lid, a glass, a champagne flute, a goblet, a napkin ring, a candle holder, and a centerpiece receptacle. 
     
     
         3 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is comprised of a metal selected from the group consisting of: silver, steel, stainless steel, chromium, aluminum, copper and gold. 
     
     
         4 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is less than 2000 nanometers in thickness. 
     
     
         5 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is less than 200 nanometers in thickness. 
     
     
         6 . The metallized plastic food service item according to  claim 1 , further comprising an overcoat on said thin metallic coating. 
     
     
         7 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is adapted for disposable use. 
     
     
         8 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is composed of a light-transmitting plastic material. 
     
     
         9 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is composed of polystyrene. 
     
     
         10 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is obtained from a plastic resin composition which is substantially free of mineral oil and wax. 
     
     
         11 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is injection molded from a plastic resin. 
     
     
         12 . The metallized plastic food service item according to  claim 1 , wherein said metallized plastic food service item has an optical density of less than 2.0. 
     
     
         13 . The metallized plastic food service item according to  claim 1 , wherein said metallized plastic food service item has an optical density of greater than 1.0. 
     
     
         14 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is produced by injection molding. 
     
     
         15 . The metallized plastic food service item according to  claim 1 , further comprising cosmetic surface features for enhancing the reflective metal-like appearance of said plastic tableware article. 
     
     
         16 . The metallized food service item according to  claim 1 , wherein approximately all of said plastic tableware article is coated with said thin metallic coating. 
     
     
         17 . The metallized food service item according to  claim 1 , wherein said thin metallic coating is deposited on only a portion of said plastic tableware article. 
     
     
         18 . The metallized plastic food service item according to  claim 1 , wherein said food service item includes a plurality of surfaces, one of said surfaces being characterized by absence of said thin metallic coating. 
     
     
         19 . The metallized plastic food service item according to  claim 1 , wherein said food service item includes a display surface and an underside, said plastic tableware article being adapted for placement on a table surface in a traditional table-setting presentation with said underside facing down towards said table surface and said display surface facing upwards, said underside being characterized by absence of said thin metallic coating. 
     
     
         20 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article includes a plastic material with a color tint. 
     
     
         21 . A metallized plastic food service item, comprising:
 a plastic tableware article having a plurality of surfaces, wherein at least one surface amongst said plurality of surfaces is deposited with a thin metal layer; said thin metal layer being suitable for food contact without an overcoat and having sufficient durability for handling and consuming food;   said thin metal layer being deposited by a sputter deposition process, whereby a reflective metal-like appearance which simulates genuine metal tableware is imparted to at least a portion of said tableware article; and   said thin metal layer being less than about 2000 nanometers in thickness.   
     
     
         22 . A metallized plastic food-service item, comprising:
 a plastic tableware article for handling and consuming food, said plastic tableware article comprising a first portion and a second portion;   a thin metallic coating deposited on said first portion of said plastic tableware article by a vacuum deposition process, wherein said thin metallic coating is of a sufficient thickness to impart a reflective metal appearance to said first portion of said plastic tableware article, said thickness being less than 2000 nanometers; and   said second portion of said tableware article being characterized by absence of said thin metallic coating, and said second portion of said plastic tableware article retaining its plastic appearance.   
     
     
         23 . The metallized plastic food-service item according to  claim 22 , wherein said first portion of said plastic tableware article comprises a head portion of said plastic tableware article. 
     
     
         24 . The metallized plastic food-service item according to  claim 22 , wherein said plastic tableware article is adapted for placement on a table surface with said first portion displaying said reflective metal appearance and said second portion displaying said plastic appearance. 
     
     
         25 . The metallized plastic food-service item according to  claim 22 , wherein said first portion is made from a light transmitting plastic material, and said second portion of said plastic tableware article is made from a colored plastic material. 
     
     
         26 . The metallized plastic food-service item according to  claim 22 , wherein said vacuum deposition process is a sputtering deposition process.