Absorbent paper laminate and food container made thereof

Abstract

An absorbent paper laminate, having an absorbent paper layer, a nonabsorbent high-density paper layer and an adhesive applied in a layer between the absorbent and nonabsorbent layers forming a laminate. The laminate has a surface which is provided with an array of perforations formed by needle punctures, or a series of slits sized to allow steam to pass therethrough while retaining grease and oil in the absorbent paper layer. The preferred adhesive layer is selectively in a cellular pattern. A paper board food container can be formed having an absorbent paper laminate body defining a cavity for receiving a food item and absorb grease and oil. Optionally an exterior surface of the container is sized to be held in the hands of a user having an exterior surface with a second absorbent layer that can act as a napkin absorbing grease and oil from the hands of the user.

1 . An absorbent paper laminate, comprising:
 an absorbent crepe paper layer having a caliper of 0.1 to 20 mils;   a nonabsorbent high-density paper layer; and   an adhesive selectively applied in a layer between the absorbent and nonabsorbent layers in a cellular pattern to form a laminate;   wherein the laminate has a surface which is provided with an array of perforations sized to allow steam to pass while retaining grease and oil.   
     
     
         2 . The paper laminate of  claim 1 , wherein at least 1 perforation per square inch is generally uniformly formed in the surface. 
     
     
         3 . The paper laminate of  claim 1 , wherein the perforations are formed by needle having a diameter of 1 to 75 mils. 
     
     
         4 . The paper laminate of  claim 1 , wherein the perforations are formed by needle having a diameter of 20 to 40 mils. 
     
     
         5 . The paper laminate of  claim 1 , wherein the perforations are formed by series cut segments. 
     
     
         6 . The paper laminate of  claim 1 , wherein the perforations are formed by series cut segments each having a length of less than 0.25 inch. 
     
     
         7 . The paper laminate of  claim 1 , wherein the cellular pattern forms a plurality of interconnected hexagons which are 0.125 to 1.0 inch across the flats. 
     
     
         8 . The paper laminate of  claim 1 , wherein the cellular pattern forms a plurality of interconnected hexagons which are 0.375 to 0.5 inch across the flats. 
     
     
         9 . The paper laminate of  claim 1 , wherein the adhesive has a melting temperature above 400° F. 
     
     
         10 . The paper laminate of  claim 1 , wherein the adhesive meets the ASTM 6400 biodegradability standard and the absorbent crepe paper layer, the high-density paper layer and the adhesive are PFAS free. 
     
     
         11 .- 17 . (canceled) 
     
     
         18 . An absorbent paper laminate, comprising:
 a first absorbent paper layer having a caliper of 0.1 to 20 mils and a basis weight of less than 100 pounds per 3,000 square feet;   a nonabsorbent high-density paper layer having a caliper 0.1 to 20 mils of and a basis weight of greater than 5 pounds per 3,000 square feet; and   a first adhesive applied in a layer between the absorbent layer and a first side of the nonabsorbent layer;   a second absorbent paper layer having a caliper of 0.1 to 20 mils and a basis weight of less than 100 pounds per 3,000 square feet; and   a second adhesive applied in a layer between the absorbent layer and a second side of the nonabsorbent layer forming a laminate.   
     
     
         19 . The absorbent paper laminate of  claim 18 , wherein the laminate has a surface which is provided with an array of perforations sized to allow steam to pass while retaining grease and oil in the first and second absorbent paper layers. 
     
     
         20 . A paper board food container formed of the paper laminate of  claim 19 , comprising:
 a paper laminate body defining an at least partially enclosed cavity for receiving a food item and an exterior surface sized to be held in hands of a user;   wherein walls of the enclosed cavity can absorb grease and oil from the food item while the exterior surface can act as a napkin absorbing grease and oil from the hands of the user.