Metallized cutlery and tableware and method therefor

Abstract

A plastic cutlery item molded from a plastic material, such as polystyrene, having a metallic coating that imparts to this cutlery item the appearance of metal cutlery or silverware. In one embodiment the plastic cutlery or tableware items are molded using injection molding techniques, and subjected to a vacuum metallizing process in an individualized non-contiguous manner, where a thin metallic layer is deposited on at least one of their surfaces. The resultant items simulate the appearance of metal cutlery or tableware. In one embodiment of the invention the plastic cutlery or tableware articles are molded from a clear polystyrene resin and are coated with a thin stainless steel layer through vacuum sputtering deposition on only one of the sides. The abrasion resistance of the metallic coating can be enhanced by subjecting the articles to a post-metallizing holding period or by applying a clear protective overcoat.

1 . A metallized plastic food service item, comprising: 
 a plastic tableware article molded from a light transmitting resin with at least a first side and a second side;    a thin metallic coating deposited on said plastic tableware article by a vacuum deposition process,    said thin metallic coating is deposited by presenting just the first side of said plastic tableware article to a metal source in said vacuum deposition process; and    said thin metallic coating is of a sufficient thickness to impart a reflective appearance to said plastic tableware article.    
     
     
         2 . The metallized plastic food service item according to  claim 1 , wherein said first side of said plastic tableware article is adapted for being displayed in a table setting presentation.  
     
     
         3 . The metallized plastic food service item according to  claim 1 , wherein said second side of said plastic tableware article is adapted for being displayed in a table setting presentation.  
     
     
         4 . The metallized plastic food service item according to  claim 1 , further comprising a tint in said light transmitting resin.  
     
     
         5 . The metallized plastic food service item according to  claim 4 , wherein said tint is light transmitting and increases an initial optical density of said plastic tableware article by about 0.1 to 0.5.  
     
     
         6 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is selected from a group consisting of: 
 silver, steel, stainless steel, chromium, aluminum, copper, gold, and compositions therewith.    
     
     
         7 . The metallized plastic food service item according to  claim 1 , wherein said metal source is selected from a group consisting of: silver, steel, stainless steel, copper, chromium, aluminum, gold and alloys thereof.  
     
     
         8 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating includes a tint.  
     
     
         9 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is less than 3,000 nanometers in thickness.  
     
     
         10 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is less than 1000 nanometers in thickness.  
     
     
         11 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is less than 200 nanometers in thickness.  
     
     
         12 . The metallized plastic food service item according to  claim 1 , wherein said thin metallic coating is more than 30 nanometers in thickness.  
     
     
         13 . The metallized plastic food service item according to  claim 1 , further comprising a clear coating over said thin metallic coating for protecting said thin metallic coating and enhancing the durability of said thin metallic coating.  
     
     
         14 . The metallized plastic food service item according to  claim 1 , further comprising a thin protective overcoat of a clear coating over said thin metallic coating, wherein said thin protective overcoat is deposited by a chemical vapor deposition process.  
     
     
         15 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is an implement for handling and consuming food, selected from a group consisting of: fork, knife and spoon.  
     
     
         16 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is selected from a group consisting of: tray, plate, cup and bowl.  
     
     
         17 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is at least partially composed of polystyrene.  
     
     
         18 . The metallized plastic food service item according to  claim 1 , wherein said metallized plastic food service item has an optical density of less than about 6.  
     
     
         19 . The metallized plastic food service item according to  claim 1 , wherein said metallized plastic food service item has an optical density of less than about 3.  
     
     
         20 . The metallized plastic food service item according to  claim 1 , wherein said metallized plastic food service item has an optical density of greater than about 0.5.  
     
     
         21 . The metallized plastic food service item according to  claim 1 , wherein said plastic tableware article is produced by injection molding.  
     
     
         22 . The metallized plastic food service item according to  claim 1 , wherein said vacuum deposition process is a sputtering deposition process.  
     
     
         23 . A method for making an aesthetically pleasing plastic food service product, comprising: 
 molding a plastic tableware article by the process of injection molding, wherein said plastic tableware article has at least a first surface and a second surface;    placing said plastic tableware article into a vacuum metallizing unit having a metal source with said first surface facing said metal source;    depositing onto said first surface of the plastic tableware article, a thin metallic coating, by a vacuum deposition process, of sufficient thickness to impart a reflective metal-like appearance to the plastic tableware article; and    subjecting said plastic tableware article with said thin metallic coating for a predetermined post-metallizing holding period.    
     
     
         24 . The method according to  claim 23 , wherein said predetermined post-metallizing holding period is implemented by heating said plastic food service product up to a temperature of about 150 degrees Fahrenheit.  
     
     
         25 . The method according to  claim 23 , wherein said predetermined post-metallizing holding period is at least 24 hours and is implemented by storing said plastic food service product under clean and dry conditions.  
     
     
         26 . The method according to  claim 23 , wherein said predetermined post-metallizing holding period is implemented by packing said plastic food service product in a suitable package, and storing said suitable package for a period of about two weeks.  
     
     
         27 . The method according to  claim 23 , further comprising spraying a clear coating and curing said clear coating.  
     
     
         28 . The method according to  claim 23 , further comprising depositing a clear coating by a vacuum deposition process.  
     
     
         29 . The method according to  claim 23 , wherein said vacuum deposition process is a physical vapor deposition.  
     
     
         30 . The method according to  claim 23 , wherein said vacuum deposition process is a sputtering vapor deposition.  
     
     
         31 . The method according to  claim 23 , wherein said thin metallic coating is selected from a metal chosen from the group of metals consisting of: 
 silver, steel, stainless steel, chromium, aluminum, copper, gold and compositions thereof.    
     
     
         32 . The method according to  claim 23 , wherein said plastic tableware article is molded from a light transmitting plastic material with a color tint.  
     
     
         33 . The method according to  claim 23 , wherein said thin metallic coating is less than 3000 nanometers in thickness.  
     
     
         34 . A metallized plastic food service item, comprising: 
 a plastic tableware article comprising at least a first portion and a second portion;    a thin metallic coating deposited on only said first portion of said plastic tableware article by a vacuum deposition process,    said thin metallic coating is deposited by presenting only said first portion of said plastic tableware article to a metal source in said vacuum deposition process;    said thin metallic coating is of a sufficient thickness to impart a reflective appearance to at least said first portion of said plastic tableware article; and    wherein said first portion of said plastic tableware article, having said thin metallic coating, has an optical density of greater than about 0.5.    
     
     
         35 . The metallized plastic food service item according to  claim 34 , wherein said first portion is molded from a light transmitting plastic resin and said second portion is molded from a colored plastic resin.