Abstract: A composite useful for making trays for the packaging of food and the like is formed from foamed polystyrene and a film bonded to the polystyrene, the film including a bonding layer of a styrene butadiene copolymer, the bonding layer including at least about 25% by weight of butadiene. The composite may be thermoformed into articles such as trays for use in the packaging of food products, especially meat products.

Abstract: The present invention provides a process for producing thermoplastic foam, including:(a) melting a thermoplastic polymer to produce a polymer melt;(b) introducing a carbon dioxide blowing agent into the polymer melt;(c) adding to the polymer melt one or more additives selected from the group consisting of(1) polysiloxane, and(2) mineral oil; and(d) extruding and foaming the melted polymer melt, blowing agent, and one or more additives to produce thermoplastic foam.The resultant thermoplastic foam can be thermoformed into various foamed articles, such as foam packaging trays. The quality of foams made from a carbon dioxide blowing agent, and particularly 100% carbon dioxide, has been found to be substantially improved by adding one or more of the foregoing additives, i.e., polysiloxane, mineral oil and, optionally, polyolefin to the polymer melt during the extrusion and foaming process.

Abstract: The present invention provides a process for producing thermoplastic foam, including:(a) melting a thermoplastic polymer to produce a polymer melt;(b) introducing a carbon dioxide blowing agent into the polymer melt;(c) adding to the polymer melt one or more additives selected from the group consisting of(1) polysiloxane, and(2) mineral oil; and(d) extruding and foaming the melted polymer melt, blowing agent, and one or more additives to produce thermoplastic foam.The resultant thermoplastic foam can be thermoformed into various foamed articles, such as foam packaging trays. The quality of foams made from a carbon dioxide blowing agent, and particularly 100% carbon dioxide, has been found to be substantially improved by adding one or more of the foregoing additives, i.e., polysiloxane, mineral oil and, optionally, polyolefin to the polymer melt during the extrusion and foaming process.

Abstract: A barrier foam tray contains recycled reclaim of barrier foam. The tray comprises a sheet of foamed polystyrene (PS) having laminated to it a flexible barrier film. The foamed polystyrene part can have admixed therein from 0.0001% up to 30% by weight of the flexible barrier film. The barrier film contains a barrier polymer such as ethylene vinyl alcohol copolymer (EVOH). The tray is made by grinding laminate scrap and extruding reclaim therefrom with virgin polystyrene.

Abstract: A barrier foam tray contains recycled reclaim of barrier foam. The tray comprises a sheet of foamed polystyrene (PS) having laminated to it a flexible barrier film. The foamed polystyrene part can have admixed therein from 0.0001% up to 30% by weight of the flexible barrier film. The barrier film contains a barrier polymer such as ethylene vinyl alcohol copolymer (EVOH). The tray is made by grinding laminate scrap and extruding reclaim therefrom with virgin polystyrene.

Abstract: The present invention relates to a food tray for supporting, containing and displaying food products which tend to exude or purge juices or liquids. In particular, the present invention relates to a food tray which comprises a sunken exudate reservoir. The reservoir is formed by adhering a sheet of a liquid impermeable material in a liquid tight manner to a raised shoulder area of a support portion of the tray to form a false bottom. The sheet material is further supported by standoffs rising up from the tray bottom. The sheet material is also perforated so as to allow flow of the exudate or purge through the sheet down into the reservoir where the exudate is trapped and retained out of contact with a food product which is located on top of said supported sheet. Preferably, the sheet material is opaque and the exudate is thereby hidden from view. Even more preferably, the sheet material is of the same color as the tray.

Abstract: The present invention is directed to a method and apparatus for manufacturing a tray having an integral purge juice trap. A particularly important step in the method is adhering a border area of a perforated thermoplastic sheet to a raised shoulder area of a tray. Preferably, this step is accomplished simultaneously with the step of perforating the thermoplastic sheet. A preferred method for adhering the border area to the shoulder area is heat sealing.