WO2023181032A1

WO2023181032A1 - Hybrid foil tray

Info

Publication number: WO2023181032A1
Application number: PCT/IL2023/050292
Authority: WO
Inventors: Eli GERASI
Original assignee: Gerasi Eli
Priority date: 2022-03-23
Filing date: 2023-03-20
Publication date: 2023-09-28
Also published as: IL315332A

Abstract

The present invention relates to hybrid foil which includes at least two layers, preferably, an aluminum layer and at least one additional layer, wherein the additional layer may be a polymer layer. The hybrid foil further includes an adhesive layer between the aluminum layer and the at least one additional layer. According to some embodiments of the invention, the aluminum layer has a matte side and a bright side and the at least one additional layer is applied to the matte side of the aluminum layer.

Description

APPLICATION FOR PATENT

Title: HYBRID FOIL TRAY

RELATED APPLICATION/S

This application claims the benefit of priority under 35 USC § 119(e) of U.S. Provisional Patent Application No. 63/322,652 filed 23 March, 2022, the contents of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention, in some embodiments thereof, relates to hybrid foil tray which includes at least two layers, preferably, a metal layer and at least one additional layer.

Disposable food preparation materials have become an integral part of our lives, especially in this fast-paced world where convenience is highly valued. These materials come in different forms and types, including aluminum foil, plastic foils, cooking bags, aluminum pans, and baking paper, among others.

Aluminum foil is a popular disposable material used for cooking, baking, and storing food. One of the significant advantages of aluminum foil is its ability to withstand high temperatures, making it suitable for cooking and baking. It is also an excellent barrier against moisture, air, and light, which helps to keep food fresh for longer periods. Aluminum foil is also flexible, which allows it to be molded into different shapes and sizes, making it versatile for different cooking and baking needs.

Aluminum pans are a popular choice for disposable cookware. One of the significant advantages of aluminum pans is their durability and strength, which makes them suitable for baking, roasting, and reheating. They are also lightweight and easy to handle, making them convenient to use in outdoor cooking events or when cooking for a large number of people. Additionally, aluminum pans are a good heat conductor, which ensures even cooking of food.

However, there are some disadvantages of using aluminum. Cooking or storing acidic or spicy foods in aluminum foil can cause the metal to leach into the food, which is believed by some to be harmful to health. Aluminum may not be suitable for storing some foods for long periods since it can react with certain foods, altering their taste, appearance and/or texture.

Aluminum foil, also called tin foil or silver foil, is aluminum prepared in thin metal leaves with athickness less than 0.2 mm. Standard household foil is typically 0.016 mm thick, and heavy-duty household foil is typically 0.024 mm. The foil is pliable and can be readily bent or wrapped around objects. It has many applications, e.g., commercial wrapping of chocolate and sweets, household wrapping of foods for refrigeration, wrapping meats and foods for putting them in oven, etc. Thicker aluminum foil is used in production of baking trays of various sizes and shapes.

An additional foil used in household is baking paper, also called parchment paper or bakery release paper. Baking paper is a cellulose-based paper that has been treated or coated to make it non-stick. It is used in baking as a disposable non-stick surface.

Cardboard cooking trays may also include a cellulose base and/or a non-stick and/or moisture barrier coating. There are some disadvantages to using cellulose based food vessels. Some cellulose based vessels are not suitable for high-temperature cooking for example, due to flammability they can catch fire, which may lead for example to food contamination and/or safety hazards. In some cases, cellulose materials are not durable, for example, they may become soggy and/or collapse when exposed to liquids or high moisture content foods. Another possible problem with cellulose based products is that they may can absorb the flavor and odor of the food; this may lead, for example, to loss of taste, change of taste, to cross-contamination and/or affect the taste and/or appearance of the food.

High-temperature polymer foils, such as cooking bags, are another popular choice for disposable cookware. One of the significant advantages of high-temperature polymer foils is their ability to withstand high temperatures, making them suitable for baking, roasting, and microwaving. They are also versatile and can be used for a variety of food types, including meats, fish, and vegetables. Additionally, cooking bags are easy to use, require minimal clean-up. Another advantage of polymer foils is that they may be configured for printing images thereon. Commonly, images and/or colors are added to and/or printed on these materials.

However, there are also some disadvantages to using high-temperature polymer foils. First, they are not suitable for all types of food, particularly those with high moisture content, as they can lead to steam build-up and affect the quality of the food. Second, cooking bags can be expensive compared to other types of disposable cookware. Finally, cooking bags can be difficult to handle and can easily puncture or tear, leading to food contamination and safety hazards.

Another foil used in household and elsewhere is plastic or nylon foils, usually in rolls. In particular, oven bags, cooking bags or roasting bags are used for various cooking methods, e.g., roasting of meat or other foods in an oven. The nylon or other polymer used for that purpose withstand the high temperatures of pot cooking or oven cooking.

SUMMARY

According to an aspect of some embodiments of the invention, there is provided a hybrid foil including an aluminum layer with at least one additional layer applied thereto.

According to some embodiments of the invention, the at least one additional layer includes a polymer layer.

According to some embodiments of the invention, the hybrid foil further includes an adhesive layer between the aluminum layer and the at least one additional layer.

According to some embodiments of the invention, the aluminum layer has a thickness in a range between about 10 pm to about 75 pm.

According to some embodiments of the invention, the aluminum layer has a matte side and a bright side.

According to some embodiments of the invention, the at least one additional layer is applied to the matte side of the aluminum layer. According to some embodiments of the invention, the polymer layer is at least partially opaque.

According to some embodiments of the invention, the polymer layer has a thickness in a between 5 pm to about 50 pm.

According to some embodiments of the invention, the polymer layer can withstand temperatures between about 200 °C to about 500 °C.

According to some embodiments of the invention, the polymer layer includes a white polyester.

According to some embodiments of the invention, the polymer layer is nylon.

According to some embodiments of the invention, the additional layer includes a non-stick substance.

According to some embodiments of the invention, the non-stick substance is silicone.

According to some embodiments of the invention, the adhesive layer has a thickness in a range between about 1 pm to about 5 pm.

According to some embodiments of the invention, the adhesive layer can withstand temperatures between about 200 °C to about 500 °C.

According to some embodiments of the invention, the hybrid foil is shaped into a tray.

According to an aspect of some embodiments of the invention, there is provided a method of manufacturing a hybrid foil, the method including: preparing an aluminum layer; and applying a polymer layer onto the aluminum layer.

According to some embodiments of the invention, the method further includes applying an adhesive layer between the aluminum layer and the polymer layer.

According to some embodiments of the invention, the applying is to a matte side of the aluminum layer.

According to an aspect of some embodiments of the invention, there is provided a method of manufacturing a hybrid baking tray, the method including: preparing an aluminum layer; applying a polymer layer onto the aluminum layer to form a hybrid foil; and stamping the hybrid foil into a tray.

According to some embodiments of the invention, the applying is to a matte side of the aluminum layer. BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

In the drawings:

Fig. 1A: An exemplary photograph showing a hybrid foil roll having a bright aluminum side and a polymer layer on a matte aluminum side, in accordance with some embodiments.

Fig. IB: A schematic diagram showing a cross section of a hybrid foil with three layers, an aluminum layer, an adhesive layer and a polymer layer, in accordance with some embodiments.

Fig. 1C: A schematic diagram showing a cross section of a hybrid foil with two layers, an aluminum layer, a polymer layer, held together by certain physical properties of the involved layers, in accordance with some embodiments.

Fig. 2A: An exemplary photograph showing a hybrid baking tray having a polymer layer on aluminum layer in the internal side, in accordance with some embodiments.

Fig. 2B: An exemplary photograph showing the external aluminum side of the baking tray of Fig. 2a, in accordance with some embodiments.

Fig. 3 A: A block diagram of a hybrid foil, in accordance with some embodiments.

Fig. 3B: A block diagram of a hybrid foil, in accordance with some embodiments.

Fig. 4: A flow chart of a method for manufacturing a hybrid foil, in accordance with some embodiments.

Fig. 5: A flow chart of a method for manufacturing a hybrid foil tray, in accordance with some embodiments. Fig. 6: A flow chart of a method for manufacturing a hybrid foil, in accordance with some embodiments.

Fig. 7: A flow chart of a method for manufacturing a hybrid foil tray, in accordance with some embodiments.

Fig . 8 : A block diagram of a hybrid tray, in accordance with some embodiments .

Fig. 9: A block diagram of a hybrid tray, in accordance with some embodiments.

DETAILED DESCRIPTION

The present invention, in some embodiments thereof, relates to hybrid foil that includes at least two layers, preferably, an aluminum layer and at least one additional layer.

OVERVIEW

Some embodiments relate to hybrid foil that includes at least two layers. According to some embodiments, the hybrid foil may include one or more metal sheet as layers. Optionally, the metal sheet may be an aluminum sheet or layer. Optionally, the metal sheet may be a foil. In some embodiments, a baking tray may be made of the hybrid foil.

As used herein, the term "foil" relates to a very thin, flexible sheet of metal, e.g., aluminum foil, tin foil, etc. According to some embodiments, the hybrid foil may have a thickness in the range between about 0.01 mm to about 0.05 mm, between about 0.05 mm to about 0.1 mm, between about 0.1 mm to about 0.5 mm, between about 0.5 mm to about 0.75 mm, and/or between about 0.75 mm to about 1 mm. Optionally, the hybrid foil may be used as standard household foil, heavy-duty foil, and/or in the manufacture of baking trays and/or cooking bags.

According to some embodiments, the hybrid foil may include a bright surface on one side. According to some embodiments, the hybrid foil may include a matte surface on one side.

As used herein, the term "matte" relates to a material having a usually smooth even surface free from shine or highlights, e.g., a surface or color or paint that is not shiny. For example, a matte surface may have diffuse reflectivity. As used herein, the term "bright" relates to emitting or reflecting light readily or in large amounts, e.g., shining or glowing with light by emitting or reflecting a high degree of light. For example, a “bright” or shiny surface may have spectral reflectivity.

According to some embodiments, the hybrid foil and/or tray may include an aluminum layer. According to some embodiments, the aluminum layer may have a thickness in the range between about 0.01 mm to about 0.05 mm, between about 0.05 mm to about 0.1 mm, between about 0.1 mm to about 0.5 mm, and/or between about 0.5 mm to about 0.75 mm. Optionally, the Aluminum layer may have a weight ranging between 1 to 2 g/mm² and/or between 2 to 3.5 g/mm² and/or between 3.5 to 5.5 g/mm² and/or between 5.5 to 10 g/mm².

According to some embodiments, the hybrid foil may include an aluminum layer and at least one additional layer. According to some embodiments, the at least one additional layer may be a polymer layer, an adhesive layer, a baking paper layer, a coating, etc. According to some embodiments, the aluminum layer may include a bright surface on one side. According to some embodiments, the aluminum layer may include a matte surface on one side. According to some embodiments, the matte aluminum layer surface may be coated by one or more additional layers. According to some embodiments, the bright aluminum layer surface may be coated by one or more additional layers. Herein, unless otherwise specified the term Aluminum is used in a general way and it is to be understood that other metals may be substituted in place of Aluminum.

In some embodiments, the polymer may cover all of one side of the metal foil and/or between 90 to 100% and/or between 70 to 90% and/or between 50 to 70% and/or between 25 to 50% of the one side. In some embodiments, the polymer may not cover any of the opposite side of the metal foil and/or between 0 to 10% and/or between 10 to 30% and/or between 30 to 50% and/or between 50 to 75% of the other side opposite the one side of the foil.

In some embodiments, adhesive may cover all of the area of contact between the metal and the polymer and/or between 90 to 100% and/or between 70 to 90% and/or between 50 to 70% and/or between 25 to 50% and/or between 0 to 25% of the area of contact between the metal and the polymer. Alternatively or additionally, adhesive may be used on one side of the foil and not on another side. As used herein the terms "baking paper" and "baking parchment" are used interchangeably, and relate to a paper that has been treated with a thin coating of food grade non-stick material (e.g., silicone) to stop food from sticking to it.

In some embodiments, a hybrid foil may provide two or more of features not available in conventional monolithic foils and/or foil combinations. For example, a hybrid foil may have malleable features of a metal foil and/or include a surface having non-stick and/or no-reactive features of polymer foils. Optionally, the foil may include a polymer surface and/or an opposing metal surface. Optionally, the user may easily differentiate the polymer surface by sight and/or feel. Therefore, there is a need for a hybrid foil that includes at least two layers, an aluminum layer and at least one additional layer and/or a tray made of such foil. In some embodiments, the layers are configured (e.g., thickness, ductility, thickness may be matched and/or the materials may be bonded) to facilitate the surfaces remaining continuous and/or unbroken and/or connected (e.g., without forming bubble and/or separating) under various stresses including bending, stretching, scraping and/or heating. In some embodiments, a hybrid foil and/or a hybrid food vessel may include the advantages of various foils and/or vessels listed herein above.

According to some embodiments, a baking paper layer may be applied to the metal layer (e.g., Aluminum foil, tin foil, copper foil and/or foils including iron and/or iron alloys). Optionally, a baking paper layer may be applied to the matte surface of the aluminum layer. Optionally, a baking paper layer may be applied to the bright surface of the aluminum layer. Optionally, the baking paper may be affixed to the aluminum layer by an adhesive layer. For example, the hybrid foil and/or the hybrid baking tray may include a layer of a baking paper. Optionally, the baking paper layer may be coated with a non-stick substance. Optionally, the non-stick substance may include silicone and/or an artificial polymer.

According to some embodiments, the matte surface of the aluminum layer may be coated by one or more polymer layers. According to some embodiments, the bright and/or the matte surface of the aluminum layer may be coated by one or more polymer layers. Optionally, the polymer may be selected and/or modified to achieve a desired appearance. For example, a polymer having an inherent color may be used (for example, an opaque and/or white polymer may be used for example, white polyester). Alternatively or additionally, both sides of the metal foil and/or tray may be coated with polymer.

According to some embodiments, the polymer layer may be capable of withstanding temperatures in the range between about 200 °C to about 300 °C, between about 300 °C to about 400 °C, and/or between about 400 °C to about 500 °C.

According to some embodiments, the polymer may be a polyester, a polyamide and/or a combination thereof, e.g., nylon, etc. Optionally, the polymer may be opaque, semi-transparent and/or transparent. Optionally, the polymer may not be dyed and/or printed e.g., to prevent contamination of food, sticking etc. Optionally, the natural color of the polymer may be maintained. Optionally, this may facilitate visibility of the polymer coating, e.g., so that the polymer layer is visible such that a user may observe that the hybrid foil is coated. Optionally, the polymer may include a solventless polymer and/or may be produced and/or the foil formed and/or adhered without added solvent. For example, the polymer may be extruded and/or the polymer and metal may be coextruded.

According to some embodiments, the polymer layer may have a thickness in the range between about 0.001 mm to about 0.01 mm, between about 0.01 mm to about 0.05 mm, and/or between about 0.05 mm to about 0.1 mm.

According to some embodiments, the polymer layer may adhere to the aluminum layer with the assistance of an adhesive layer. Optionally, the adhesive layer may be capable of withstanding temperatures in the range between about 200 °C to about 300 °C, between about 300 °C to about 400 °C, and/or between about 400 °C to about 500 °C. Optionally, the adhesive layer may be composed of a polymeric adhesive. Optionally, the polymer adhesive may include a polyester and/or a nylon.

According to some embodiments, the adhesive layer may have a thickness in the range between about 0.0001 mm to about 0.001 mm, between about 0.001 mm to about 0.005 mm, and/or between about 0.005 mm to about 0.01 mm.

In some embodiments, a polymer foil may be attached to a metal foil using an adhesive, for example reactive polyurethane adhesives, polyurethane adhesives (optionally including Diisocyanates for example, a form of MDI (Diphenylmethanediisocyanate) and/or a form of TDI (Toluene diisocyanate) and/or IPDI (Isophorone diisocyanate), and/or HMDI (Hexamethylene- 1,6-diisocyanate), acrylates (e.g., cyanoacrylate), polyepoxides (e.g., epoxy), Adhesives based on acrylic polymers and copolymers and/or resins. Preferentially a solvent free adhesive is used. Alternatively or additionally, a solvent based adhesive may be used. Alternatively or additionally, non adhesive bonding may be used, for example via thermal or ultrasonic bonding.

According to some embodiments, the adhesive layer may be applied using a solvent during the lamination process. Optionally, the polymer layer may be applied to the foil without the use of an adhesive layer.

According to some embodiments, the hybrid foil may be used to make prefabricated items, e.g., shaped containers, such as rolls of foil, baking trays, cooking bags, prepared food containers, gas burner protectors, etc.

SPECIFIC EMBODIMENTS

The present invention will now be described in terms of specific example embodiments. It is to be understood that the invention is not limited to the example embodiments disclosed. It should also be understood that not every feature of the methods and systems described are necessary to implement the invention as claimed in any particular one of the appended claims. Various elements and features of the invented article are described to fully enable the invention. It should also be understood that throughout this disclosure, where a method is shown or described, the steps of the method may be performed in any order or simultaneously, unless it is clear from the context that one step depends on another being performed first.

Before explaining several embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

Reference is now made to the figures.

Fig. 1A illustrates a hybrid foil roll, in accordance with an embodiment of the invention. According to some embodiments, a hybrid foil roll 102, includes a bare metal surface and a nonmetal surface (e.g., a surface coated with a polymer). Optionally, the surfaces are configured so that a consumer may easily discern that the surfaces differ and/or may determine which is the coated surface and/or may see that at least one of the surfaces in nonmetal. Optionally, the non-metal surface should look safe and clean (e.g., have a white appearance). For example, the polymer may be selected for its transmittance. For example, a polymer foil may have a transmittance of between 0 to 5% and/or between 5 to 20% and/or between 20 to 50% and/or between 50 to 75% and/or between 75 to 85% and/or between 85 to 95% and/or between 95 to 100%. Optionally, the polymer layer may not include added dye and/or printing. Reducing use of dye and/or printed may in some embodiments inhibit contamination of food and/or facilitate adhesion between the metal and the polymer. For example, the polymer layer may include a naturally opaque polymer. For example, the polymer foil may include white polyester. Alternatively or additionally, the polymer may be dyed and/or printed upon.

In some embodiments, the hybrid foil may include metallic surface and a nonmetallic surface (e.g., the metallic surface may have a higher spectral reflectivity than the nonmetallic surface). In some embodiments, a metal foil may include a bright surface and a matte surface. Optionally, the polymer coating is applied to the matte side. For example, a hybrid foil may have a bright side and a matte side. For example, the bright side may include an aluminum side 104 and/or the matte side may include a polymer layer applied to a matte aluminum side 106 of the metal foil. For example, an aluminum layer may be configured to have a bright side and a matte side. Alternatively or additionally, the coating layer (e.g., polymer) may be applied to the shiny meatal surface and/or the opposite surface may be a matte metal surface. According to some embodiments, the hybrid foil may be configured to have a bright aluminum layer side on one side and matte aluminum layer on the other side. According to some embodiments, the matte aluminum layer surface may be coated by a polymer layer. According to some embodiments, the bright aluminum layer surface may be coated by a polymer layer.

Fig. IB is a schematic diagram showing a cross-section of a hybrid foil with three layers, in accordance with some embodiments. For example, the hybrid foil may include an aluminum layer 108, an adhesive layer 110 and a polymer layer 112, e.g., a polyester, polyamide, such as nylon, etc. Fig. 1C is a schematic diagram showing a cross-section of a hybrid foil with two layers, in accordance with some embodiments. For example, the hybrid foil may include an aluminum layer 114 and a polymer layer 116, e.g., a polyester, polyamide, such as nylon, etc. Optionally, the aluminum layer 114 and the polymer layer 116 may adhere together by certain physical properties of the involved layers, e.g., the polymer layer may have adhesive properties, the surface quality of the sides facing each other may be as high as to enable optical bonding, etc.

In certain embodiments, the thickness of the metal (e.g., Aluminum) layer may range between 0.01 mm to 0.05 mm, and/or between 0.05 mm to 0.1 mm and/or between 0.1 mm to 0.2 mm and/or between 0.2 mm to 0.3 mm and/or between 0.3 mm to 0.5 mm, and/or between 0.5 mm to 0.75 mm. In certain embodiments, the thickness of the aluminum layer is less than about 0.1 mm, about 0.15 mm, about 0.2 mm, about 0.25 mm, about 0.3 mm, about 0.7 mm, and/or about 0.75 mm. Optionally, the aluminum layer may be used as standard household foil, heavy-duty foil, and/or in the manufacture of baking trays and/or cooking bags.

In certain embodiments, the thickness of the adhesive layer is between 0.001 mm to 0.005 mm and/or between 0.005 to 0.01 mm and/or between 0.01 to 0.05 mm and/or between 0.05 to 0.1 mm and/or between 0.1 to 0.2 mm. In certain embodiments, the thickness of the adhesive layer is less than about 0.005, about 0.01, about 0.05 mm, about 0. 1mm, and/or about 0.15 mm.

In certain embodiments, the thickness of the polymer layer is between 0.001 mm to 0.005 mm and/or between 0.005 to 0.01 mm and/or between 0.01 to 0.05 mm and/or between 0.05 to 0.1 mm and/or between 0.1 to 0.15 mm. In certain embodiments, the thickness of the polymer layer is less than about 0.005, about 0.01, about 0.05 mm, about 0.1mm, and/or about 0.15 mm.

Figs. 2A and 2B are exemplary photographs showing a hybrid baking tray having a polymer layer on metal layer (e.g., Aluminum), in accordance with some embodiments. Optionally the polymer layer is in the internal side. For example, hybrid foil baking tray 202 may include a polymer layer 204 on a matte inner surface, and/or on an outer bright surface 206. Optionally, the outer bright surface 206 may not include a polymer layer. In some embodiments, the polymer has a white color. For example, the polymer may include white polyester. Advantageously, such a hybrid baking tray may be attractive for people which suspect aluminum tray of leaving certain metal residues on the baked food, non-stick cooking and/or baking applications.

According to some embodiments, the cross-section of the hybrid baking tray may include three layers, e.g., aluminum layer, adhesive layer and a polymer layer, and/or aluminum layer, adhesive layer and a baking paper layer. Additionally, and/or alternatively, the cross-section of the hybrid baking tray may include two layers, e.g., aluminum layer and a polymer layer, or an aluminum layer and a baking paper layer.

In some embodiments, the polymer may cover all of one side of the tray and/or between 90 to 100% and/or between 70 to 90% and/or between 50 to 70% and/or between 25 to 50% of the one side. In some embodiments, the polymer may not cover any of the opposite side of the tray and/or between 0 to 10% and/or between 10 to 30% and/or between 30 to 50% and/or between 50 to 75% of the other side opposite the one side of the tray.

In some embodiments, adhesive may cover all of the area of contact between the metal and the polymer and/or between 90 to 100% and/or between 70 to 90% and/or between 50 to 70% and/or between 25 to 50% and/or between 0 to 25% of the area of contact between the metal and the polymer.

Figs. 3A and 3B are block diagrams of a hybrid foil, in accordance with some embodiments. For example, the hybrid foil 300 may include an aluminum (and/or another metal) layer 302, an adhesive layer 304 and a polymer layer 306 (e.g., Fig. 3a). Alternatively, the hybrid foil 308 may include an aluminum layer 310 and a polymer layer 312 (e.g., 3b).

According to some embodiments, the polymer layer may adhere to the metal sheet using an adhesive layer. Optionally, the adhesive may be capable of withstanding temperatures in the range between about 200 °C to about 300 °C, between about 300 °C to about 400 °C, and/or between about 400 °C to about 500 °C. Optionally, the adhesive layer may be composed of a polymeric adhesive. Optionally, the polymer adhesive may be a polyester. Fig. 4 is a flow chart of a method for manufacturing a hybrid foil, in accordance with some embodiments. For example, in method 400, a metal layer (e.g., aluminum foil) is prepared 402 and/or supplied, an adhesive layer is applied 404 to the aluminum layer, a polymer layer is applied 406 to the adhesive layer. Optionally, the polymer layer may be applied as a coating. Optionally, the polymer layer may be laminated onto the aluminum layer and/or adhesive layer. Optionally, the polymer layer may be applied as a polymer film which may adhere to the aluminum layer and/or adhesive layer. Optionally, the polymer layer may be applied by lamination. Alternatively or additionally, both surfaces of the metal may be coated.

Fig. 5 is a flow chart of a method for manufacturing a hybrid foil tray 500, in accordance with some embodiments. For example, in method 400, a metal layer (e.g., Aluminum) is prepared 402 and/or supplied, an adhesive layer is applied 404 to the aluminum layer, a polymer layer is applied 406 either to the adhesive layer. Optionally, the polymer layer may be applied as a coating. Optionally, the polymer layer may be laminated onto the adhesive layer. Optionally, the polymer layer may be applied as a polymer film which may adhere to the aluminum layer and/or adhesive layer. Optionally, the polymer layer may be applied by lamination. In some embodiments, the hybrid foil is stamped 508 into a tray and/or another food vessel. For example, the inner surface of the tray may be the polymer and/or the outer surface and/or both.

Fig. 6 is a flow chart of a method for manufacturing a hybrid foil, in accordance with some embodiments. For example, in method 600, a metal layer (e.g., aluminum foil) is prepared 602 and/or supplied, a polymer layer is applied 606 directly onto the aluminum sheet. Optionally, the polymer layer may be applied as a coating. Optionally, the polymer layer may be laminated onto the aluminum layer. Optionally, the polymer layer may be applied as a polymer film which may adhere to the aluminum layer. Optionally, the polymer layer may be applied by lamination. Alternatively or additionally, both surfaces of the metal may be coated.

Fig. 7 is a flow chart of a method for manufacturing a hybrid foil tray, in accordance with some embodiments. For example, in method 700, a metal layer (e.g., Aluminum) is prepared 602 and/or supplied, a polymer layer is applied 606 directly onto the aluminum sheet. Optionally, the polymer layer may be applied as a coating. Optionally, the polymer layer may be laminated onto the aluminum layer. Optionally, the polymer layer may be applied as a polymer film which may adhere to the aluminum layer. Optionally, the polymer layer may be applied by lamination. In some embodiments, the hybrid foil is stamped 708 into a tray and/or another food vessel. For example, the inner surface of the tray may be the polymer and/or the outer surface and/or both.

Fig. 8: A block diagram of a hybrid tray 800, in accordance with some embodiments. Optionally the tray includes a metal base layer 302. For example, the metal layer may include Aluminum and/or characteristics as described in any of the embodiments herein above. Optionally an outer surface 801 of the tray may be a surface of the metal layer 302. Optionally the tray includes a polymer layer 306. For example, the polymer layer may include material and/or characteristics as described in any of the embodiments herein above. Optionally an inner surface 803 of the tray may be coated by the layer 306. Alternatively or additionally, both and inner and outer surface 801, 803 of the tray 800 may be coated with polymer.

Fig. 9: A block diagram of a hybrid tray 900, in accordance with some embodiments. Optionally the tray includes a metal base layer 302. For example, the metal layer may include Aluminum and/or characteristics as described in any of the embodiments herein above. Optionally an outer surface 901 of the tray may be a surface of the metal layer 302. Optionally the tray includes a polymer layer 306. For example, the polymer layer may include material and/or characteristics as described in any of the embodiments herein above. Optionally an inner surface 903 of the tray may be coated by the layer 306. Optionally an adhesive layer 304 may be sandwiched between the metal layer 302 and the polymer layer 306. Alternatively or additionally, both and inner and outer surface 901, 903 of the tray 800 may be coated with polymer.

These embodiments are provided by way of example and are in no means intended to be limiting the scope of the invention.

While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.

GENERAL Implementation of the method and/or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of embodiments of the method and/or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof using an operating system.

For example, hardware for performing selected tasks according to embodiments of the invention could be implemented as a chip or a circuit. As software, selected tasks according to embodiments of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In an exemplary embodiment of the invention, one or more tasks according to exemplary embodiments of method and/or system as described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions. Optionally, the data processor includes a volatile memory for storing instructions and/or data and/or a non-volatile storage, for example, a magnetic harddisk and/or removable media, for storing instructions and/or data. Optionally, a network connection is provided as well. A display and/or a user input device such as a keyboard or mouse are optionally provided as well.

It is expected that during the life of a patent maturing from this application many relevant building technologies, artificial intelligence methodologies, computer user interfaces, image capture devices will be developed and the scope of the terms for design elements, analysis routines, user devices is intended to include all such new technologies a priori.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein may be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

As used herein the term “about” refers to ± 10%

The terms "comprises", "comprising", "includes", "including", “having” and their conjugates mean "including but not limited to". The term “consisting of’ means “including and limited to”.

The term "consisting essentially of means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

As used herein, the singular form "a", "an" and "the" include plural references unless the context clearly dictates otherwise.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. The phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

All publications, patents and patent applications mentioned in this specification are herein incorporated in their entirety by reference into the specification, to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated herein by reference. In addition, citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting.

Claims

CLAIMS What is claimed is:

1. A hybrid foil comprising an aluminum layer with at least one additional layer applied thereto.

2. The hybrid foil of claim 1, wherein the at least one additional layer includes a polymer layer.

3. The hybrid foil of claim 1, further comprising an adhesive layer between the aluminum layer and the at least one additional layer.

4. The hybrid foil of claim 1, wherein the aluminum layer has a thickness in a range between about 10 pm to about 75 pm.

5. The hybrid foil of claim 1, wherein the aluminum layer has a matte side and a bright side.

6. The hybrid foil of claim 5, wherein the at least one additional layer is applied to the matte side of the aluminum layer.

7. The hybrid foil of claim 2, wherein the polymer layer is at least partially opaque .

8. The hybrid foil of claim 2, wherein the polymer layer has a thickness in a between 5 pm to about 50 pm.

9. The hybrid foil of claim 2, wherein the polymer layer can withstand temperatures between about 200 °C to about 500 °C.

10. The hybrid foil of claim 2, wherein the polymer layer comprises a white polyester.

11. The hybrid foil of claim 2, wherein the polymer layer is nylon.

12. The hybrid foil of claim 1, wherein the additional layer includes a non-stick substance.

13. The hybrid foil of claim 12, wherein the non-stick substance is silicone.

14. The hybrid foil of claim 3, wherein the adhesive layer has a thickness in a range between about 1 pm to about 5 pm.

15. The hybrid foil of claim 3, wherein the adhesive layer can withstand temperatures between about 200 °C to about 500 °C.

16. The hybrid foil of claim 1, wherein the hybrid foil is shaped into a tray.

17. A method of manufacturing a hybrid foil, the method comprising: preparing an aluminum layer; and applying a polymer layer onto the aluminum layer.

18. The method of claim 17, further comprising applying an adhesive layer between the aluminum layer and the polymer layer.

19. The method of claim 17 or claim 18, wherein the applying is to a matte side of the aluminum layer.

20. A method of manufacturing a hybrid baking tray, the method comprising: preparing an aluminum layer; applying a polymer layer onto the aluminum layer to form a hybrid foil; and stamping the hybrid foil into a tray.

21. The method of claim 20, further comprising applying an adhesive layer between the aluminum layer and the polymer layer.

22. The method of claim 20 or claim 21, wherein the applying is to a matte side of the aluminum layer.