BACKGROUND ART Various materials have been made with combined layers of material so that the final product exhibits the properties of both layers. No materials exist, however, possessing the unique properties of the present invention, including a very thin material which adsorbs fats, grease and oil, repels water, and is a barrier to grease. Likewise, methods exist for the separating of fats, oils and grease, from a substrate while repelling water. No methods exist with the unique abilities of the present invention to remove fats, grease and oil, repel water and create a barrier to the fats, grease and oil.

Food-grade, polypropylene web material for absorbing fats and repelling water are known in the prior art. U. S. Patent No.

3,764, 527 issued to Sohl on October 9,1973 discloses a method for separating water-immiscible oils and oil-like substances from mixtures including oils in an aqueous medium which comprises contacting the mixture with an oleophilic fibrous web comprising large numbers of interconnected, interstitial spaces for reception and retention of the oil to the exclusion of water. The oleophilic fibrous web may be composed of polypropylene. The method of Sohl is restricted to the removal of water-immiscible oils and oil-like substances from mixtures with an aqueous component, and is not applicable to removing fats, grease and oil from a solid surface.

U. S. Patent Nos. 4,851, 273 and 5,094, 869 issued to Brown, Jr. on July 25,1989 and March 10,1992 disclose an apparatus, and

method, for de-greasing or de-oiling fried foods; the apparatus has an outer protective layer and an inner absorbent layer. The inner absorbent layer may comprise a variety of oil absorbing materials, including conventional ones. The outer protective layer is generally oil permeable, and operates to protect food from direct contact with the absorbent material, and also to disperse heat from the food, which might otherwise inhibit the ability of the absorbent inner material to perform. The preferred outer protective material is a permeable, nonwoven, polypropylene web arrangement having the physical characteristics described. The outer protective layer has a lower capacity for retaining the oil or grease than the inner absorbent layer. A thick pillow-like configuration results with the inner layer being relatively thick and the outer layer, which encompasses both sides of the inner layer, being relatively thin. The protective layer is designed to protect the food from the inner layer, and neither layer is designed for handling by the user to keep grease from getting on their hands. The invention of Brown, Jr. is not suitable as a napkin or paper towel type of utility.

U. S. Patent No. 5,744, 406 issued to Novak on April 28,1998 discloses a device and method for removing any single component or mixture of fats, oils and greases which have been added to or rendered out of an animal or vegetable product during cooking, without removing the water and water soluble flavors and nutrients.

The method utilizes a fabric substrate to remove fats, oils and greases from sauces, gravies, soups and any other cooking product regardless of type of cooking or type of fat, oil or grease. The substrate may be woven or nonwoven and may be food grade materials.

One or two coatings are added to the substrate; the first coating is nonabsorbent for water or soluble salts and a second coating may be provided to prevent the first coating from dissolving and/or dispersing in mixtures of water, salts, fats, oils and greases, etc. The coating materials are typically waxy materials. The fabric may be a material such as polypropylene or polyethylene which is naturally hydrophobic, and would not require the hydrophobic coating. The invention of Novak is useful for removing fats, grease and oils from cooking food; it is not constructed to be used for the consumer to remove fats, grease and oils from the surface of cooked food.

Material or pads that have been designed for absorbing oils and grease in conjunction with microwave cooking or reheating are well known. U. S. Patent No. 4,935, 276 issued to Pawlowski et al. on June 19,1990 discloses a multi-layered absorbent pad for use in vacuum packaging food products and microwave cooking the food products contained therein. U. S. Patent No. 5, 096,722 issued to Bair on March 17,1992 discloses a, package for microwave cooking of food which has a grease-absorbing pad that has a porous spun- bonded polyester outer fabric bonded to a needle-punched nonwoven polyester staple-fiber core layer; the pad serves to absorb and retain liquid fat and grease generated during microwave cooking.

U. S. Patent No. 5,414, 248 issued to Phillips on May 9,1995 shows an insert useful in a microwavable food container comprising a metalized layer of heat susceptor thickness or a plastic layer, having openings which are in a position to be adjacent to food in the container, a layer of absorbent material comprising fibers, and a substrate layer which is stable to microwave heating conditions; the invention also discloses other inserts useful in microwavable food containers having fibers which are capable of spontaneously transporting water or n-decane on the surface thereof. European Patent Application 0 535 451 Al discloses a pad for use in the cooking of food placed thereon in a microwave oven; the pad is made of a multilayer microfiber made by combining at least two streams of flowable polymer materials such as polypropylene and polyethylene terephthalate. None of these inventions are useable as napkins, or the like, for the removal of fats, grease and oil from the surface of food. They are designed to absorb excess grease and fat generated during the microwave cooking process.

U. S. Patent No. 4,587, 154 issued to Hotchkiss et al. on May 6,1986 describes an oil and grease absorbent rinsable nonwoven fabric or web. Useful fibers include polyolefins, especially polypropylene, polyesters, and polyamides. The web is used as a wiper for food service applications where it absorbs and retains oily and greasy materials and rinses out. U. S. Patent No.

5,834, 104 issued to Cordani on November 10,1998 describes a fluid absorption mat which is constructed from non-flammable material for placement beneath fluid leaking machinery. The material is composed of at least one layer of nonwoven fluid absorbing polypropylene that is bonded to at least one fluid impervious

backing sheet such as a polyester or polyethylene by the use of heat sensitive adhesive. The nonwoven absorbent polypropylene sheet has a basis weight of approximately 16 oz. per square yard, and the backing sheet is constructed of approximately 0.57 mils thick polyester. The backing sheet has foam tape attached to secure the mat in place. A coating of non-skid material may be added to the polyester. The inventions of Hotchkiss et al. and Cordani are not useful for food handling but are utilized in cleaning up grease and oil, and catching spills.

None of the above inventions and patents, taken either singularly or in combination, is seen to describe the instant invention as claimed. Thus grease absorbing napkins solving the aforementioned problems is desired.

DISCLOSURE OF THE INVENTION A grease absorbent sheet is disclosed for removing grease, oil and fats from food. The grease absorbent sheet has a first layer and a second layer. The first layer is a flexible sheet of nonwoven grease, oil and fat absorbent thermoplastic polymer having a top surface, a bottom surface, and a peripheral edge. The first layer is permeable to grease, oil and fats in liquid form. The second layer is a flexible, impermeable film. The second layer is bonded to the first layer. Preferably the first layer is polypropylene. Preferably the second layer is made from a thermoplastic material.

Also part of the invention is a method for removing fats, grease and oil from the surface of food. The method includes contacting the surface of the food with a grease absorbing layer of a grease absorbent sheet having a grease absorbing layer and a layer of grease impermeable film. The fat, grease and oil are allowed to wet the grease absorbing material to the exclusion of the aqueous components of the food. The grease absorbing material is then removed from the surface of the food.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a top perspective view of a grease absorbent sheet according to the present invention.

Fig. 2 is a bottom perspective view of a grease absorbent sheet according to the present invention.

Fig. 3 is a section view drawn along lines 3-3 of Fig. 2.

Similar reference characters denote corresponding features consistently throughout the attached drawings.

BEST MODES FOR CARRYING OUT THE INVENTION Fast food restaurants, and restaurants in general, prepare food having too much fat, cholesterol, sugar, and salt content.

Cholesterol and fat, including grease and oils, are undesirable, especially for individuals trying to lose weight or needing to watch their cholesterol levels. There is a need to remove the fats and cholesterol from food served at restaurants and homes.

Although humans get less energy from fat, they store the calories from fat very efficiently. Fat has nine kilocalories per gram which is more than twice the calories derived from carbohydrates and proteins. No convenient method exists for a consumer to remove the undesirable fat and cholesterol from the food prepared by someone else.

The grease absorbent sheet of the present invention fills a void in the materials currently available. Some individuals attempt to remove fats from their food utilizing a conventional paper or cloth napkin without much success. Likewise, this practice is very messy and the consumer generally gets fat, grease and oil all over their hands. A material which can be used as a napkin or in lieu of paper towels which removes the fat, grease and oil from the surface of food is highly desirable. By removing fats, grease and oil from food items, the sheet material of the present invention also helps to reduce the dietary intake of cholesterol.

The present invention is a thin sheet of material which may be used to adsorb excess fats, oils and grease from food. The thin sheet of material is highly adsorbent to fats, grease and oil, repellent to water and a barrier to the fats, grease and oil. The thin sheet of material is utilized to remove fats, grease and oil from the surface of food and protect the consumer's hands from coming into contact with the grease, fat and oil. The sheet material may be formed into napkins, wipes, towel rolls, and other

useful forms for removing fat, grease and oil from the surface of cooked foods. A food item may be folded in between two sheets of the sheet material and pressed to express grease from the food, which is then absorbed and adsorbed by the sheet material.

The sheet is formed from two layers: a first layer of nonwoven, oil absorbent, thermoplastic polymeric material, and a second layer of thin film thermoplastic material laminated, and preferably semi-laminated, thereto. The close approximation of the two layers provides a capillary effect which enhances the lipophilic absorption of grease by the nonwoven layer, while the film layer is impermeable to lipids so that grease, oils and fats do not penetrate one side of the sheet. It is therefore possible to utilize the present invention to form the top surface of a paper plate, having the sheet of nonwoven material exposed to the food placed thereon and the thin film opposite thereto in order to protect the consumer's hands. It will be understood that according to the present invention the term"grease absorbent"refers greases which are lipids naturally occurring in foods and cooking oils or which may be expressed on foods in the food preparation process.

The material of the present invention is fabricated from polymeric materials, specifically, thermoplastic films and fibers.

In the preferred embodiments, the layers of the material are composed entirely of nonwoven polypropylene, and polypropylene or polyethylene film.

The preferred embodiment of the invention is a grease absorbing sheet 10 which has two layers. As shown in Figs. 1 and 3, the first layer 12 is a flexible sheet of nonwoven, grease absorbent thermoplastic polymer, preferably nonwoven polypropylene (although the scope of the invention extends to any other polymer that adsorbs grease, oil, or fats), having a top surface 14, a bottom surface 16 and a peripheral edge 18. According to the present invention, the term nonwoven polypropylene refers to any form of polypropylene-laid nonwoven, including fabrics made by spunbond, meltblown, and textured or apertured film processes. The nonwoven polypropylene be formed by a plurality of short, thin diameter fibers formed into a web by mechanical, chemical or solvent bonding, or textured or apertured film, either of which presents a relatively larger surface area than a smooth sheet, with pores 20 or depressions presenting an extremely thin layer of

fibers which are permeable to lipids for trapping and absorbing lipids. The surface of the nonwoven polypropylene may be textured into, for example, a cross-hatch pattern as shown in Fig. 1, by calendaring. Preferably, the material forming the first layer has a basis weight from approximately 0.5 oz. per square yard to 5 oz. per square yard, preferably 3.0 ounces per square yard, and a thickness between about 0.4 mils and 5 mils. The nonwoven polypropylene fibers have the highly desirable attribute of absorbing grease, fats and oils to the exclusion of water.

. General product specifications for the material of the first layer is shown in the following table. The average weight is a measurement of the fabric expressed in ounces per square yard. The thickness is a measure of the thickness of the media under a specific load of compression and is expressed in mils.

Table : Spun-Bond/Point Bonded Polypropylene Avg. Avg. Mullen Grab Strength: Frazier Nominal Wt. Thick Burst Direct Perm. Micron (O. S. Y. (mils) Rating Machine Mcross. 0.5 4.1 46.0 10.8 6.8 880.0 85 0.8 5.3 50.0 17. 1 11. 9 660.0 50 1.0 7.6 54.0 23.3 16. 9 555.0 40 1.25 10.1 57.0 29.6 22.0 500.0 30 1.5 11.5 61.0 35.9 27.1 420.0 20 2.0 15.1 68.0 48.4 37.3 335.0 12 2.5 16.0 75.0 61.5 48.1 284. 8 9 3.0 18.8 77.0 60.4 52.1 250. 0- The grab strength is a measure of the effective strength of the fabric. In other words, the strength of the fibers in a specific width together with the additional strength contributed by adjacent fibers. The tensile load is applied at the midpoint of the width through one inch wide jaw faces that are used to clamp the fabric. The breaking loads are averages for the nearest pound for both the linear direction and the cross width direction of the

fabric. The mullen burst strength measures the ability of the fabric to resist rupture as a result of pressure added thereto.

The burst strength is expressed in pounds per square inch of fabric. The burst strength measures the ability of the fabric to withstand bursting in spite of the amount of liquid pressure that loads the fabric. The air permeability is a measure of the ease with which air will pass through the fabric. Permeability is measured in cubic feet of air passing through a square foot of fabric in a minute at a given pressure differential across the fabric. Any oil absorbing thermoplastic polymer having these or similar specifications are suitable substitutes for the first sheet of this invention. Optionally, both sides of the first layer may be burned out at high speed to melt any loose fibers thereon, thus keeping fibers from becoming dislodged and sticking to the food.

The second layer 22, as shown in Figs. 2 and 3, is an impermeable, flexible film approximately 0.5 mils to 3 mils thick.

The film is taken from the group consisting of high density polypropylene, low density polypropylene, high density polyethylene, and low density polyethylene. The film is impermeable and serves to keep the grease, fat and oils from exuding through the napkin and onto the hands of the consumer, or from staining tablecloths and the like. The first and second layers may be in a sterilized or food grade form which meet the requirements of the FDA and the USDA for food grade materials.

Although the two layers 12 and 22 could be fully laminated by cohering or adhering the entire face of each layer together, preferably the film 22 is"semi-laminated"to the bottom surface 16 of the sheet 12 of nonwoven oil absorbent thermoplastic polymer by a bonding means. In order to form a semi-laminate structure, the layers may be bonded together in narrow strips, as depicted by the lines 24 in Fig. 2, at the edges of the respective layers and/or at discrete, discontinuous intervals, as depicted by the lines 26 in Fig. 2, across the width of the layers forming a bonding pattern. The semi-laminating process, of the preferred embodiments, is analogous to the method disclosed in my patent, U. S. Patent No. 5,958, 805 issued on September 28,1999, which is incorporated herein by reference. The bonding means is taken from the group consisting of point welding, heat bonding, ultrasonic bonding, and adhesive bonding. The bonding is in narrow continuous

strips, and in discrete, discontinuous intervals across the first and second layers between the edges and defining spaces therebetween. Alternatively, the bonding pattern may be along and around the peripheral edge of the napkin. Alternatively, the layers may be point bonded together in such a fashion as to create a design thereon. Such designs are common and are found on many paper napkins and paper towel products.

As shown in Fig. 3, semi-lamination of the two layers 12 and 22 defines narrow gaps 28 between the layers. The spaces 28 between the two layers 12 and 22 resulting from the semi-lamination process permit a capillary effect in the napkin that pulls liquid fat, grease and oils by a capillary action. Such fat, grease and oil are pulled strongly through the pores 20 in the first layer 12, into the gaps or spaces 28 between the first 12 and second 22 layers, thus trapping the fat, grease and oil between the first and second layers.

The first and/or second layers may be colored, or the film layer 22 may be transparent. The coloring includes having a design imprinted thereon. The two layers once bonded may be cut and folded to make a traditional napkin. The invention herein may be perforated and rolled onto a roll to form a paper towel-like embodiment. Alternatively, the two layers may be delivered on separate rolls, semi-laminated together, and then cut into the desired size pieces with a heating device which serves to heat-seal the two layers about the edges.

A method for removing fats, grease and oil from the surface of food is also included in the present invention. The method includes the steps of contacting the surface of the food with a grease absorbing napkin, allowing the fat, grease and oil to wet the grease absorbing napkin to the exclusion of the aqueous components of the food, and removing the grease absorbing napkin from the surface of the food. The grease absorbing napkin disclosed herein is ideal for removing fats, grease and oil from the surface of food as disclosed herein.

The preferred embodiments of the invention provide a thin sheet of material which may be utilized as a napkin, towel, wipe, and the like which is used to remove grease, fats and oil from the surface of cooked food by contacting the material with the food.

The sheet of material has a first surface for absorbing grease,

oils and fats from foods, and a second surface which is impermeable to lipids. The thin sheet of material has a lipophilic surface made from two layers which are not fully laminated to each other so that the adsorption of grease is enhanced by a capillary effect between lipids and the two layers of the sheet. The sheet provides an easy method of removing the fat, grease and oils from the surface of foods without removing the moisture (water) from the food.

It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.