Note: Descriptions are shown in the official language in which they were submitted.
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INSULATED PACKAGES FOR MICROWAVEABLE FOODS
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No.
60/626,659, filed November 10, 2004, and U.S. Provisi onal Application No.
60/628,703, filed November 17, 2004, both of which are incorporated by
reference
in their entirety.
BACKGROUND
Microwave ovens have become a principle form of cooking food in a rapid
and effective manner. As a result, the number of food items and packages
available for use with a microwave oven is increasing. There is always a need
for
improved materials, blanks, and packages.
SUMMARY
Various packages for heating a food item in a microwave oven are
disclosed. In one aspect, a package according to the present invention
includes a
susceptor, a thermal insulating material, and anoptional support. Qther
aspects,
features, and advantages of the present invention will become apparent from
the
following description and accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The description refers to the accompanying drawings in which like
reference characters refer to like parts throughout the several views, and in
which:
FIG. 1 depicts an exemplary package including a susceptor sleeve and a
thermal insulating shell in accordance with the present invention;
FIG. 2 depicts the package of FIG. 1 in an upright position with a food
item contained therein;
FIG. 3 depicts an exemplary blank for preparing the package of FIGS. 1
and 2;
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FIG. 4 depicts the package of FIGS. 1 and 2 in a partially opened
condition;
FIG. 5 depicts an exemplary package including a susceptor sleeve and a
thermal insulating shell formed from a corrugated material in accordance with
the
present invention;
FIG. 6 depicts an exemplary package including a susceptor sleeve and a
thermal insulating sheath in accordance with the present invention;
FIG. 7 depicts an exemplary package including a semi-rigid susceptor
sleeve and a thermal insulating material applied thereto in accordance with
the
present invention;
FIG. 8 depicts an exemplary blank for forming the package of FIG. 7;
FIG. 9 depicts the package of FIG. 7 with a closed bottom panel;
FIG. 10 depicts an alternate view of the package of FIG. 9;
FIG. 11 depicts an exemplary blank that may be used to form a package
having two locking ends according to the present invention;
FIG. 12 depicts an exemplary package having a double flap construction at
one end in accordance with the present invention;
FIG. 13 depicts an exemplary package including a susceptor sleeve formed
from a thermal insulating corrugated material in accordance with the present
invention;
FIG. 14 depicts an exemplary package including a susceptor sleeve formed
from a thermal insulating bubble material in accordance with the present
invention;
FIG. 15 depicts the various layers of an exemplary susceptor used in the
exemplary package of FIG. 14;
FIG. 16 depicts an exemplary package including a susceptor sleeve formed
from a thermal insulating foam in accordance with the present invention;
FIG. 17 depicts the various layers of an exemplary susceptor used in the
exemplary package of FIG. 16;
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FIG. 18 depicts an exemplary package including a susceptor sleeve formed
from a thermal insulating bubble material, and without a paper layer, in
accordance with the present invention;
FIG. 19 depicts an exemplary package including a sleeve formed from
multiple layers of nylon film and nylon strips in accordance with the present
invention;
FIG. 20 depicts a food item cooked in the exemplary package of FIG. 14;
and
FIG. 21 depicts a food item cooked in the exemplary package of FIG. 18.
DETAILED DESCRIPTION
The present invention generally relates to a package for cooking food item
in a microwave oven. The food item may be provided to the consumer pre-
inserted into the package, or may be provided separately from the package. The
package includes a susceptor that provides effective heating and/or browning
of
the food item, a thermal insulating material (also referred to herein as
"insulating
material") that provides a surface for safe and comfortable handling by a
consumer, and an optional support for the susceptor. In some aspects of the
present invention, the insulating material may serve as the support for the
susceptor. The package additionally includes features that enable the consumer
to
consuine the food item "on the go", without the need for transferring the food
item
to another utensil.
Susceptor
The susceptor of the present invention comprises a microwave energy
interactive material deposited on or supported by a substrate. Depending on
the
microwave energy interactive material selected and its positioning in the
packaging, the susceptor may absorb microwave energy, transmit microwave
energy, or reflect microwave energy as desired for a particular food item.
When
the food item is placed inside the package, the microwave energy interactive
material may be in proximate contact with the surface of the food item,
intimate
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contact with the food item, or a combination thereof, as needed to achieve the
desired cooking results.
The microwave energy interactive material may comprise an
electroconductive or semiconductive material. According to one aspect of the
present invention, the microwave energy interactive material may comprise a
metal or a metal alloy provided as a metal foil; a vacuum deposited metal or
metal
alloy; or a metallic ink, an organic ink, an inorganic ink, a metallic paste,
an
organic paste, an inorganic paste, or any combination thereof. Examples of
metals
and metal alloys that may be suitable for use with the present invention
include,
but are not limited to, aluminum, chromium, copper, inconel alloys (nickel-
chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless
steel, tin, titanium, tungsten, and any combination thereof.
While metals are inexpensive and easy to obtain in both vacuum deposited
or foil forms, metals may not be suitable for every application. For example,
in
high vacuum deposited thickness and in foil form, metals are opaque to visible
light and may not be suitable for forming a clear microwave package or
component. Further, the interactive properties of such vacuum deposited metals
for heating often are limited to heating for narrow ranges of heat flux and
temperature. Such materials therefore may not be optimal for heating,
browning,
and crisping all food items. Additionally, for field management uses, metal
foils
and vacuum deposited coatings can be difficult to handle and design into
packages, and can lead to arcing at small defects in the structure.
Thus, according to another aspect of the present invention, the microwave
interactive energy material may comprise a metal oxide. Examples of metal
oxides that may be suitable for use with the present invention include, but
are not
limited to, oxides of aluminum, iron, and tin, used in conjunction with an
electrically conductive material where needed. Another example of a metal
oxide
that may be suitable for use with the present invention is indium tin oxide
(ITO).
ITO can be used as a microwave energy interactive material to provide a
heating
effect, a shielding effect, or a combination thereof. To form the susceptor,
ITO
typically is sputtered onto a clear polymeric film. The sputtering process
typically
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occurs at a lower temperature than the evaporative deposition process used for
metal deposition. ITO has a more uniform crystal structure and, therefore, is
clear
at most coating thicknesses. Additionally, ITO can be used for either heating
or
field management effects. ITO also may have fewer defects than metals, thereby
making thick coatings of ITO more suitable for field management than thick
coatings of metals, such as aluminum. Alternatively, the microwave energy
interactive material may comprise a suitable electroconductive,
semiconductive, or
non-conductive artificial dielectric or ferroelectric. Artificial dielectrics
comprise
conductive, subdivided material in a polymeric or other suitable matrix or
binder,
and may include flakes of an electroconductive metal, for example, aluminum.
The substrate used in accordance with the present invention typically
comprises an electrical insulator, for example, a polymeric film. The
thickness of
the film may typically be from about 40 to about 55 gauge. In one aspect, the
thickness of the film is from about 43 to about 52 gauge. In another aspect,
the
thickness of the film is from about 45 to about 50 gauge. In still another
aspect,
the thickness of the film is about 48 gauge. Examples of polymeric films that
may
be suitable include, but are not limited to, polyolefins, polyesters,
polyamides,
polyimides, polysulfones, polyether ketones, cellophanes, or any combination
thereof. Other non-conducting substrate materials such as paper and paper
laminates, metal oxides, silicates, cellulosics, or any combination thereof,
may
also be used.
According to one aspect of the present invention, the polymeric film may
comprise polyethylene terephthalate. Exainples of polyethylene terephthalate
film
that may be suitable for use as the substrate include, but are not limited to,
Melinex , commercially available from DuPont Teijan Films (Hopewell,
Virginia), and SKYROL, commercially available from SKC, Inc. (Covington,
Georgia). Polyethylene terephthalate films are used in commercially available
susceptors, for example, the QWIK WAVE Focus susceptor and the MICRO-
RITE susceptor, both available from Graphic Packaging International
(Marietta,
Georgia).
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According to another aspect of the present invention, the polymeric film
may be selected to provide a water barrier, oxygen barrier, or a combination
thereof to the susceptor. This "barrier susceptor" may be used in combination
with gas flushing using carbon dioxide or nitrogen to provide an extended
shelf
life product for refrigerated, shelf stable, or frozen foods. The barrier
susceptor
may be used to form a package that stores the product from the time of
manufacture and shipping, through the cooking process, and during consumption.
Any suitable film may be used to form a susceptor in accordance with the
present
invention including, but not limited to, ethylene vinyl alcohol, barrier
nylon,
polyvinylidene chloride, barrier fluoropolymer, nylon 6, nylon 66, silicon
oxide
coated film, or any combination thereof. Additional examples barrier materials
that may be suitable are provided in U.S. Patent Application Serial No.
10/954,435, incorporated by reference herein in its entirety.
The microwave energy interactive material may be applied to the substrate
in any suitable manner, and in some instances, the microwave energy
interactive
material is printed on, extruded onto, sputtered onto, evaporated on, or
laminated
to the substrate. The microwave energy interactive material may be applied to
the
substrate in any pattern, and using any technique, to achieve the desired
heating
effect of the food item. For example, the microwave energy interactive
material
may be provided as a continuous or discontinuous layer or coating, circles,
loops,
hexagons, islands, squares, rectangles, octagons, and so forth. Examples of
alternative patterns and methods that may be suitable for use with the present
invention are provided in U.S. Patent Nos. 6,765,182; 6,717,121; 6,677,563;
6,552,315; 6,455,827; 6,433,322; 6,414,290; 6,251,451; 6,204,492; 6,150,646;
6,114,679; 5,800,724; 5,759,422; 5,672,407; 5,628,921; 5,519,195; 5,424,517;
5,410,135; 5,354,973; 5,340,436; 5,266,386; 5,260,537; 5221,419; 5,213,902;
5,117,078; 5,039,364; 4,963,424; 4,936,935; 4,865,921; 4,890,439; 4,775,771;
and
Re. 34,683; each of which is incorporated by reference herein in its entirety.
Although particular examples of the microwave energy interactive material are
shown and described herein, it should be understood that other patterns of
microwave energy interactive material are contemplated by the present
invention.
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According to yet another aspect of the present invention, the susceptor
optionally is laminated to a support. The support may comprise a partial or
complete layer of the susceptor. The support may be formed from paper,
paperboard, a low shrink polymer, or any other suitable material. Thus, for
example, a metallized polymer film may be laminated to a paper, for example, a
kraft paper, or alternatively, a low shrink polymer film, for example, a cast
nylon 6
or nylon 6,6 film, or a coextruded film containing such polymers. One such
material that may be suitable for use with the present invention is DARTEK,
commercially available from DuPont Canada. Where the support is paper, the
support may have a basis weight of about 15 to about 30 lbs/ream. In one
aspect,
the paper support as a basis weight of about 20 to about 30 lbs/ream. In
another
aspect, the paper support has a basis weight of about 25 lbs/ream. Where the
support is paperboard, the support may have a thickness of about 8 to about 20
mils. In one aspect, the paperboard support has a thickness of about 10 to
about
18 mils. In another aspect, the paperboard support has a thickness of about 13
mils.
If desired, the support may be coated or laminated with other materials to
impart other properties, such as absorbency, repellency, opacity, color,
printability, stiffness, or cushioning. Absorbent susceptors are described in
U.S.
Provisional Patent Application No. 60/604,637, filed August 25, 2004, and U.S.
Patent Application No. , to Middleton, et al., titled "Absorbent Microwave
Interactive Packaging", filed August 25, 2005, both of which are incorporated
herein by reference in its entirety. Additionally, the support may include
graphics
or indicia printed thereon. Where no additional support is present, the
insulating
material may act as a support for the susceptor, may be in direct contact with
the
susceptor, and/or may be affixed thereto thermally, adhesively, mechanically,
or
any combination thereof, as is shown and described herein.
Insulating Material
The thermal insulating material of the present invention comprises any
flexible, substantially flexible, substantially rigid, or rigid material that
minimizes
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the heat flux from the hot food item to the exterior of the package. As a
result, the
insulating material protects the consumer from contact with the heat generated
during the cooking process. Typically, the insulating material provides a
surface
that is "cool to the touch", referring to a surface temperature of less than
from
about 130 F to about 140 F.
Various insulating materials are contemplated by the present invention
including, but not limited to, extruded polymers, injection molded polymers,
thermoformed polymers, polymeric foams, bubble material, paperboard,
paperboard laminates, cardboard, laminated molded pulp, single side fluted
board,
double side fluted board, corrugated board, or any combination thereof. If
desired,
the insulating material may be coated or laminated with other materials to
impart
various properties, such as absorbency, repellency, opacity, color,
printability,
stiffness, or cushioning. Additionally, the insulating material may include
graphics or indicia printed thereon.
The insulating material typically is positioned exterior to the susceptor, and
distal from the food item. The insulating material may be the outermost layer
of
the packaging and may be in direct contact with the hand of the user.
Alternatively, the insulating material may not be the outermost layer of the
packaging and may not be in direct contact witli the hand of the user.
Alternatively still, the insulating material may not be the outermost layer of
the
packaging and may be in direct contact with the hand of the user. For example,
where the insulating material serves as the support for the susceptor, all or
a
portion of the insulating material may be in direct contact with the food
item, and
all or a portion of the insulating material may be in direct contact with the
hand of
the user.
Additionally, the insulating material may be provided as various shapes and
configurations. For example, the insulating material may form a shell into
which
all or a portion of the susceptor is placed. Alternatively, the insulating
material
may form a sleeve into which all or a portion of the susceptor is placed.
Alternatively, still, the insulating material may be applied to an otherwise
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supported susceptor to provide one or more insulated regions in the package
into
which the susceptor material is placed.
Furthermore, the insulating material may be provided as a separate
construct from the susceptor. For example, the insulating material may be
provided as a pouch into which a susceptor material is inserted by the user.
The
insulating material may alternatively be provided as unitary construct in
which the
components are joined together by adhesive bonding, thermal bonding,
mechanical bonding, mechanical fastening, or by any other method technique, or
by any combination thereof, prior to use by the consumer.
According to one aspect of the present invention, the overall dimensions of
the insulating material are substantially equal to the overall dimensions of
the
susceptor so that the entire surface of the susceptor is enclosed by the
insulating
material. According to another aspect of the present invention, the overall
dimensions of the insulating material are less than the overall dimensions of
the
susceptor, so that the insulating material covers only a portion or portions
of the
susceptor. In some instances, the insulating material may be positioned to
correspond to the locations that a user typically would contact when handling
the
packaged food item. Thus, for example, the insulating material may be present
to
cover the bottom edge and some lower portion of the susceptor. Further, if
desired, the insulating material may serve as the support for the susceptor,
as is
shown and described herein.
It should be understood that while various exemplary arrangements and
configurations are provided herein, numerous other arrangements and
configurations are contemplated by the present invention.
Bubble Material
According to one aspect of the present invention, the insulating material
comprises a flexible bubble packing material, for example, BUBBLE WRAP ,
commercially available from Sealed Air Corporation (Saddle Brook, New Jersey).
Various other flexible bubble packing materials are commercially available,
and
their use is contemplated hereby.
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Bubble materials typically comprise two layers of flexible film. Bubbles
are thermally formed in a first layer, which is then attached to a flat second
layer.
Optionally, the second layer also may be formed to include bubbles. In such
instances, the bubbles in the first layer and the bubbles in the second layer
may be
formed in any pattern or configuration, for example staggered or registered,
facing
toward each other or facing away from each other. However, it should be
understood that other bubble materials are contemplated by the present
invention,
including bubble materials having multiple layers with multiple
configurations,
and laminates and alternate constructions thereof.
Typically, a non-raised area is present between the bubbles. According to
one aspect of the present invention, the flat surface of the bubble material
is
positioned in the package proximal to the susceptor. According to another
aspect
of the present invention, the flat surface of the bubble material is
positioned in the
package distal from the susceptor.
If desired, the bubble may be formed in a single ply of flexible film, which
then may be adhered to the exterior surface of the susceptor or optional
support.
Additionally, according to another aspect of the present invention, the
susceptor may be formed by laminating a metallized polymer film directly to a
flexible film or by extrusion coating the metallized surface with a polymer
film.
This highly flexible susceptor then may be used in combination with the bubble
material concepts described herein, thereby obviating the need for a separate
support such as paper for the susceptor. Further still, a transparent package
may
be constructed according to this aspect of the present invention by using ITO
as
the microwave energy interactive material.
According to one aspect of the present invention, the overall dimensions of
the insulating bubble material are substantially equal to the overall
dimensions of
the susceptor, so that the bubble material substantially surrounds the
susceptor. In
this aspect, the bubble material may have a single open end that corresponds
to the
open end of the susceptor. Alternatively, the bubble material may have two
open
ends, one that corresponds to the open end of the susceptor, and one that
corresponds to the closed end of the susceptor distal from the open end of the
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susceptor. Still further, it is contemplated that a bubble material having two
open
ends may be slidably adjusted to position the insulating material in the
location
that the consumer grips the package. In this and other aspects of the present
invention, the bubble material may be affixed to the susceptor or the optional
support if desired. Any suitable method of affixing the bubble material to the
other components may be used, for example, thermal bonding, adhesive bonding,
mechanical bonding, or any combination thereof.
According to another aspect of the present invention, the overall
dimensions of the bubble material are less than the overall dimensions of the
susceptor, so that the bubble material covers only a portion or portions of
the
susceptor. For example, the bubble material may be positioned on the food item
package to provide discrete insulated areas to grip the package when the food
item
contained therein is hot.
If desired, the pattern of bubbles may be modified as needed for a
particular food item. Such a modification might be made, for example, where it
is
desirable to provide some bubbles and the one or two layers of film typically
used
to form the bubble material, but it is not necessary or desirable to have a
continuous pattern of bubbles.
Furthermore, the height of the bubbles may be modified as desired for each
food item. A greater volume of air within the bubble generally corresponds to
greater insulation of the food item. Thus, for a food item that does not
require as
much heat to be prepared, for example, certain sandwich products, it might not
be
necessary to have a thick insulating layer. In contrast, for a food item that
requires
more heat to be prepared, for exainple, a fruit pie, it might be necessary or
desirable to have a thicker insulating layer. In one aspect, the thickness of
the
bubble material is about 1/16 in., 1/8 in., 3/16 in., 1/4 in., 5/16 in., 3/8
in., 1/2 in., or
any thickness therebetween.
The present invention also contemplates using a range of bubble heights
and sizes in the bubble material, so that each package has selectively varying
bubble dimensions. This might be desirable where, for example, the product has
an irregular shape and the product will not fit readily into the product box
with
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other wrapped food items. This might also be desirable where, for example, the
intended use for the food item is an "on the go meal" and it is desirable to
have a
package that conforms to a cup holder in an automobile. In some such
instances,
it might be necessary or desirable to use a larger bubble size on the bottom
portion
of the package to stabilize the package when it is in an upright position. In
contrast, depending on the size of the product, it might be necessary or
desirable to
have a package having a smaller bubble size on the bottom portion of the
package
to enable the package to fit within a cup holder of an automobile. Thus, it
should
be understood that numerous combinations of bubble heights and sizes are
contemplated by the present invention for the purpose of achieving different
package attributes.
If desired, the flexible bubble material may be perforated or apertured in
the non-raised or flattened areas to permit moisture to vent away from the
food
during microwave heating, thereby enhancing the browning and crisping of the
food. According to one aspect of the present invention, the bubble material
includes perforations or apertures that substantially correspond in location
and size
to perforations or apertures in the susceptor. According to another aspect of
the
present invention, the bubble material includes perforations or apertures that
may
or may not correspond to perforations or apertures in the susceptor. According
to
yet another aspect, the bubble material includes perforations or apertures,
and the
susceptor does not.
The flexible bubble wrap may be produced from any flexible,
thennoformable polymer including, but not limited to, ethylene vinyl alcohol
copolymer, polyethylene, polypropylene, nylon, or polyester, or any blend or
copolymer thereof, or any laininated or coextruded multilayer structure
thereof.
According to one aspect of the present invention, the bubble material
comprises a
coextruded barrier film. When used in connection with gas flushing using
carbon
dioxide or nitrogen gas, the package may provide an extended shelf life for
refrigerated, shelf stable, or frozen foods.
If desired, the bubble material may be formed at the point of food
manufacture to eliminate the costs associated with shipping the large volume
of air
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that would otherwise be contained in the bubbles. The method of forming the
bubble material at the point of manufacturing comprises providing flexible
film
roll stock to a machine with inline thermoforming and packaging capabilities,
thermoforming the film into the desired bubble configuration, and bonding the
thermoformed film to, for example, a flat film, a susceptor support, or a
susceptor.
The method also contemplates additional processing steps including, for
example,
placing the food inside the package, drawing a vacuum on the package, flushing
the package, heat sealing the package, and discharging the package. Food
packaging machines of this nature may be provided by, for example, Multivac
Inc.
(Kansas City, Missouri).
Paperboard
According to another aspect of the present invention, the insulating
material comprises paperboard, which may be provided as a "shell". The shell
may be formed from any suitable semi-rigid or rigid paperboard that is capable
of
supporting the susceptor and a food item contained therein. Typically, the
paperboard may have a thickness of about 8 to about 20 mils. In one aspect,
the
paperboard support has a thickness of about 10 to about 18 mils. In another
aspect, the paperboard support has a thickness of about 13 mils. The
paperboard
shell may receive a portion of the susceptor, or may receive substantially the
entire
susceptor. The paperboard shell may be adapted to accommodate different shaped
food items using folds, gussets, pleats, and so forth. If sufficiently rigid,
the
paperboard shell may be used to form a shell that enables the food item to
stand
upright on a surface for easy handling. The paperboard shell may be coated or
laminated with other materials to impart other properties, such as absorbency,
repellency, opacity, color, printability, stiffness, cushioning, or surface
texture.
Further, the paperboard may be bleached. Additionally, the paperboard shell
may
include graphics or indicia printed thereon.
Corrugated Paperboard or Cardboard
According to another aspect of the present invention, the insulating
material comprises a corrugated paperboard or cardboard (collectively
"corrugated
materials"). Corrugated materials may be used to form a partial or complete
shell
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or sheath for the susceptor, may be used as a support for the susceptor, may
be
applied to a portion or portions of an otherwise supported susceptor, or any
combination thereof.
As stated above, corrugated materials may be used in accordance with the
present invention in a variety of manners. According to one aspect, a
corrugated
material is used as the support for a susceptor. In this aspect, the
corrugated
material has overall dimensions that are substantially equal to that of the
susceptor. The food item to be heated is inserted into the package, or sleeve,
for
heating.
According to another aspect of the present invention, a corrugated material
sheath partially receives the susceptor, which is supported by, for example,
paper
or flexible paperboard. In this aspect, the sheath has a first open end for
receiving
the susceptor and, optionally, a second open end distal from the open end of
the
susceptor.
According to yet another aspect of the present invention, a corrugated
material is applied to a supported susceptor to protect the consumer from heat
generated during the cooking process. In this aspect, the corrugated material
may
be applied in any pattern including, but not limited to, a stripe, square,
circle,
rectangle, or any other shape, or any plurality or combination thereof.
Some corrugated materials comprise a flat side and a corrugated side. Such
materials often are referred to as "single faced". Single faced corrugated
materials
that may be suitable for use with the present invention include, but are not
limited
to, flute sizes A, B (47 flutes/linear ft), and E (90 flutes/linear ft). Other
corrugated materials comprise a first flat side, a second flat side, and
corrugated
material therebetween. Such materials often are referred to as "double faced".
Double faced corrugated materials that may be suitable for use with the
present
invention include, but are not limited to, flute sizes B, C, E, and F. The
present
invention contemplates any configuration of these materials in the package.
Thus,
according to one aspect of the present invention, a flat side of a corrugated
material is disposed in a direction towards the susceptor. According to
another
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aspect of the present invention, a corrugated side of a corrugated material is
disposed in a direction towards the susceptor.
Corrugated paperboard and cardboard materials have a longitudinal
direction that runs along the length of the flutes, and a transverse direction
that
runs across the flutes. Corrugated materials may be relatively stiff when the
material is flexed in the longitudinal direction, and relatively flexible when
flexed
in the transverse direction. As such, some packages using corrugated materials
may use fold lines, perforations, gussets, or other structural features to
enable a
product to be inserted into the package.
The corrugated material or cardboard may be coated or laminated with
other materials to impart other properties, such as absorbency, repellency,
opacity,
color, printability, stiffness, cushioning, or surface texture. Further, the
material
may be bleached. Additionally, the material may include graphics or indicia
printed thereon.
Foams
According to another aspect of the present invention, the insulating
material comprises a flexible or semi-rigid, open or closed cell foam. In one
aspect, the thickness of the foam is about 1/16 in., 1/8 in., 3/16 in., 1/4
in., 5/16 in.,
3/8 in., %2 in., or any thickness therebetween. The foam may be formed from
any
natural or synthetic material, for example, a polymeric material. The foam may
be
applied as a spray, a pre-formed material, or may be formed during the
microwave
cooking process. The foam may be used to form a partial or complete shell or
sheath for the susceptor, may be used as a support for the susceptor, may be
applied to a portion or portions of an otherwise supported susceptor, or any
combination thereof.
As stated above, foams may be used in accordance with the present
invention in a variety of manners. According to one aspect of the present
invention, a foam sheath partially receives the susceptor material, which is
supported by, for example, paper or flexible paperboard. In this aspect, the
sheath
has a first open end for receiving the susceptor, and optionally, a second
open end
distal from the open end of the susceptor.
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According to another aspect of the present invention, a foam is used as the
support for a susceptor. In this aspect, the foam has overall dimensions that
are
substantially equal to that of the susceptor.
According to yet another aspect of the present invention, a foam may be
applied to an otherwise supported susceptor to protect the consumer from the
heat
generated during the cooking process. In this aspect, the foam may be applied
in
any pattern including, but not limited to, a stripe, square, circle,
rectangle, any
other shape, or any plurality or combination thereof.
According to another aspect of the present invention, an insulating foam is
formed in situ by applying microwave energy to the package. In this aspect,
the
release of water from the food item or a paper layer may be used to initiate a
chemical reaction or physical change in a polymer layer that results in the
production of a polymer foam on or within the package. The polymer layer may
form the exterior of the package, so that the resulting foam is in contact
with the
hand of the user. Alternatively, the polymer layer may be disposed between
other
layers, so that the change in construction is more subtle to the user.
Examples of polymers that may be used to form a foam layer in situ
include, but are not limited to, low density, medium density, and high density
polyethylene; polypropylene; polyvinyl chloride; polystyrene; polyester;
nylon; or
any combination thereof. A metliod for creating a foam layer from such
polymers
is provided in U.S. Patent No. 4,435,344, incorporated by reference herein in
its
entirety.
There are numerous advantages to producing the insulating material in this
manner. For example, the packaging constructs are reduced in size, thereby
decreasing packaging size and weight, and therefore shipping and
transportation
costs. Additionally, consumers who might otherwise find a packaging construct
to
be excessive might be less likely to do so when the insulating material is
formed in
this manner.
Adhesives
According to another aspect of the present invention, the thermal insulting
material comprises an adhesive. Any adhesive may be used, provided that the
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melting point of the adhesive is above the temperature to which it will be
exposed
before, during, and after the cooking process. The adhesive typically is
applied to
the exterior of the package to form one or more areas for gripping the
package.
Thus, the adhesive may be applied as one or more stripes, circles, rectangles,
squares, diamonds, wavy lines, squiggles, or any combination thereof, or any
other
shape or pattern as desired. The adhesive may be applied using any suitable
technique, such as slot coating, spray coating, roll coating, extrusion, or
any
combination thereof.
Polymers
According to still another aspect of the present invention, the thermal
insulating material comprises a polymer, or combination of polymers. Any
polymer may be used, provided that the melting point of the polymer is above
the
temperature to which it will be exposed before, during, and after the cooking
process. Examples of polymers that may be suitable for use with the present
invention include, but are not limited to, polypropylene, polyethylene, nylon,
and
polyethylene terephthalate.
In one aspect, the polymer is applied to the exterior of the package, for
example, a sleeve. The polymer may be positioned on the exterior of the
package
to provide discrete insulated areas to grip the package when the food item
contained therein is hot.
The polymer may be applied as one or more stripes, circles, rectangles,
squares, diamonds, wavy lines, squiggles, or any combination thereof, or any
other
shape or pattern as desired. It is contemplated that various patterns and
designs
may be used to provide aesthetic benefits in addition to the functional
insulating
benefits. Thus, for instance, a polymer may be applied in a colored or
textured
pattern, to indicate how to handle the product (e.g., an arrow to indicate how
to
handle the product or to indicate which end is up), what the product is (e.g.,
a
sandwich design on a sleeve for a microwave sandwich product, an apple design
for a microwaveable apple pie product, and so forth), or to provide some
aesthetically pleasing visual image (e.g., the sun, flowers, smiley faces,
cars,
sailboats, and so forth).
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In another aspect, the insulating polymer is applied between layers of
material that form the sleeve, shell, or other packaging construct. For
example,
the polymer may be applied in stripes, circles, or otherwise as described
above
between two layers of film, between a layer of film and paper, between a layer
of
film or paper and the susceptor, or in any other manner as desired.
In still another aspect of the present invention, the insulating polymer may
be applied both to the exterior of the package and between various materials
used
to construct the package. In this and other aspects, the polymer may be
applied to
the package or to any of the various components thereof using any suitable
technique, such as slot coating, spray coating, roll coating, extrusion, or
any
combination thereof.
Exemplary Package Constructs
Various package constructs are contemplated by the present invention.
FIGS. 1-20 depict several exemplary constructs that may be formed according to
the present invention. The exemplary constructs have a "sleeve" or "pocket" or
"pouch" configuration and are shown to be a hand-held package. However, it
should be understood that other shapes and configurations are contemplated by
the
present invention. Examples of other shapes encompassed hereby include, but
are
not limited to, polygons, circles, ovals, cylinders, prisms, spheres,
polyhedrons,
and ellipsoids. The shape of the package may be determined largely by the
shape
of the food item, and it should be understood that different packages are
contemplated for different food items, for example, sandwiches, pizzas, French
fries, soft pretzels, pizza bites, cheese sticks, pastries, doughs, and so
forth.
Additionally, it should be understood that the present invention contemplates
packages for single-serving portions and for multiple-serving portions, and is
not
restricted to hand-held packages. It also should be understood that various
components used to form the packages of the present invention may be
interchanged. Thus, while only certain combinations are illustrated herein,
numerous other combinations and configurations are contemplated hereby.
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Turning to FIGS. 1 and 2, a package 10 for a microwaveable food item
100 is provided. The package 10 includes a susceptor in the form of a sleeve
15 in
which the food item 100 is placed for cooking. The sleeve 15 includes an open
end 20 for receiving the food item 100.
The package 10 further includes an insulating shel125 that receives at least
a portion of a susceptor sleeve 15. The shell 25 provides a stable device for
supporting the food item in an upright position (best seen in FIGS. 3 and 4).
The
shell 25 may be provided with a self-supporting base 32 for placing the food
item
on a surface, in the cup holder of a vehicle, and so forth, without causing
the food
item to tip over. The shell 25 may be formed from any suitable rigid or semi-
rigid
material, and in some instances, the shell 25 may be formed from paperboard.
The shell 25 includes an open end 30 and a closed end 35. The closed end
35 may be formed by adhesive bonding, thermal bonding, mechanical bonding,
any combination thereof, or by any other suitable mechanical folding or
locking
mechanism. The open end 30 of the shell 25 may have any suitable shape, and in
some instances, the open end 30 has an arcuate shape. The arcuate shape
permits
the sides of the food item 100 to be supported, while exposing more food item
100
for access by the consumer.
An exemplary construction of the shell 25 and susceptor sleeve 15 of
FIGS. 1 and 2 is provided in FIG. 3. A paperboard blank 40 comprises a front
panel 45, a back panel 50 having the susceptor sleeve 15 attached thereto, a
first
side panel 55, a second side panel 60, and a bottom panel or base 32. The
first
side panel 55 and the second side panel 60 are perforated or scored at lines
70 to
enable folding. The bottom panel 40 includes arcuate perforations or fold
lines
75a and 75b and tabs 80a and 80b. To assemble the package 10, the back panel
50 is brought toward the front panel 45 and folded at fold lines 75. The first
side
pane155 and the second side panel 60 are brought together to form an overlap
and
joined using adhesive. The tabs 80 provide feet for the shell 25 to stand on
when
the package 10 is placed on a surface.
The food item inserted into the sleeve may be heated in a microwave oven
until the product reaches the desired temperature. In some instances, the
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temperature of the surface of food item may be as high as 400 F. However, the
presence of the thermal insulating shell enables the user to remove the item
from
the microwave oven without potential for burns or discomfort.
Turning to FIG. 4, to consume the food item 100, the user can peel the
layers or panels 102a, 102b of the susceptor sleeve 15 apart at seams 80a, 80b
and
pull the layers towards the shell 25. The consumer can confidently handle the
food item 100 without concern about portions of the food item leaking from the
base 32 of the shell 25. Upon reaching the shell 25, the consumer can apply a
gentle pressure to the bottom of the food item 100 disposed within the sleeve
15
inside the shell 25, thereby causing the food item 100 to move upward in a
direction Y toward the open end 30 of the shell 25. Alternatively, if the food
item
100 has sufficiently cooled, the user optionally may remove the remainder of
the
product 100 from the package and consume it.
According to another aspect of the present invention depicted in FIG. 5,
the shell 105 is formed from a corrugated material. The shell 105 may include
an
arcuate front panel 110 and/or an arcuate back panel (not shown).
Additionally,
the base 115 may be arcuate in shape and may include tabs or feet (not shown)
for
supporting the shell 105 when the food item/package is placed on a surface. In
this exemplary construction, the corrugated side of the paperboard is facing
outward from the sleeve 118 in a direction away from the susceptor. It should
be
understood that the corrugated side may alternatively face inward in a
direction
toward the susceptor if desired.
According to another aspect of the present invention depicted in FIG. 6, a
package 120 comprising a susceptor sleeve 130 and a sheath 125 is provided.
The
susceptor sleeve 130 may be formed as above, with sealed side edges 135a and
135b and a sealed bottom edge 140 (not shown). The flexible sheath 130 is
formed from a material having a longitudinal direction Y and a transverse
direction X, for example, a corrugated material. The corrugated material is
folded
over from a side 122 and affixed adhesively or otherwise to the surface of the
sleeve 130 to form the sheath 125. The sheath 125 is flexible in the
transverse
direction X, but semi-rigid to rigid in the transverse direction Y. The sheath
125
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features an open bottom end 145 in addition to an open top end 150. The sheath
125 thus "opens up" to receive the food item (not shown) within the sleeve
130.
The food item (not shown) can be inserted readily into the sleeve 130 without
damaging the packaging or the food item (not shown).
Turning to FIGS. 7-10, another package 155 forme d according to the
present invention is provided. The susceptor shell 160 is formed from a semi-
rigid
or flexible paperboard having the microwave energy interactive material
supported
thereon (not shown). The microwave energy interactive material may be applied
in any pattern as desired, and in some instances, may be substantially
continuous.
The shell 160 includes a front panel 165 and a back panel 170. The front
panel 165 is generally rectangular in shape, and has one end 175 having an
amygdaloidal (almond-shaped) flap 180 extending therefrom. The flap 180 is
formed at a perforation or fold line 185 in the front panel 165. At a portion
of the
flap 180 distal from the perforation or fold line 185, the flap 180 may
include a tab
190. The back panel 170 may include a slot 195 for receiving the tab 190 to
form
a bottom panel 200. The slot 195 may have any suitable shape (depending on the
shape of the tab 190), and in some instances, the slot 195 may be diamond-
shaped.
Upon insertion of the tab 190 into the slot 195, the bottom panel 200 remains
locked during use and fully supports the food item contained therein when the
package 155 is held in a generally upright position.
An exemplary blank 210 for forming the package 155 is provided in FIG.
8. To assemble the package 155, the back panel 170 is brought towards a side
flap
215 so that the susceptor is on the interior of the package 155. The side flap
215 is
tucked under the back panel 170 and adhered thereto using an adhesive or other
suitable method. Flap 180 is then folded towards the back panel 170, and tab
190
is inserted into slot 195. The package 155 remains in a locked position at
this
closed end 200 and open at an open end 225 for receiving the food item (not
shown).
At least a portion of the interior of the front panel 165 or the back panel
175, or both, includes an insulating material 205 applied thereto. The
insulating
material may be a corrugated paper as shown, or may be any other material
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described herein or contemplated hereby. The insulating material 205 typically
may be applied in places on the front panel 165, back panel 170 (not shown),
or
both, where a user would hold the package 155 to consume the food item (not
shown). The insulating material 205 may be applied as a continuous insulating
region or as one or more several separate insulating regions, and may extend
around the susceptor, from the top to the bottom of the susceptor if desired.
According to one aspect of the present invention, an insulating material 205
is
applied to a portion of the exterior of the front panel 165 and to a portion
of the
exterior of the back panel 170 (not shown). Thus, a package is provided that
protects the user from the heat generated during the cooking process, contains
the
food item without leaking, and is conveniently transported from the microwave
to
the user's destination.
Additionally, one or more apertures 210a and 210b may be provided to
assist with venting of the package 155 during cooking. Circular apertures are
shown; however, it should be understood that any shaped aperture may be used
as
desired. The use of apertures to enllance the results of microwave cooking are
described in U.S. Patent No. 4,948,932, incorporated by reference herein it
its
entirety.
According to another aspect of the present invention not shown, the
package may have a front panel comprising a first end flap and a second end
flap,
each of which is adapted to be inserted into a first slot and a second slot in
the
back panel. Thus, according to this aspect, either or both ends may be sealed
during the cooking process and/or for handling of the food item. Thus, a
consumer who, for example, cooks a food item in a microwave oven, is able to
transport the food item from one location to another, e.g., home to work, work
to
home, etc., without concern about the food item dislodging from the package.
FIG. 11 depicts an alternative construction of a package blank 230 that
forms a package capable of closing at each end. The package blank 230
comprises
a front pane1235 including a first end flap 240a and a second end flap 240b,
each
of which includes an arcuate cutout 242a and 242b, respectively, and is
adapted to
be folded toward the interior of the package at arcuate perforations or fold
lines
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245a and 245b. The package blank 230 also includes a back panel 250 including
a
third end flap 255a and a fourth end flap 255b, each of which is adapted to be
folded towards the interior of the package at arcuate perforations or fold
lines
260a and 260b. To assemble the package blank 230 into a package (not shown),
the front pane1235 is folded in a direction towards a side pane1265 that
results in
the susceptor being on the interior of the package. The side flap 265 is
tucked
under the front panel 235 and adhered thereto using an adhesive or any other
suitable method. End flaps 240a and 255a are folded toward one another,
thereby
closing a first end 270. End flaps 240b and 255b are folded toward one
another,
thereby closing a second end 275.
By way of example and not by limitation, FIG. 12 depicts an exemplary
package 280 having the double flap construction described in connection with
FIG. 11 at one end 285 of the package 280. The package further includes an
insulating material 290, in this instance, a corrugated material. An
insulating
material 290 also may be present on the back panel (not shown). Furthermore,
while the package depicted in FIG. 12 includes an insulating material having
the
corrugations facing in a direction away from the susceptor, alternative
constructions in which the corrugations are facing in a direction toward the
susceptor are also contemplated hereby.
According to another aspect of the present invention depicted in two views
in FIG. 13, a package 300 formed from a corrugated material is provided. The
package 300 includes an open end 305 for inserting the food item (not shown)
therein. The susceptor 310 is on the corrugated side of the corrugated
material,
such that the flutes of the corrugated material comprise the susceptor. Thus,
some
of the susceptor 310 is in intimate contact with the food item (not shown),
and
some of the susceptor 310 is in proximate contact with the food item (not
shown).
The flutes 315 on the interior of the package 300 provide the desired
insulating
effect to enable the consumer to handle the package comfortably, and also
channel
moisture generated during the cooking cycle to the open end 305 of the package
300. Thus, this construction additionally improves the browning and crisping
of
the food item.
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An alternate construction of a package 325 of the present invention is
provided in FIG. 14. The package 325 includes an open end 327 and a closed end
329. According to this aspect, a susceptor 330 is laminated to a bubble
material
335. The susceptor comprises a metal 340 deposited on a polyester film 342 and
laminated to a paper 344, as provided in FIG. 15. However, it should be
understood that the susceptor alternatively may include a metal or a metal
alloy
provided as a metal foil; a vacuum deposited metal or metal alloy; or a
metallic
ink, an organic ink, an inorganic ink, a metallic paste, an organic paste, an
inorganic paste, or any combination thereof. The bubble material 335 may be
positioned in a direction towards or away from the susceptor 330. In the
example
depicted in FIG. 14, the bubble material 345 is positioned in a direction away
from the susceptor 330. Additionally, the bubble material 335 substantially
covers
the susceptor 330. However, it should be understood that the bubble material
345
may be applied to any portion of the susceptor 330 as needed to support the
food
item (not shown) contained therein, and to provide sufficient insulation to
protect
the consumer from the hot product.
According to another aspect of the present invention depicted in FIG. 16, a
package 350 for microwave cooking comprises an open end 355 and a closed end
360. The package 350 comprises a susceptor 365 laminated to an foam insulating
material 370. In this exemplary construction, the insulating material 370 is a
closed cell foam; however, open cell foams and other insulating materials
described herein or contemplated hereby may be used. The susceptor 365 is
formed from a metal 375 deposited on a polyester film 380 and laminated to a
paper 385, as shown in FIG. 17. However, it should be understood that the
susceptor alternatively may include a metal or a metal alloy provided as a
metal
foil; a vacuum deposited metal or metal alloy; or a metallic ink, an organic
ink, an
inorganic ink, a metallic paste, an organic paste, an inorganic paste, or any
combination thereof. In the exemplary configuration of FIG. 16, the foam 370
substantially covers the susceptor 365. However, it should be understood that
the
foam 370 may be applied to any portion of the susceptor 365 as needed to
support
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the food item 390 contained therein, and to provide sufficient insulation to
shield
the consumer from the heat generated during the cooking process.
FIG. 18 depicts yet another aspect of the present invention. A package 400
includes an open end 405 and a closed end 410, and is formed from a bubble
material 415 laminated to a metallized polyester film susceptor 420. In this
example, the susceptor 420 does not include a paper layer. Thus, where vacuum
deposited aluminum or other metals are used, the package is a translucent
gray, in
contrast to the more opaque packages typically formed using a paper support.
In
this exemplary configuration, the package 400 substantially covers the food
item
425. However, it should be understood that the package 400 may be designed so
that the bubble material 415 and susceptor 420 only partially cover the food
item
425. In this and other aspects, the configuration of the package will depend
on the
size and shape of the food item contained therein, the desired degree of
browning
and crisping, and the amount of coverage needed to provide sufficient
insulation to
provide for comfortable handling and protect the consumer from the hot
product.
FIG. 19 depicts still another aspect of the present invention. A package or
sleeve 450 includes an open end 455 and a closed end 460, and is formed from a
material comprising two layers of flexible nylon film having nylon insulating
strips 465 laminated therebetween. The nylon film layers are laminated to a
metallized PET film, such that the metallized side of the PET film is
positioned in
a direction away from the food item (not shown). In this aspect, the nylon
strips
act as the insulating material to protect the consumer from the heat generated
during the cooking process. Those of ordinary skill in the art will understand
that
other arrangements of the various layers may be used in the present invention.
For
example, to achieve enhanced browning of the food item, the metallized layer
could be positioned in a direction toward the food item.
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EXAMPLES
In each of the following examples, the efficacy of the package of the
present invention was evaluated for (1) providing the desired heating and
browning effect, and (2) providing the desired thermal insulation so that the
product was cool to the touch upon removal from the microwave oven. In each
example, a Nestle HOT POCKET with a precooked pastry outer shell and
chicken & cheddar filling (4 oz.) was cooked for 2 minutes in a 1999 Panasonic
I100 watt model NNS540-BFW microwave oven (manufactured Sep. 2001) with
a turntable. The products were stored in a non-"frost free" freezer to avoid
cycling
temperatures. The temperature of the food item was monitored to assure a zero
degree start point for product. Prior to each evaluation, the oven was pre-
conditioned for 5 minutes with a 2000 gram water load. Also, the turntable was
cooled to ambient temperature after each test to prevent accumulation of heat.
The
oven was periodically power tested via a standard water heating test to
confirm
performance. Additionally, the oven was on its own separate electrical circuit
to
control line voltage variation from test-to-test.
EXAMPLE 1
The package of FIGS. 1-3 was used to prepare a HOT POCKET brand
sandwich according to the procedure described above. FIG. 4 depicts the
resulting food item. The package was cool to the touch upon removal of the
food
item from the oven. Additionally, the product was sufficiently heated,
crisped,
and browned.
EXAMPLE 2
The package of FIG. 14 was used to prepare a HOT POCKET brand
sandwich from according to the procedure described above. FIG. 20 depicts the
,resulting food item. The package was cool to the touch upon removal of the
food
iterri from the oven. Additionally, the product was sufficiently heated,
crisped,
and browned.
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EXAMPLE 3
The package of FIG. 16 was used to prepare a HOT POCKET brand
sandwich according to the procedure described above. FIG. 16 depicts the
resulting product. The package was cool to the touch upon removal of the food
item from the oven. Additionally, the product was sufficiently heated,
crisped,
and browned.
EXAMPLE 4
The package of FIG. 18 was used to prepare a HOT POCKET brand
sandwich according to the procedure described above. FIG. 21 depicts the
resulting product. The package was cool to the touch upon removal of the food
item from the oven. Additionally, the product was sufficiently heated,
crisped,
and browned.
In sum, the various packages encompassed by the present invention each
include a susceptor, an insulating material, and an optional support. The
packages
of the present invention provide numerous advantages over currently available
food item packages from the time of manufacture through storage, cooking, and
consumption.
First, the present invention contemplates packages for use with single-
serving products or multiple-serving products. Thus, the packages of the
present
invention are readily adaptable for use with a point of sale product.
Additionally,
the package configurations are compatible with high speed packaging equipment.
Further, by selecting the materials to have barrier properties, the packages
of the
present invention may be used with foods that are desired to have a longer
shelf
life.
Furthermore, the packages of the present invention provide superior
heating, browning, and crisping. The packages are sufficiently flexible to
provide
intimate or proximate food contact, thereby permitting the susceptor to remain
in
intimate or proximate contact with irregular and inconsistent food shapes,
including rising dough food formulations, for maximum heat flux from the
susceptor to the food surface. Additionally, various packages of the present
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invention provide features that increase the contact between the susceptor and
the
food item, thereby increasing the rate of heat transfer to the food. Further,
the
packages of the present invention are vented to evacuate moisture, which in
turn
provides even browning and crisping over the entire food item. Additionally,
the
packages of the present invention are adapted readily to include susceptor
technologies, such as the QWIK WAVE Focus Susceptor or the MICRO-RITE
susceptor, that provide and enhance uniform product heating.
The packages of the present invention also offer greater convenience to the
user. The packages feature an insulating material that provides a cool surface
for
handling immediately from the microwave oven. Additionally, the various
packages of the present invention provide features that prevent the food from
leaking from the bottom of the package when held in an upright position.
Furthermore, depending on the materials selected, many of the components offer
an oil and moisture absorbing feature to maintain the quality of the food item
and
prevent accidental drips onto clothing or skin. The packages are also portable
and
convenient to eat from.
Accordingly, it will be readily understood by those persons skilled in the
art that, in view of the above detailed description of the invention, the
present
invention is susceptible of broad utility and application. Many methods,
embodiments, and adaptations of the present invention other than those herein
described, as well as many variations, modifications, and equivalent
arrangements
will be apparent from or reasonably suggested by the present invention and the
above detailed description thereof, without departing from the substance or
scope
of the present invention. Accordingly, while the present invention is
described
herein in detail in relation to specific aspects, it is to be understood that
this
detailed description is only illustrative and exemplary of the present
invention and
is made merely for purposes of providing a full and enabling disclosure of the
present invention. The detailed description set forth herein is not intended
nor is
to be construed to limit the present invention or otherwise to exclude any
such
other embodiments, adaptations, variations, modifications, and equivalent
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arrangements of the present invention, the present invention being limited
solely
by the claims appended hereto and the equivalents thereof.
29
