Note: Descriptions are shown in the official language in which they were submitted.
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FIELD OF THE INVENTION
The present invention relates generally to containers and packaging for food
items.
More specifically, the invention relates to containers and packages for liquid
based food
items that separate ingredients of the food item.
BACKGROUND
Traditionally, soup and other related liquid-based food items are either home
made or
processed and packaged by commercial preparers of such products. Home made
soups may
provide the most natural and appealing taste, particularly since they can
include selected
ingredients and seasonings to suit individual preferences. Preparing home made
soups,
however, can require a substantial amount of time. For example, particulates,
such as
vegetables and meat items, must be prepared, which may involve washing and
cutting
vegetables and meats. The vegetable and meat ingredients are added to water or
a broth,
which can include seasonings and flavorings, such as salt, pepper, sugar,
garlic and onion,
etc. These seasonings can also be added to water. The ingredients are then
heated and
served. Packaged, processed, ready-to-eat soups have become very popular since
they are
convenient and can be quickly and easily prepared compared to home made soups.
A typical
can of processed soup includes a mixture of various ingredients, including a
broth or a liquid
stock, particulates such as meats and vegetables in different combinations,
and seasonings,
including salt. In use, a consumer opens the can, empties the contents of the
can into a pan or
bowl, and heats the soup over a range or in a microwave oven.
The manner of making processed soups is well known. Typically, they are made
by
metering a predetermined quantity of an ingredient or mixture of selected
ingredients, which
are combined and mixed in a can. A lid is placed on the can and the lid and
the can are
sealed together. The sealed can is sterilized and pressurized and prepared for
storage or
distribution. Sterilization involves exposing the can of soup to temperatures
from about
240 F to about 265 F for about 12-60 minutes depending on the container size,
soup
thickness and rate of agitation. Sterilization issues are of particular
concern with the meat
and vegetable ingredients within the mixture because they may contain
pathogens, which
must be rendered commercially sterile for shelf stability or pasteurized in
the case of
refrigerated distribution. The heat source must be applied for a sufficient
amount of time so
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that the thermal center of the food in the container achieves commercial
sterility or
pasteurization.
Processed soups typically have relatively large quantities of salt (sodium
chloride),
which is the main source of sodium in foods. Large quantities of salt are
typically used to
provide a sufficient flavor impact to a consumer. Sodium is carried in the
broth, and over
time, the sodium diffuses or migrates from the broth into particulates, such
as meats and
vegetables. This "sodium diffusion" typically occurs during processing or
distribution of the
prepared soups (e.g., sterilization, pressurization, freezing, refrigeration,
storage and
distribution). Thus, a commercial preparer of soups must add enough salt to
the can to
compensate for sodium diffusion so that a desired flavor impact is achieved.
Although a
package soup delivers an adequate salt content, it contains salt levels that
are typically higher
than those considered healthy for consumers.
Home made soups and other liquid-based food items, such as stews, on the other
hand, typically do not these high quantities of salt since the salt is mostly
concentrated in the
surrounding broth. Thus, home made soups and stews taste fresher and healthier
and have
lower salt contents compared to processed food items, while still providing
desirable flavor
impact.
High sodium contents may cause various health problems, particularly
considering
United States Department of Agriculture (USDA) recommendations and that it is
generally
accepted that high sodium diets can contribute to health problems, such as
high blood
pressure. For example, a single can of certain processed "Chunky" brand soups
available
from Campbell Soup Company has about 1,800 mg of sodium, or 900 mg per
serving. The
USDA recommends that the amount of salt consumed on a daily basis not exceed
2,400 mg.
Thus, a single can of processed, ready-to-eat soup almost meets the
recommended daily
allowance of sodium.
Attempts have been made to reduce sodium content by reducing the quantity of
salt
that is added to a can of soup. While the objective is on the right track, the
taste of the
resulting processed soup may not be satisfactory since the reduced amount of
salt is absorbed
by the particulates and does not provide sufficient salt flavor.
Processed soups and other liquid-based food items, therefore, can be improved.
Soups can be made to deliver a more natural, home-cooked taste by providing a
naturally
occurring flavor gradient so that sodium does not diffuse into particulates.
In other words, it
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is desirable that salt remains in the surrounding broth and is added to the
particulates when
the soup is prepared. The amount of salt and sodium that is added to processed
foods should
also be reduced to provide a healthier food item, while not sacrificing taste.
Reducing the
amount of sodium in processed soups can contribute to healthier diets.
Further, processed soups can be prepared and processed more efficiently. Known
sterilization steps must apply heat to a can of soup for a sufficient amount
of time to ensure
mass average sterilization and/or thermal center sterilization or
pasteurization of the soup
mixture, particularly the meat and vegetable particulates. The time required
for the middle
sections of the soup mixture to be heated can be reduced while still achieving
the desired
sterilization, thereby maximizing nutrient retention, color, flavor and other
quality attributes,
while processing soup products in a more efficient manner.
Accordingly, there exists a need for improved and healthier processed soup
products
and other liquid based food items that have reduced salt and sodium contents,
have
acceptable flavor impact, and that can be processed more efficiently than
known processed
soup products and liquid-based food items.
SUMMARY
According to one embodiment, a segmented pouch for a liquid-based food item
includes a flexible outer pouch, a flexible inner pouch, and a seal. The
flexible inner pouch is
disposed within the flexible outer pouch so that an inner surface of the
flexible inner pouch at
least partially defines an inner cavity, and an outer surface of the flexible
inner pouch and an
inner surface of the flexible outer pouch define an outer cavity. The seal
extends across tops
of the flexible inner and outer pouches and closes the inner and outer
cavities. The inner
cavity can be filled with a liquid and a seasoning and the outer cavity can be
filled with
particulates so that the seasoning and the particulates are separated from
each other. When
the seal is removed or broken to open the segmented pouch, the liquid, the
seasoning, and the
particulates are pourable from their respective inner and outer cavities in a
single motion.
According to another embodiment, a segmented pouch for a liquid-based food
item
includes a flexible plastic outer pouch, a flexible plastic inner pouch, and a
seal. The flexible
plastic outer pouch includes a gusseted bottom surface that enables the
segmented pouch to
stand upright. The flexible plastic inner pouch is disposed within the
flexible outer pouch so
that an inner surface of the flexible plastic inner pouch at least partially
defines an inner
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cavity, and an outer surface of the flexible plastic inner pouch and an inner
surface of the
flexible plastic outer pouch define an outer cavity. The seal extends across
tops of the
flexible plastic inner and outer pouches and closes the inner and outer
cavities. The inner
cavity can be filled with a seasoning and a liquid and the outer cavity can be
filled with
particulates so that the seasoning and the particulates are separated from
each other. When
the seal is removed or broken to open the segmented pouch, the liquid, the
seasoning, and the
particulates are pourable from their respective inner and outer cavities in a
single motion.
In accordance with a further alternative embodiment is a packaged liquid-based
food
item that includes a flexible outer pouch, a flexible inner pouch, a seal, a
liquid, a seasoning
and a plurality of particulates. The flexible inner pouch is disposed within
the flexible outer
pouch. An inner surface of the flexible inner pouch at least partially defines
an inner cavity.
An outer surface of the flexible inner pouch and an inner surface of the
flexible outer pouch
define an outer cavity. A seal extends across the tops of the flexible inner
and outer pouches
and closes the inner and outer cavities. The inner cavity is filled with a
seasoning and liquid,
and the outer cavity is filled with particulates. Thus, the seasoning and
particulates are
separated from each other. When seal is removed or broken to open the pouch,
the liquid, the
seasoning, and the particulates are pourable from their respective inner and
outer cavities in a
single motion.
In various embodiments, the height of the outer pouch and outer cavity can be
greater
than that of the inner pouch and inner cavity. The width of the outer pouch
and outer cavity
can be the same or greater than that of the inner pouch and inner cavity. The
inner and outer
pouches can have various shapes, e.g., rectangular and square shapes.
The inner and outer pouches can be transparent or translucent plastic
material. Lateral
support members can extend between outer sides of the inner pouch and inner
sides of the
outer pouch.
The pouch can be gusseted so that the pouch can stand upright. For example,
the
bottom surface of the outer pouch can be gusseted. The outer cavity can extend
into areas
defined by the gusseted bottom surface. A tear strip extends along the seal of
the inner and
outer pouches and can be torn or broken to access the contents in the outer
and inner cavities,
e.g., ingredients of a soup.
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BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, in which like reference numbers represent
corresponding parts throughout, and in which:
Figure 1 is top view of a segmented container for a liquid-based food item
according
to one embodiment;
Figure 2 is a side view of the container shown in Figure 1;
Figure 3 is an illustrative cross-sectional view of a liquid based food item
having the
container shown in Figures 1 and 2, illustrating separation of particulates
and seasonings
according to one embodiment;
Figure 4 is bottom view of a lid having a sealing member or cushion according
to one
embodiment;
Figure 5 is a cross-sectional view of the container shown in Figures 1 and 2
showing
how sterilization is improved by separating particulates within a container
according to one
embodiment;
Figure 6 further illustrates heat transfer characteristics of package
embodiments
shown in Figure 5;
Figure 7 is top view of a container for a liquid-based food item according to
another
embodiment that includes an offset inner dividing member;
Figure 8 is a side view of the container shown in Figure 7;
Figure 9 is bottom view of a lid according to one embodiment that can be used
with
the container shown in Figure 7;
Figure 10 is top view of a container for a liquid-based food item according to
a further
embodiment that includes an inner dividing member that extends between inner
surfaces of
an outer member;
Figure 11 is a side view of the container shown in Figure 10;
Figure 12 is bottom view of a lid according to one embodiment for use with the
container shown in Figure 10;
Figure 13 is top view of a container for a liquid-based food item according to
another
alternative embodiment that includes a square- or rectangular-shaped inner
dividing member;
Figure 14 is a side view of the container shown in Figure 13;
Figure 15 is bottom view of a lid according to one embodiment for use with the
container shown in Figure 13;
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Figure 16 is top view of a container for a liquid-based food item according to
yet a
further alternative embodiment that includes an inner dividing member that is
connected to an
inner surface of an outer member;
Figure 17 is a side view of the container shown in Figure 16;
Figure 18 is bottom view of a lid according to one embodiment for use with the
container shown in Figure 16;
Figure 19 is top view of a container for a liquid-based food item according to
another
alternative embodiment that includes an inner dividing member that is
connected to an inner
surface of an outer member and that extends partially between the top and
bottom of the outer
member;
Figure 20 is a side view of the container shown in Figure 19;
Figure 21 is bottom view of a lid according to one embodiment for use with the
container shown in Figure 19;
Figure 22 is top view of a square- or rectangular-shaped container for a
liquid-based
food item according to another embodiment that includes an inner dividing
member;
Figure 23 is a side view of the container shown in Figure 22;
Figure 24 is bottom view of a lid according to one embodiment for use with the
container shown in Figure 22;
Figure 25 is a front view of a flexible segmented pouch for a liquid-based
food item
according to one embodiment having a "pouch within a pouch" in which the
widths of the
inner and outer members are the same;
Figure 26 is a side view of the flexible segmented pouch shown in Figure 26;
Figure 27 is a bottom view of the flexible segmented pouch shown in Figure 26;
Figure 28 is a front view of a flexible segmented pouch for a liquid-based
food item
according to one embodiment having a "pouch within a pouch" in which the width
of the
inner member is less than the width of the outer member;
Figure 29 is a side view of the flexible segmented pouch shown in Figure 28;
Figure 30 is a bottom view of the flexible segmented pouch shown in Figure 28;
Figure 31 illustrates a flexible segmented pouch having an inner pouch that is
narrower than the outer pouch;
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Figure 32 illustrates a flexible segmented pouch having an inner pouch that is
centrally disposed within an outer pouch and that includes lateral support
members extending
between outer sides of the inner pouch and the inner sides of the outer pouch;
Figure 33 illustrates an alternative embodiment of a segmented pouch having an
inner
pouch that is centrally disposed within an outer pouch without lateral support
members;
Figure 34 illustrates an alternative embodiment of a segmented pouch having an
inner
pouch that is disposed within and along a side of an outer pouch; and
Figure 35 is a flow chart illustrating preparation of a packaged liquid-based
food item
according to one embodiment.
DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS
Embodiments of segmented or flavor gradient package of container, a packaged
liquid-based food item, and a method of manufacturing a packaged liquid-based
food item are
described. With various embodiments, soups and other liquid-based food items
(generally
"soup") can be prepared so that flavorings and seasonings, such as salt,
pepper, sugar, onion
powder or flavoring, garlic powder or flavoring, and any necessary colorings
(hereafter
referred to as "seasonings") in a broth do not diffuse or migrate into
particulates, such as
meats and vegetables. Rather, the broth and the seasonings are stored in one
segment, and
particulates and water (as necessary) are stored in another segment. In some
applications, a
portion of the seasonings (and colorants if necessary) can be added to the
particulate
containing segment to provide an improved flavor impact. In use, the package
or container is
tilted and the broth and seasonings are poured out with the particulates and
water from the
respective cavities in a single pouring motion. As a result, the soup product
is more similar
to home made soups since the seasoning is added just prior to cooking, thus
providing a more
natural tasting product compared to typical processed soups in which the salt
and sodium
diffuses into the particulates. Since salt is not fully absorbed by
particulates, a similar salt or
flavor impact can be provided with reduced amounts of salt, thereby providing
a soup with
more natural taste and a healthier soup with reduced sodium contents compared
to known
processed soup products.
Referring to Figures 1-2, one embodiment of a container or package 100
suitable for a
liquid-based food item, such as a soup and a stew, includes an outer member
110 and an inner
dividing member 120. The outer and inner members 110 and 120 may have various
shapes.
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In the illustrated embodiment, the outer and inner members 110 and 120 are
cylindrical,
however, other shapes can be utilized.
The outer member 110 includes an inner surface 111 and an outer surface 112,
which
is typically handled by a consumer, a bottom surface 113 and a top edge or
surface 114. The
inner dividing member 120 is disposed or positioned inside of the outer member
110 and
includes an inner surface 121, an outer surface 122, a top edge or surface 123
and a bottom
edge or surface 124. In the illustrated embodiment the inner surface 121 of
the inner member
120 defines a vertical, inner cavity 125, e.g., a circular or cylindrical
cavity. An outer cavity
115 is defined between the outer surface 122 of the inner member 120 and the
inner surface
111 of the outer member 110. In the illustrated embodiment, the outer and
inner members
110 and 120 are cylindrical and concentric, or share a common axis or center
point. Thus, the
corresponding outer cavity 115 is annular or ring-like, and the inner cavity
125 is cylindrical.
The outer and inner members 110 and 120 may be formed using various techniques
and food-grade materials. For example, the inner and outer members 110 and 120
can be
substantially rigid and made of a substantially rigid metal or plastic, e.g.,
aluminum and other
materials that are used to make soup cans and packages. The outer and inner
members 110
and 120 can be formed together as a unitary piece or, alternatively, connected
together using,
for example, adhesive or welding, depending on the materials that are
selected. As a further
alternative, the inner and outer members 110 and 120 can be plastic and made
using, for
example, injection molding. Thus, in these embodiments, the outer and inner
cavities 115
and 125 have pre-defined shapes. Further, the inner member 120 can be hollow
so that the
bottom of the hollow inner member 120 is sealed against the bottom 113 of the
outer member
110, or the inner member 120 can have its own bottom surface. Persons skilled
in the art will
appreciate that various segmented configurations can be made with various
techniques and
materials.
Referring to Figure 3, the inner cavity 125 is filled with a liquid or broth
300
containing seasonings 302. The outer cavity 115 is filed with particulate
ingredients 310.
Water 311 or other liquids can be added to the outer cavity 115, as necessary,
so that the
particulates 310 can be poured out of the package 100 with the water.
Exemplary particulates
include meat particulates, such as chicken, .beef, turkey and meat
substitutes, and vegetable
particulates, such as celery, carrots, corn, peas, beans and potatoes.
Particulates 310 may also
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include noodles and rice. Thus, the seasonings 302, including salt, are
separated from
particulates 310 that would otherwise absorb the seasonings 302 if they were
not separated.
Referring to Figures 3-5, a sealing member 320, such as a lid or cover as
illustrated,
is placed on top of the package, i.e., over top edges or surfaces 114 and 124
of the outer and
inner members 110 and 120, to close the package 100. The inner cavity 125
extends between
radius r=o and radius rl - The outer cavity 115 extends between radius ri and
radius r2.
In the embodiment shown in Figure 3, the sealing member 320 includes a body or
plate 322 and a sealing member or cushion 324. The cushion 324 can be, for
example,
Teflon , rubber or another food-grade material. The sealing cushion 324 is
shaped and
positioned so that it overlays the top edge or surface 124 of the inner member
120 to ensure
that the contents of the inner cavity 125 do not leak into the outer cavity
115 holding the
particulates. Thus, the cushion 324 is preferably larger than radius rl. The
cushion can be
shaped appropriately to mate with the to edge or surface 124.
For example, as shown in Figure 1 and 2, the top surface 124 of the inner
member 120
has a circular shape and is placed in the middle of the space defined by the
outer member
110. The sealing cushion 324, as shown in Fig 4 can be correspondingly shaped
and sized to
cover the top circular section of the inner member 120 when the lid 320 is
placed over the
inner and outer members 110 and 120 to seal or close the package 100. This can
be
accomplished with a circularly shaped cushion 324, as illustrated. However,
the sealing
cushion 324 may or may not have a similar shape as the top edge or surface 124
of the inner
member 120 since a sealing cushion 324 having various shapes and sizes can
adequately
cover and seal the top of the inner member 120. For example, the cushion 324
may be a
solid piece that occupies most of the bottom surface 322 of the sealing
member, or as a ring,
as shown in Figure 3. Accordingly, sealing cushions 324 having various shapes
and sizes can
be used to cover and seal top edges or surfaces 124 of various shapes and
sizes.
The sealing member 320 is placed on top of the container after the inner
cavity 125 is
filled with broth 300 and seasonings 302 and the outer cavity 115 is filled
with particulates
310 and water or other liquids 311. Thus, all or the majority of the salt and
other seasonings
320 remain contained in the inner cavity 125, advantageously separated from
the particulates
310 in the outer cavity 115. This separation is maintained from the beginning
of production,
during storage, distribution, sales, and subsequent consumer storage, thereby
maintaining a
flavor gradient to prevent "sodium diffusion" or other flavorings into the
particulates.
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Referring to Figure 5, separating particulates 310 and broth and seasoning
components 302 provides the additional benefit of more efficient
sterilization. In the
illustrated embodiment, the particulates 310 are retained and concentrated in
the outer cavity
115 and against the inner surface 111 of the outer member 110. As a result,
heat 500 is more
easily applied to the particulates 310 since they are concentrated in a
particular area in the
package and removed from the thermal geometrical center of the container,
rather than being
diffused and mixed together throughout the package as in conventional
processed soups.
Thus, embodiments provide for faster heat transfer and faster sterilization
compared to
traditional soup mixtures -since the particulates 310 are separated from the
faster heating
thermolabile broth or fluid center 300 with salt, sugar and other seasonings
302. In other
words, the fluid center is more readily sterilized by heat 500. Further, while
heat is being
applied to the particulates in the outer cavity 115, the particulates 310 are
also heated by
conductive heating from the convective heated fluid center. One can
selectively control the
heat transfer within the segmented container by selectively "insulating" the
concentric
material 120, 121 and 122 illustrated in Fig 1
As a result of the segmented configuration, shorter heating durations can be
used to
achieve the same sterilization results while optimizing flavor, color and
nutrient retention. In
contrast, traditional soups having mixtures of ingredients require longer
heating durations
since the particulates are mixed together with the broth and are not heated as
easily, since
thermal processes have to be assumed at the thermal center of the container
which is typically
along the axis of the container where heating lags are notable when compared
to the outer
layers of the container. Thus, the traditional soup or food containers require
longer heating
durations. Further, food items according to various embodiments are subjected
to less heat
500. This reduced thermal stress, results in a higher quality food item that
is not otherwise
subjected to unnecessary heating and flavor and texture degradation.
The benefit of faster sterilization times and reduced thermal stress on the
food item is
further illustrated in Figure 6. As shown in Figure 6, the heat transfer 500
to the center or to
a particular width of a concentric ring can be determined as follows:
Liquid or particulate: T= jrl *(Tl - To) * 10 ~"~~'~
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This equation represents the heat transfer in the water, broth or puree after
the curvilinear
heating (Hayakawa, 1980) has been transposed. In some foods there are "broken"
heating
curves that require to solve the equation through specific mathematical
algorithms for varying
values of fh. Numerical solutions can also be applied to solve heat transfer
within containers.
The governing differential equations vary and follow simple energy balances as
shown in the
following one dimensional equation
k*p*cp* dT / dt = a*dZt/dr2
for 0< x< rl in axi-symmetric heating
Boundary conditions have to be defined according to heating medium
characteristics
where T= Temperature of food
j = heating lag factor in the liquid or solid particles
r = dimensional location within the container
Tl = Heating medium temperature
To = Initial food temperature
f = empirically measured heating rates
h = heat transfer coefficient
k = thennal conductivity of food
p (rho) = food density
Cp = food specific heat
This equation represents a simplified heat transfer system and one versed in
the
science of heat transfer would conclude that multiple complex conditions of
heat transfer
would apply. The solutions currently applied in the industry typically require
numerical
solutions to complex partial differential equations. Exemplary numerical
methods include
finite differences and finite elements.
Various other package designs can be utilized to provide a flavor gradient in
liquid-
based food items and/or provide more efficient sterilization by separating out
particulates
from thermolable broth having seasonings.
In one alternative embodiment, referring to Figures 7-9, the vertical inner
dividing
member 120 can be offset relative to the outer member 110 so that the inner
and outer
members 120 and 110 do not share a common center point or axis, as do the
embodiments
shown in Figure 1-6.
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In. another alternative embodiment, referring to Figures 10-12, the vertical
inner
dividing member 110 may be connected to the inner surface 111 of the outer
member 110.
In this embodiment, the inner cavity 125 is defined by a combination of the
inner surface 111
of the outer member 110, and an inner surface 121 of the inner member 120.
A further alternative embodiment is shown in Figures 13-15, In the illustrated
embodiment, the inner dividing member 110 can have a square or rectangular
shape, and the
outer member 120 can have a cylindrical shape. The sealing cushion 324 can
also have a
corresponding square or rectangle shape, or be large enough to cover the
square-shaped inner
member 110. The inner member 110 can have other shapes besides cylindrical,
square and
rectangle shapes, as necessary.
Figures 16-18 illustrate yet a further alternative embodiment. The inner
dividing
member 120 can be side-mounted to an inner surface 111 of the outer member 110
using side
mounting component 1600. As shown in the Figures, in this embodiment, the
inner member
120 extends between the top 114 and the bottom 113 of the outer member 110. It
may or
may not be necessary to secure the bottom of the inner dividing member 120 to
a bottom of
the outer member 110. Alternatively, as shown in Figures 19-21, a similar side-
mounting
configuration can be used, and the inner member 120 can extend from the top
114 and
partially down into the outer member 110. In other words, the bottom 123 of
the inner
member 120 may be suspended above the bottom 113 of the outer member 110. A
smaller
inner cavity 125 area may be useful if, for example, a higher concentration
broth or brine is
utilized, and less volume is needed to contain the broth. The particulates 310
and water 311
can also flow around the bottom of the suspended inner member 120 shown in
Figures 19-21.
Further alternative embodiments are shown in Figures 22-24. In this
embodiment, the
outer member 110 and package design can be square or rectangular rather than
cylindrical.
Further, the shape of the inner dividing member 120 can be cylindrical (as
illustrated) or
square, such as shown in Figures 13-15.
Figures 25-27 illustrate an additional alternative embodiment of a segmented
container or package that provides a flavor gradient. The package is a
flexible pouch 2500
and, more particularly, a "pouch within a pouch" that includes an outer member
or pouch
2510 and an inner dividing member or pouch 2520. The outer member 2510
includes two
panels 2511 and 2512, and the inner member 2520 includes two panels 2521 and
2522. The
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outer member 2510 and the inner member 2520 are flexible, e.g., flexible
plastic. The plastic
can be transparent, translucent or colored.
A seal 2530 extends across the tops 2514 and 2524 of the outer and inner
members
2510 and 2520. The seal 2530 can be, for example, heat seal. The sides of the
outer and
inner members 2510 and 2520 can be similarly sealed. A tear strip 2532 can be
provided
across a top portion of the package to allow a consumer to tear open the top
of the sealed
package and access the contents in the outer and inner pockets or cavities
2515 and 2525 and
allow the contents to be poured out of the package in a single pouring motion.
The outer member 2510 includes an inner surface and an outer surface. The
inner
member 2520 includes an inner surface and an outer surface. The inner surface
of the inner
member 2520 at least partially defines an inner pocket or cavity 2525 for
holding seasonings.
An outer pocket or cavity 2515 is defined between the outer surface of the
inner member
2520 and the inner surface of the outer member 2510. The outer pocket 2515
includes
particulates, such as meat and vegetable particulates, and water, as
necessary. The pouch
2500 shown in Figures 25-27 is shown having liquid for purposes of
illustration, but the outer
and inner cavities 2515 and 2525 can be filled with various ingredients as
appropriate. In the
illustrated embodiment, the inner member 2520 is shorter than the outer member
2510 so that
the outer member 2510 and the outer cavity 2515 substantially envelope the
inner member
2520, i.e., the side and bottom portions of the inner member 2520.
The flexible segmented pouch 2500 provides a flavor gradient by separating the
salt
and other seasonings from particulates, and allowing a consumer to empty the
pouch contents
in a single motion. The embodiment of a segmented pouch also decreases
sterilization times
since particulates are concentrated in one area or pocket and can be readily
heated through a
plastic material. Further, the outer and inner members are flexible, thus
allowing the package
to assume different shapes. The packages are also durable since they are made
of plastic or
other durable flexible materials.
In the embodiment shown in Figures 25-27, the pouch 2500 includes a gusseted
bottom 2540 that is formed by bottom portions of the outer member 2510 being
folded
upwardly at 2542. The bottom of the pouch 2500 is flexible and flares
outwardly, thereby
forming a base or bottom 2540 upon which the pouch can stand. As shown in
Figure 25, the
outer cavity 2515 can extend into an area defined by the gusseted bottom 2540.
In
alternative embodiments, the bottom can be non-gusseted.
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Figures 28-30 illustrate an alternative embodiment of a flexible segmented
package or
pouch 2800. The embodiment shown in Figures 28-30 is similar to the embodiment
shown in
Figures 25-27 in that the pouch 2800 includes flexible outer and inner members
2810 and
2820 that form outer and inner cavities 2815 and 2825 and a gusseted bottom
2840 to form a
base upon which the package 2800 can stand. The tops 2814 and 2824 are sealed.
A tear
strip, although not shown, can also be used to allow the tops of the pouch to
be easily opened.
The package 2800 shown in Figures 28-30 includes an inner member or pouch 2810
having a width that is less than the width of the outer member or pouch 2820.
In the
illustrated embodiment, the inner member 2820 is disposed or positioned
centrally within the
outer member 2810. The width of the narrower inner member 2820 can vary as
needed. The
outer cavity 2825 can extend into an area defined by the gusseted bottom 2840.
In alternative
embodiments, the bottom of the package can be non-gusseted.
Figure 31 illustrates a further alternative embodiment of a pouch 3100 that is
similar
to the embodiment shown in Figures 28-30, but includes a different bottom or
base 3140. In
the illustrated embodiment, the base 3140 extends outwardly from the front of
the package to
allow the package to stand upright.
Figure 32 illustrates an alternative embodiment of a segmented pouch that is
similar
to the pouch shown in Figure 28 and further illustrates lateral support
members 3200 that
extend between the sides of the inner member or pouch 2820 to the sides of the
outer member
or pouch 2810. Thus, when the tops of the outer and inner members 2810 and
2820 are
broken or torn, the inner member 2820 is laterally supported by members 3200,
and the
contents can be poured from their respective outer and inner cavities 2815 and
2825.
Alternatively, as shown in Figure 33, the sides and the bottom of the inner
member 2820 may
be unattached to the outer member 2810.
Referring to Figure 34, in a further alternative embodiments, the inner member
or
pouch 2820 and inner cavity 2825 can be displaced from the central portion of
the outer
member or pouch 2810. In the illustrated embodiment, the inner member 2820 is
disposed
along one side of the outer member 2810. This configuration may be beneficial
when, for
example, the pouch is tilted to one side to pour the contents from the
respective cavities 2815
and 2825.
Figure 35 illustrates a method of making a packaged liquid-based food item can
be
summarized as follows, although additional details have been previously
discussed. In step
CA 02609320 2007-11-22
WO 2006/127186 PCT/US2006/014899
3500 a segmented package having an outer member and an inner dividing member
is
provided. In step 3510 the inner cavity is filled with a liquid and
seasonings. In step 3520,
the other cavity is filled with particulates and any necessary water or broth.
The inner and
outer cavities may be filled simultaneously or at different times depending on
the
configuration of the equipment. As a result, the broth and seasonings are
separated from the
particulates so that the seasonings do not diffuse into the particulates. The
package is then
sealed by placing a sealing member across over the inner and outer members in
step 3530.
The tops of the outer and inner members can be different heights so that the
tops can
be engaged more easily by a filling machine. Additionally, a vacuum can be
used to engage
the outer faces of the outer member and to make the inner and outer cavities
more accessible.
A filling machine can a rotary machine that includes multiple heads, or
multiple stage filling
process can be used.
The embodiments shown and described are not intended to be limiting, but are
provided for purposes of explanation and illustration. Various segmented
package
configurations, shapes, sizes and designs can be used to provide a flavor
gradient. For
example, the containers can have a size suitable for both individual
consumption and for
commercial or large scale use. Further, square-or rectangular-shaped outer
members can be
paired with inner members having cylindrical, square, rectangular or other
shapes. Similarly,
cylindrical-shaped outer members can be paired with inner members having
cylindrical,
square, rectangular or other shapes. Further, the inner members can be
concentric or offset
relative to the outer member, stand-alone or connected to the inner surface of
the outer
member. The inner members can extend between the top and bottom of an outer
member or a
portion thereof. The package can also be designed so that the package is easy
to hold, e.g.,
the outer member can be contoured to fit a person's hand. Thus, persons
skilled in the art
will appreciate that various segmented designs that provide flavor gradients
can be utilized
depending on, for example, food item ingredients, concentrations and packaging
considerations.
16
