Note: Descriptions are shown in the official language in which they were submitted.
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TRAY WITH COMPARTMENTS
CROSS-REFERENCE TO RELATED APPLICATION
[0001]
This application claims the benefit of U.S. Provisional Patent Application No.
63/159,015,
filed on March 10, 2021.
INCORPORATION BY REFERENCE
[0002]
The disclosures of U.S. Provisional Patent Application No. 63/159,015, filed
on March 10,
2021, U.S. Patent Application No. 16/532,819, filed on August 6, 2019, U.S.
Provisional Patent
Application No. 62/851,932, filed May 23, 2019, U.S. Provisional Patent
Application No.
62/796,716, filed January 25, 2019, U.S. Provisional Patent Application No.
62/715,520, filed August
7, 2018, U.S. Patent Application No. 16/037,425, filed July 17, 2018, U.S.
Provisional Patent
Application No. 62/649,159, filed March 28, 2018, U.S. Provisional Patent
Application No.
62/643,914, filed March 16, 2018, U.S. Patent Application No. 15/654,814,
filed July 20, 2017, U.S.
Provisional Patent Application No. 62/365,635, filed July 22, 2016, and U.S.
Patent Application No.
12/992,131, filed February 11, 2011, PCT Patent Application No.
PCT/GB/09/50506, filed May 13,
2009, are hereby incorporated by reference for all purposes as if presented
herein in their entirety.
BACKGROUND OF THE DISCLOSURE
[0003]
The present disclosure relates to blanks, containers, trays, constructs, and
various features
and methods for forming a container from a blank. More specifically, the
disclosure is generally
directed to a container with multiple compartments.
SUMMARY OF THE DISCLOSURE
[0004]
According to one aspect, the disclosure is generally directed to a tray for
holding one or more
food products, the tray comprising a plurality of panels comprising a central
panel, a plurality of
compartment flaps foldably connected to a respective panel of the plurality of
panels, and a plurality
of end flaps foldably connected to a respective panel of the plurality of
panels, the plurality of
compartment flaps and the plurality of end flaps are overlapped to form a
plurality of compartments
of the tray.
[0005]
According to another aspect, the disclosure is generally directed to a blank
for forming a tray
for holding one or more food products, the blank comprising a plurality of
panels comprising a
central panel, a plurality of compartment flaps foldably connected to a
respective panel of the
plurality of panels, and a plurality of end flaps foldably connected to a
respective panel of the
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plurality of panels, the plurality of compartment flaps and the plurality of
end flaps are for being
overlapped to form a plurality of compartments of the tray formed from the
blank.
[0006] According to another aspect, the disclosure is generally directed to
a method of forming a
tray for holding one or more food products, the method comprising obtaining a
blank comprising a
plurality of panels comprising a central panel, a plurality of compartment
flaps foldably connected to
a respective panel of the plurality of panels, and a plurality of end flaps
foldably connected to a
respective panel of the plurality of panels. The method further comprises
overlapping the plurality of
compartment flaps and the plurality of end flaps to form a plurality of
compartments of the tray.
[0007] Those skilled in the art will appreciate the above stated advantages
and other advantages and
benefits of various additional embodiments reading the following detailed
description of the
embodiments with reference to the below-listed drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] According to common practice, the various features of the drawings
discussed below are not
necessarily drawn to scale. Dimensions of various features and elements in the
drawings may be
expanded or reduced to more clearly illustrate the embodiments of the
disclosure.
[0009] Fig. 1 is a plan view of a blank used for forming a tray according
to a first exemplary
embodiment of the disclosure.
[0010] Fig. 2 is a top perspective views of a tray formed from the blank of
Fig. 1 according to the
first exemplary embodiment of the disclosure.
[0011] Fig. 3 is a bottom perspective view of the tray of Fig. 2.
[0012] Fig. 4 is a schematic of an apparatus for forming a container in an
exemplary embodiment of
the disclosure.
[0013] Fig. 5 is a plan view of a blank used for forming a tray according
to a second exemplary
embodiment of the disclosure.
[0014] Fig. 6 is a top perspective views of a tray formed from the blank of
Fig. 5 according to the
second exemplary embodiment of the disclosure.
[0015] Fig. 7 is a bottom perspective view of the tray of Fig. 6.
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[0016]
Corresponding parts are designated by corresponding reference numbers
throughout the
drawings.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0017]
The present disclosure relates generally to various aspects of containers,
constructs, trays,
materials, packages, elements, and articles, and methods of making such
containers, constructs, trays,
materials, packages, elements, and articles. Although several different
aspects, implementations, and
embodiments are disclosed, numerous interrelationships between, combinations
thereof, and
modifications of the various aspects, implementations, and embodiments are
contemplated hereby. In
one illustrated embodiment, the present disclosure relates to forming a
container or tray for holding
food items or various other articles. However, in other embodiments, the
container or tray can be
used to form other non-food containing articles or may be used for heating or
cooking.
[0018]
Fig. 1 illustrates an exterior surface 101 of a blank 103 for forming a tray
105 (Fig. 2) or
other container according to an exemplary embodiment of the disclosure. In one
embodiment, the
blank 103 comprises paperboard (e.g., solid bleached sulphate folding
boxboard), or other suitable
material that can be recyclable and/or suitable for use in an oven (not
shown). The blank 103 can be
provided with a liner L that comprises a plastic layer such as polyethylene, a
polyethylene
terephthalate (PET) material, or any other thermoplastic material, or a
bioplastic, such as vegetable
oil or starch based plastics. In one embodiment, such liner can comprise
polyethylene that can be
softened and fused to the blank 103. In an alternative embodiment, a liner for
being attached to the
blank 103 can comprise PET or a similar material that is at least partially
attached to the blank 103 by
a heat seal layer (e.g., a thermoformable sealant grade transparent polyester
packaging film, such as
Mylar XMPOL12 available from DuPont Teij in Films U.S. Limited Partnership of
Hopewell,
Virginia, or any suitable thermoformable sealant or adhesive, any suitable
heat or pressure activated
adhesive, or any other suitable material), wherein a PET liner can be more
suitable for uses that
require heating of the container in an oven. Such a liner can be at least
partially attached to the blank
103 for being positioned in contact with one or more food products held in the
container 105 (e.g.,
during heating). In one embodiment, after heating the food product, the blank
103 and an
accompanying liner L can be separated to allow both the blank 103 and the
liner to be recycled
separately.
[0019]
The blank 103 can be formed from a single ply of material, such as but not
limited to
paperboard, cardboard, paper, a polymeric sheet, and/or a laminate that
includes more than one layer.
In one embodiment, the blank 103 can include a microwave interactive layer
(not shown) such as is
common in MicroRitee containers available from Graphic Packaging International
of Atlanta, GA.
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The microwave interactive layer can be commonly referred to as, or can have as
one of its
components, a susceptor, a foil, a microwave shield, or any other term or
component that refers to a
layer of material suitable for shielding microwave energy and/or causing
heating in a microwave
oven.
[0020] As
shown in Fig. 1, the blank 103 has a longitudinal direction Li and a lateral
direction L2.
In the illustrated embodiment, the blank 103 has a central panel 111, a first
side attachment panel 113
foldably connected to the central panel 111 at a lateral fold line 115, and a
second side attachment
panel 117 foldably connected to the central panel 111 at a lateral fold line
119.
[0021] As
shown, a peripheral region of the central panel 111 can form a flange 120 of
the blank
103/container 105.
[0022] A
first compartment flap 121 and a second compartment flap 123 can be foldably
connected
to the central panel 111 at respective longitudinal fold lines 125, 127
(broadly, respective "first fold
line") and positioned within the outer edges of the central panel 111 for at
least partially forming a
first compartment of the tray 105, and a first compartment flap 129 (broadly,
"third compartment
flap") and a second compartment flap 131 (broadly, "fourth compartment flap")
can be foldably
connected to the central panel 111 at respective longitudinal fold lines 133,
135 (broadly, respective
"first fold line") and positioned within the outer edges of the central panel
111 for forming a second
compartment of the tray 105.
[0023] An
attachment tab 137 can be foldably connected to the first compartment flap 121
at a
longitudinal fold line 139. The attachment tab 137 can be separable from the
second compartment
flap 123 at a cut 141 having one or more angled, oblique, and/or curved
portions, and the
compartment flaps 121, 123 can be separable at a longitudinal cut 143
interrupted by the fold line
139. As also shown, a pair of generally triangular cutouts 145, 147 can be
provided in the central
panel 111 on opposing sides of the compartment flaps 121, 123, and can define
respective free edges
of the respective compartment flaps 121, 123.
[0024]
Similarly, an attachment tab 149 can be foldably connected to the first
compartment flap 129
at a longitudinal fold line 151 and an attachment tab 153 can be foldably
connected to the second
compartment flap 131 at a longitudinal fold line 155, the attachment tabs 149,
153 separable at a
longitudinal cut 157. A pair of generally triangular cutouts 159, 161 can be
provided in the central
panel 111 on opposing sides of the compartment flaps 129, 131 and can define
respective free edges
of the respective compartment flaps 129, 131.
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[0025] In
this regard, the fold lines 125, 127, 133, 135 can be positioned along and/or
intersecting
with a portion of the respective cutouts 145, 147, 159, 161 and/or respective
openings in the central
panel 111 formed by the respective compartment flaps 121, 123, 129, 131.
[0026] A
plurality of end flaps are attached to respective panels of the plurality of
panels of the
blank 103, and can include a first side end flap 163 (broadly, "first end
flap") foldably connected to
the first side attachment panel 113 at a lateral fold line 165 (broadly,
"second fold line"), a second
side end flap 167 (broadly, "first end flap" or "third end flap") foldably
connected to the first side
attachment panel 113 at a lateral fold line 169 (broadly, "second fold line"),
a first side end flap 171
(broadly, "second end flap") foldably connected to the second side attachment
panel 117 at a lateral
fold line 173 (broadly, "second fold line"), and a second side end flap 175
(broadly, "second end
flap" or "fourth end flap") foldably connected to the second side attachment
panel 117 at a lateral
fold line 177 (broadly, "second fold line"). In this regard, the fold lines
165, 169, 173, 177 can be
positioned spaced apart from the cutouts 145, 147, 159, 161 and/or an opening
in the central panel
111 formed by the compartment flaps 121, 123, 129, 131.
[0027]
The first side end flap 163, as shown, can include a base/side portion 179
foldably connected
to the first side attachment panel 113 at the lateral fold line 165, and a
distal/bottom portion 181
foldably connected to the base portion 179 at a lateral fold line 182. An
attachment tab 183 can be
foldably connected to the distal portion 181 of the end flap 163 at a
longitudinal fold line 185.
[0028]
The second side end flap 167 can include a base/side portion 187 foldably
connected to the
first side attachment panel 113 at the lateral fold line 169, and a
distal/bottom portion 189 foldably
connected to the base portion 187 at a lateral fold line 191.
[0029]
Similarly, the first side end flap 171, as shown, can include a base/side
portion 193 foldably
connected to the second side attachment panel 117 at the lateral fold line
173, and a distal/bottom
portion 195 foldably connected to the base portion 193 at a lateral fold line
197. An attachment tab
199 can be foldably connected to the distal portion 195 of the end flap 171 at
a longitudinal fold line
201. The second side end flap 175 can include a base/side portion 203 foldably
connected to the
second side attachment panel 117 at the lateral fold line 117, and a
distal/bottom portion 205 foldably
connected to the base portion 203 at a lateral fold line 207.
[0030]
With additional reference to Figs. 2 and 3, according to one embodiment, the
attachment
panels 113, 117 can be folded at the respective fold lines 115, 119 into at
least partial face-to-face
contact with respective portions of the central panel 111. In addition, the
compartment flap
121/attachment tab 137 and compartment flap 123 can be separated at the
respective cuts 141, 143
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and folded downwardly at the respective fold lines 125, 127 away from the
central panel 111.
Similarly, the compartment flap 129/attachment tab 149 and the compartment
flap 131/attachment tab
153 can be separated at the cut 157 and folded downwardly at the respective
fold lines 133, 135 away
from the central panel 111.
[0031]
The end flaps 163, 171 can be folded inwardly at the respective fold lines
165, 173 so as to
extend away from the central panel 111 toward an engagement with the
downwardly-depending
compartment flaps 121, 123. In this regard, an edge or surface of each of the
base portions 179, 193
can intersect an edge or surface of the respective compartment flaps 121, 123.
[0032]
Furthermore, the distal portions 181, 195 can be folded at the respective fold
lines 182, 197
into a generally spaced and parallel arrangement with the central panel 111,
with an edge or surface
of each of the distal portions 181, 195 intersecting an edge or surface of the
respective compartment
flaps 121, 123. In such an arrangement, the attachment tabs 183, 199
associated with the end flaps
163, 171 can be folded at the respective fold lines 185, 201 into at least
partial face-to-face contact
with the compartment flap 123 to overlie a space formed by the separation of
the attachment tab 137
from the compartment flap 123, and the attachment tab 137 associated with the
compartment flap 121
can be folded into at least partial face-to-face contact with the respective
distal portions 181, 195 of
the end flaps 163, 171.
[0033] In
the foregoing arrangement, the end flaps 163, 171 and the compartment flaps
121, 123 and
associated attachment tab 137 cooperate for form a first compartment 209, with
the base portions
179, 193 of the respective end flaps 163, 171 and the compartment flaps 121,
123 forming sides of
the compartment 209 that are obliquely arranged relative to the central panel
111, and with the base
portions 181, 195 of the respective end flaps 163, 171 forming the bottom of
the compartment 209.
The aforementioned arrangement of the first compartment 209 can be maintained
via the attachment
of the tabs 137, 183, 199 to respective panels and flaps, and which can be at
least partially maintained
with an adhesive such as glue.
[0034]
Similarly, the end flaps 167, 175 can be folded inwardly at the respective
fold lines 169, 177
so as to extend from the central panel 111 toward an engagement with the
downwardly-depending
compartment flaps 129, 131, and the distal portions 189, 205 thereof can be
folded at the respective
fold lines 191, 207 into a generally spaced and parallel arrangement with the
central panel 111, with
an edge or surface of each of the distal portions 181, 195 intersecting an
edge or surface of the
respective compartment flaps 129, 131. In such an arrangement, the attachment
tabs 149, 153
associated with the compartment flaps 129, 131 can be folded at the respective
fold lines 151, 155
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into at least partial face-to-face contact with the respective portions of the
end flaps 167, 175, e.g., the
distal portions 189, 205 of the respective end flaps 167, 175.
[0035]
The end flaps 167, 175 and the compartment flaps 129, 131 and associated
attachment tabs
can thus cooperate for form a second compartment 211, with the base portions
187, 203 of the
respective end flaps 167, 175 and the compartment flaps 129, 131 forming sides
of the compartment
211 that are obliquely arranged relative to the central panel 111, and with
the base portions 189, 205
of the respective end flaps 167, 175 forming the bottom of the compartment
211. The
aforementioned arrangement of the compartment 211 can be maintained via the
attachment of the
tabs 149, 153 to the respective end flaps, and which can be at least partially
maintained with an
adhesive.
[0036]
The aforementioned arrangement of the tray 105 provides a plurality of
compartments, e.g.,
compartments 209, 211, that allow for separation of food products, e.g., for
serving to one or more
person, to prevent commingling thereof, to provide a main dish and a side
dish, to utilize one or more
of the compartments 209, 211 to hold a condiment, etc. Furthermore, the
overlapping arrangement of
the compartment flaps 121, 123 and end flaps 163, 171 provides the compartment
209 with a robust
construction that resists deformation, bending, crushing etc. The overlapping
arrangement of the
compartment flaps 129, 131 and end flaps 167, 175 provides a similarly robust
construction to the
second compartment 211. In this regard, the end flaps 167, 175 can be
considered reinforcing
features of the respective compartments 209, 211/tray 105.
[0037] In
this regard, a first interior volume V1 of the first compartment 209 can be
defined between
the end flaps 163, 171 and the compartment flaps 121, 123, and a second
interior volume V2 of the
second compartment 211 can be defined between the end flaps 167, 175 and the
compartment flaps
129, 131.
[0038]
While the first compartment 209 is illustrated as defining an interior 213
with an interior
volume V1 that is different, e.g., larger, than the interior volume V2 of an
interior 215 of the second
compartment 211, it will be understood that one or both of the compartments
209, 211 can have a
different configuration or interior volume than that illustrated, or can have
the same configuration or
volume.
[0039]
Furthermore, the aforementioned configuration of the tray 105 allows for
nesting or stacking
or multiple trays 105 upon one another. For example, an upper tray 105 can be
seated or nested into a
lower tray below by at least partially positioning the end flaps and
compartment flaps defining the
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respective compartments 209, 211 in the respective interiors 213, 215 of the
respective compartments
209, 211 of the lower tray 105.
[0040] It
will be understood that, in embodiments, a liner such as liner L (Fig. 1) can
be applied to at
least the interiors 213, 215 of the respective compartments 209, 211, and can
overlie seams/points of
intersection between the respective compartment flaps and end flaps, e.g.,
such that the compartments
209, 211 have leak-resistant properties.
[0041] In
one embodiment, the container 105 can be formed similarly to the formation of
the
containers as shown and described in the incorporated-by-reference
applications (e.g., the '425
Application, the '814 Application, and/or the '131 Application). In an
exemplary embodiment shown
schematically in Fig. 4, the blank 103/container 105 or a folded configuration
thereof can be placed
on a lower die 215 of a system 217 and a liner material or film sheet 219
(e.g., a polyethylene or PET
web) can be fed from a supply roller 221 above the blank 103/folded blank 103.
An upper die 223
has a heater plate surface 225 having a PTFE coating, for example a Teflon
coating. Alternatively,
the heater plate surface 225 could have a coating of any suitable material or
the coating could be
omitted. As schematically shown in Fig. 4, the upper die 223 can include a
plurality of holes or ducts
227 in the heater plate surface 225 for applying a vacuum and/or air pressure
on the sheet 219. The
lower die 215 and/or the upper die 223, including the ducts 227 and/or the
heater plate 225, could be
otherwise shaped, arranged, positioned, and/or configured without departing
from the disclosure. For
example, the heater plate 225 could be omitted and the heat could be
alternatively applied to the sheet
219 (e.g., with a flow of hot air).
[0042] In
the illustrated embodiment, the lower die 215 can hold the blank 103/folded
blank 103
over a cavity 214 in the lower die 215 while supporting the blank
103/container 105 at the central
panel 111 and/or the attachment panels 113, 117 (e.g., so that the central
panel 111 is facing
upwardly). An initial vacuum can be applied to ducts 227 to draw the film
sheet 219 toward the
upper die 223, the upper die 223 can be heated to a suitable temperature to
soften the film sheet 219
and/or to activate a heat seal layer. Instead of, or in addition to, the
initial vacuum, air pressure under
the film sheet 219 can be employed with similar or equal effect. Subsequently,
the film sheet 219 can
be forced downwardly (e.g., by air pressure applied by the ducts 227 and/or a
vacuum applied from
below the blank 103/container 105). The air pressure can move the film sheet
219 toward the blank
103/folded blank 103 and the lower die 215 can support the blank 103/container
105 as the film sheet
219 is applied to portions of one or more of the flange 120, the compartment
flaps 121, 123, 129, 131,
and the end flaps 163, 167, 171, 175 to form the liner L. In one embodiment,
the liner L can help
retain the container 105 in its tray shape after the liner L is applied to the
blank 103/folded blank
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103/container 105. In one embodiment, the container 105 can be ejected from
the lower die 215 and
transported away from the forming tool on a conveyor, for example.
[0043] In
one embodiment, the container 105 can be formed from the blank 103 and have
the liner L
applied thereto at a much higher rate than systems that separately form the
container 105 from the
blank 103 blank and then place that formed container 105 into the lower die
215. In one example, the
container 105 of the present embodiment can be formed from the blank 103
together with the liner L
at a rate of approximately 200 trays per minute. The container 105 could be
otherwise formed
without departing from the disclosure. For example, the container 105 could be
formed from the
blank 103 prior to applying the liner L (e.g., prior to engaging the lower die
215).
[0044]
Referring to Fig. 5, an exterior surface 301 of a blank for forming a tray 305
(Fig. 6)
according to a second exemplary embodiment of the disclosure is generally
designated 393. The
blank 303 and tray 305 can have one or more features that are substantially
similar to those described
above with regard to the blank 103 and tray 105, and like or similar features
are designated with like
or similar reference numerals.
[0045]
The blank 303 can have generally the same configuration as the blank 103
described above,
except that the end flaps foldably attached to the side attachment panels 113,
117 are respective end
flaps 363, 371.
[0046] As
shown, the end flap 363 can have a base portion 379 foldably connected to the
side
attachment panel 113 at a lateral fold line 365 (broadly, "second fold line"),
with the distal portions
181, 189 (broadly, "first distal portion" and "second distal portion")
foldably connected to the base
portion 379 at the respective fold lines 182, 191, and with the attachment tab
183 foldably connected
to the distal portion 181 at the fold line 185.
[0047]
Similarly, the end flap 371 can have a base portion 393 foldably connected to
the side
attachment panel 117 at a lateral fold line 373 (broadly, "second fold line"),
with the distal portions
195, 205 (broadly, "first base portion" and "second base portion") foldably
connected to the base
portion 393 at the respective fold lines 197, 207, and with the attachment tab
199 foldably connected
to the distal portion 195 at the fold line 201. In this regard, the distal
portions 181, 189 of the end
flap 363 share the common base portion 379, and the distal portions 195, 205
of the end flap 371
share the common base portion 393.
[0048]
With additional reference to Figs. 6 and 7, the tray 305 can be formed in a
manner similar to
that described above with regard to the tray 105, except that the base
portions 379, 393 of the
respective end flaps 363, 373 form the side portions of each of the
compartments 309, 311 such that
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the base portions 379, 393 span each of the compartments 309, 311, and is
provided with similar
advantages to those described above with regard to the tray 105. The
aforementioned arrangement of
the tray 305 can be at least partially maintained with one or more
applications of an adhesive such as
glue.
[0049] It
will be understood that, in embodiments, a liner such as liner L (Fig. 1) can
be applied to at
least the interiors 413, 415 of the respective compartments 409, 411, and can
overlie seams/points of
intersection between the respective compartment flaps and end flaps. Such
application of the liner L
to the container 305 can be accomplished in the manner described above with
regard to the container
105, for example.
[0050] In
one embodiment, a lid (not shown) can comprise packaging film that is a thin
plastic layer
used to preserve and protect a food item contained in the trays 105, 305 and
can be removably
attached to a flange of the trays 105, 305, e.g., defined by a portion of the
central panel 111. Any
plastic film, such as polyethylene, polypropylene, polyethylene terephthalate,
polyvinylchloride,
polyamide, and ethylene vinyl alcohol, or other suitable material, can be used
for forming the lid that
is sealed against the sealing surface of the flange/central panel 111.
Further, adhesives can be used
between the lid and the sealing surface of the flange/central panel without
departing from the
disclosure. In one embodiment, the sealing surface of the flange comprises an
upper surface of the
central panel 111 that is generally free from joints, creases, folds, pleats,
edges, and other features
that can make sealing a lidding film to the flange more difficult (e.g., that
can reduce the smoothness
of the flange). Accordingly, the upper surface of the central panel 111 in the
trays 105, 305 of the
illustrated embodiment can provide a superior sealing surface than a container
that has features such
as pleats or joints on its upper flange surface.
[0051]
Any of the features of the various embodiments of the disclosure can be
combined with,
replaced by, or otherwise configured with other features of other embodiments
of the disclosure
without departing from the scope of this disclosure.
[0052]
Optionally, one or more portions of the blank or other constructs described
herein or
contemplated hereby may be coated with varnish, clay, or other materials,
either alone or in
combination. The coating may then be printed over with product advertising or
other information or
images. The blanks or other constructs also may be selectively coated and/or
printed so that less than
the entire surface area of the blank or substantially the entire surface area
of the blank may be coated
and/or printed.
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[0053]
Any of the blanks, trays, or other constructs of this disclosure may
optionally include one or
more features that alter the effect of microwave energy during the heating or
cooking of a food item
that is associated with the tray or other construct. For example, the blank,
tray, container, or other
construct may be formed at least partially from one or more microwave energy
interactive elements
(hereinafter sometimes referred to as "microwave interactive elements") that
promote heating,
browning and/or crisping of a particular area of the food item, shield a
particular area of the food
item from microwave energy to prevent overcooking thereof, or transmit
microwave energy towards
or away from a particular area of the food item. Each microwave interactive
element comprises one
or more microwave energy interactive materials or segments arranged in a
particular configuration to
absorb microwave energy, transmit microwave energy, reflect microwave energy,
or direct
microwave energy, as needed or desired for a particular construct and food
item.
[0054] In
the case of a susceptor or shield, the microwave energy interactive material
may comprise
an electroconductive or semiconductive material, for example, 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 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 or alloy thereof
[0055]
Alternatively, the microwave energy interactive material may comprise a metal
oxide, for
example, oxides of aluminum, iron, and tin, optionally used in conjunction
with an electrically
conductive material. Another metal oxide that may be suitable is indium tin
oxide (ITO). ITO has a
more uniform crystal structure and, therefore, is clear at most coating
thicknesses.
[0056]
Alternatively still, 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.
[0057] In
other embodiments, the microwave energy interactive material may be carbon-
based, for
example, as disclosed in U.S. Patent Nos. 4,943,456, 5,002,826, 5,118,747, and
5,410,135.
[0058] In
still other embodiments, the microwave energy interactive material may
interact with the
magnetic portion of the electromagnetic energy in the microwave oven.
Correctly chosen materials
of this type can self-limit based on the loss of interaction when the Curie
temperature of the material
is reached. An example of such an interactive coating is described in U.S.
Patent No. 4,283,427.
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[0059]
The use of other microwave energy interactive elements is also contemplated.
In one
example, the microwave energy interactive element may comprise a foil or high
optical density
evaporated material having a thickness sufficient to reflect a substantial
portion of impinging
microwave energy. Such elements typically are formed from a conductive,
reflective metal or metal
alloy, for example, aluminum, copper, or stainless steel, in the form of a
solid "patch" generally
having a thickness of from about 0.000285 inches to about 0.005 inches, for
example, from about
0.0003 inches to about 0.003 inches. Other such elements may have a thickness
of from about
0.00035 inches to about 0.002 inches, for example, 0.0016 inches.
[0060] In
some cases, microwave energy reflecting (or reflective) elements may be used
as shielding
elements where the food item is prone to scorching or drying out during
heating. In other cases,
smaller microwave energy reflecting elements may be used to diffuse or lessen
the intensity of
microwave energy. One example of a material utilizing such microwave energy
reflecting elements is
commercially available from Graphic Packaging International, Inc. (Atlanta,
GA) under the trade
name MicroRite packaging material. In other examples, a plurality of
microwave energy reflecting
elements may be arranged to form a microwave energy distributing element to
direct microwave
energy to specific areas of the food item. If desired, the loops may be of a
length that causes
microwave energy to resonate, thereby enhancing the distribution effect.
Microwave energy
distributing elements are described in U.S. Patent Nos. 6,204,492, 6,433,322,
6,552,315, and
6,677,563, each of which is incorporated by reference in its entirety.
[0061] If
desired, any of the numerous microwave energy interactive elements described
herein or
contemplated hereby may be substantially continuous, that is, without
substantial breaks or
interruptions, or may be discontinuous, for example, by including one or more
breaks or apertures
that transmit microwave energy. The breaks or apertures may extend through the
entire structure, or
only through one or more layers. The number, shape, size, and positioning of
such breaks or
apertures may vary for a particular application depending on the type of
construct being formed, the
food item to be heated therein or thereon, the desired degree of heating,
browning, and/or crisping,
whether direct exposure to microwave energy is needed or desired to attain
uniform heating of the
food item, the need for regulating the change in temperature of the food item
through direct heating,
and whether and to what extent there is a need for venting.
[0062] By
way of illustration, a microwave energy interactive element may include one or
more
transparent areas to effect dielectric heating of the food item. However,
where the microwave energy
interactive element comprises a susceptor, such apertures decrease the total
microwave energy
interactive area, and therefore, decrease the amount of microwave energy
interactive material
available for heating, browning, and/or crisping the surface of the food item.
Thus, the relative
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amounts of microwave energy interactive areas and microwave energy transparent
areas may be
balanced to attain the desired overall heating characteristics for the
particular food item.
[0063] As
another example, one or more portions of a susceptor may be designed to be
microwave
energy inactive to ensure that the microwave energy is focused efficiently on
the areas to be heated,
browned, and/or crisped, rather than being lost to portions of the food item
not intended to be
browned and/or crisped or to the heating environment. Additionally or
alternatively, it may be
beneficial to create one or more discontinuities or inactive regions to
prevent overheating or charring
of the food item and/or the construct including the susceptor.
[0064] As
still another example, a susceptor may incorporate one or more "fuse" elements
that limit
the propagation of cracks in the susceptor, and thereby control overheating,
in areas of the susceptor
where heat transfer to the food is low and the susceptor might tend to become
too hot. The size and
shape of the fuses may be varied as needed. Examples of susceptors including
such fuses are
provided, for example, in U.S. Patent No. 5,412,187, U.S. Patent No.
5,530,231, U.S. Patent
Application Publication No. US 2008/0035634A1, published February 14, 2008,
and PCT
Application Publication No. WO 2007/127371, published November 8, 2007, each
of which is
incorporated by reference herein in its entirety.
[0065]
All dimensional information presented herein is intended to be illustrative of
certain aspects,
features, etc., of various embodiments of the disclosure, and is not intended
to limit the scope of the
disclosure. The dimensions of the blanks, containers, forming tools, features,
or any other dimension,
can be more or less than what is shown and described in this disclosure
without departing from the
scope of this disclosure and can be within the listed ranges of dimensions for
each feature or outside
the listed ranges of dimensions for each feature without departing from the
scope of this disclosure.
[0066]
The blanks according to the present invention can be, for example, formed from
coated
paperboard and similar materials. For example, the interior and/or exterior
sides of the blanks can be
coated with a clay coating. The clay coating may then be printed over with
product, advertising,
price coding, and other information or images. The blanks may then be coated
with a varnish to
protect any information printed on the blanks. The blanks may also be coated
with, for example, a
moisture barrier layer, on either or both sides of the blanks.
[0067] In
accordance with the exemplary embodiments, the blanks may be constructed of
paperboard of a caliper such that it is heavier and more rigid than ordinary
paper. The blanks can
also be constructed of other materials, such as cardboard, hard paper, or any
other material having
properties suitable for enabling the carton package to function at least
generally as described above.
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[0068]
The foregoing description illustrates and describes various embodiments of the
present
disclosure. As various changes could be made in the above construction without
departing from the
scope of the disclosure, it is intended that all matter contained in the above
description or shown in
the accompanying drawings shall be interpreted as illustrative and not in a
limiting sense.
Furthermore, the scope of the present disclosure covers various modifications,
combinations, and
alterations, etc., of the above-described embodiments. Additionally, the
disclosure shows and
describes only selected embodiments, but various other combinations,
modifications, and
environments are contemplated and are within the scope of the inventive
concept as expressed herein,
commensurate with the above teachings, and/or within the skill or knowledge of
the relevant art.
Furthermore, certain features and characteristics of each embodiment may be
selectively interchanged
and applied to other illustrated and non-illustrated embodiments without
departing from the scope of
the disclosure.
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