Microwavable construct for heating, browning, and crisping rounded food items

Abstract

Various blanks, trays, cartons, systems, and other constructs for heating, browning, and/or crisping a food item are provided.

Description

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. 1A depicts an exemplary blank that may be used to form a microwave energy interactive heating tray, according to various aspects of the present invention;

FIGS. 1B and 1C depict an exemplary receiving element according to various aspects of the present invention, in use;

FIG. 1D depicts a prior art susceptor;

FIG. 1E depicts a microwave interactive heating tray formed from the exemplary blank of FIG. 1A;

FIGS. 1F and 1G schematically depict the tray of FIG. 1A in use;

FIG. 2A depicts another exemplary blank that may be used to form a microwave energy interactive heating tray, according to various aspects of the present invention;

FIG. 2B depicts a microwave interactive heating tray formed from the exemplary blank of FIG. 2A, in use;

FIGS. 3A and 3B depict an exemplary tray assembly that may be used in according to various aspects of the present invention;

FIG. 4A depicts yet another exemplary blank that may be used to form a microwave energy interactive heating tray, according to various aspects of the present invention;

FIG. 4B depicts a microwave interactive heating tray formed from the exemplary blank of FIG. 4A, in use;

FIG. 5 depicts an exemplary blank that may be used to form a carton for use with a microwave energy interactive heating tray, according to various aspects of the present invention;

FIG. 6A depicts an exemplary microwave heating system according to various aspects of the present invention;

FIG. 6B depicts the exemplary microwave heating package of FIG. 6A in use;

FIG. 7A depicts an exemplary microwave energy interactive insulating material for use with various aspects of the present invention;

FIG. 7B depicts another exemplary microwave energy interactive insulating material for use with various aspects of the present invention;

FIG. 7C depicts the exemplary microwave energy interactive insulating material of FIG. 7A in the form of a cut insulating sheet, for use with various aspects of the present invention;

FIG. 7D depicts the insulating sheet of FIG. 7C upon exposure to microwave energy;

FIG. 8 depicts another exemplary microwave energy interactive insulating material for use with various aspects of the present invention;

FIG. 9 depicts yet another exemplary microwave energy interactive insulating material for use with various aspects of the present invention;

FIG. 10 depicts yet another exemplary blank that may be used to form a microwave interactive carton for use with a microwave energy interactive heating tray, according to various aspects of the present invention;

FIG. 11A depicts another exemplary microwave heating system according to various aspects of the present invention;

FIG. 11B depicts the microwave heating package of FIG. 11A in use;

FIG. 12 depicts another exemplary blank that may be used to form a carton for use with a microwave energy interactive heating tray, according to various aspects of the present invention;

FIG. 13A depicts an exemplary carton formed from the blank of FIG. 12, that may be used with a microwave heating system according to various aspects of the present invention.

FIG. 13B illustrates the carton of FIG. 13A in use; and

FIG. 14 depicts still another exemplary blank that may be used to form a microwave interactive carton for use with a microwave energy interactive heating tray, according to various aspects of the present invention.

Claims

1. A blank for forming a microwave energy interactive construct, the blank comprising: a laminate comprising a microwave energy interactive element at least partially secured to a panel in an at least partially overlapping relationship; andat least one flanged receiving element including a plurality of flange segments, wherein the flange segments extend at least generally inwardly and are respectively adjacent to one another, andthe flange segments are at least partially defined by a plurality of disruptions that (a) are respectively disposed between adjacent flange segments of the plurality of flange segments,(b) extend at least partially through the microwave energy interactive element, and(c) extend at least partially through the panel.

2. The blank of claim 1, wherein the plurality of disruptions comprises a plurality of slits.

3. The blank of claim 1, wherein the plurality of disruptions are arranged radially.

4. The blank of claim 1, wherein the flange segments are coplanar with the laminate.

5. A construct formed from the blank of claim 1, wherein the flange segments extend obliquely with respect to a generally planar portion of the laminate.

6. A construct formed from the blank of claim 5, wherein the generally planar portion of the laminate extends at least partially around the flanged receiving element.

7. The construct of claim 6, wherein the generally planar portion of the laminate includes opposite first and second sides,the microwave energy interactive element forms the first side of the generally planar portion of the laminate, andthe flange segments are capable of projecting away from, and are adjacent to, the second side of the generally planar portion of the laminate.

8. The construct of claim 7, wherein the flange segments of the flanged receiving element extend at least partially around and define a receptacle.

9. The construct of claim 8 in combination with a food item, wherein the food item is disposed in the receptacle,portions of the microwave energy interactive element are respective parts of the flanged segments of the flanged receiving element, andat least some of the portions of the microwave energy interactive element that are respective parts of the flanged segments of the flanged receiving element are in opposing face-to-face contact with the food item.

10. A blank for forming a microwave energy interactive tray, the blank comprising: (a) a base panel;(b) a microwave energy interactive element at least partially overlying the base panel; and(c) at least one flanged receiving element including a plurality of flange segments, the flange segments being defined by a plurality of radially arranged slits extending through the microwave energy interactive element and base panel.

11. The blank of claim 10, wherein the microwave energy interactive element comprises a microwave energy interactive material supported on a microwave transparent substrate.

12. The blank of claim 10, wherein the radially arranged slits extend from a physical aperture through the microwave energy interactive element and base panel.

13. The blank of claim 10, wherein the radially arranged slits are arranged in a starburst pattern.

14. The blank of claim 10, wherein the radially arranged slits are arranged in a spiral pattern.

15. The blank of claim 10, wherein each flange segment is defined by a pair of adjacent slits terminating at respective end points, and wherein the blank further comprises a fold line extending between the respective end points.

16. The blank of claim 10, further comprising at least one side panel joined to the base panel.

17. A tray formed from the blank of claim 10.

18. A blank for forming a microwave energy interactive tray, the blank comprising: a first major panel and a second major panel joined along a major fold line, each independently including a microwave energy interactive element, andat least one flanged receiving element including a plurality of flange segments, the flange segments being defined by a plurality of radially arranged slits,wherein the flanged receiving element in the first major panel and the flanged receiving element in the second major panel are arranged in a substantially aligned, opposed relation along a line of symmetry defined by the major fold line.

19. The blank of claim 18, wherein the radially arranged slits extend from a physical aperture through the microwave energy interactive element and the panel.

20. The blank of claim 18, wherein each flange segment is defined by a pair of adjacent slits terminating at respective end points, and wherein the blank further comprises a fold line extending between the respective end points.

21. The blank of claim 18, further comprising at least one minor panel joined to the second major panel along at least one minor fold line.

22. The blank of claim 18, further comprising a first minor panel extending from a first edge of the second major panel along a first minor fold line, a second minor panel extending from a second edge of the second major panel along a second minor fold line, and a third minor panel extending from a third edge of the second major panel along a third minor fold line.

23. A method of forming a microwave interactive heating tray from the blank of claim 12, comprising: (a) folding the first minor panel, the second minor panel, and the third minor panel along the first minor fold line, the second minor fold line, and the third minor fold line, respectively, in a direction away from the microwave energy interactive element;(b) folding the first major panel toward the second major panel along the major fold line; and(c) positioning the folded panels on a substantially planar surface such that the folded first minor panel, the second minor panel, and the third minor panel serve as support elements for the first major panel and the second major panel.

24. A tray formed from the blank of claim 18.

25. A tray assembly comprising: at least one pair of substantially aligned flanged receiving elements in an opposed, facing relation in a first tray and a second tray, wherein each of the flanged receiving elements in the first tray and the second tray includes (a) a plurality of flange segments defined by radially arranged slits extending through the tray, and(b) a microwave energy interactive element independently overlying a substantial portion of each of the flange segments.

26. The tray assembly of claim 25, wherein at least one of the first tray and the second tray comprises at least one elevating element extending therefrom.

27. The tray assembly of claim 25, wherein the radially arranged slits extend in a starburst configuration from a physical aperture.

28. The tray assembly of claim 25, wherein each flange segment is defined by a pair of adjacent slits terminating at respective end points, and wherein the tray further comprises a fold line extending between the respective end points.

29. The tray assembly of claim 25, wherein the flange segments hinge along a fold line between adjacent slits in response to the application of an urging force to the segments.

30. The tray assembly of claim 25, wherein each microwave energy interactive element independently comprises a microwave energy interactive material supported on a microwave transparent substrate.

31. A microwave energy interactive heating system comprising: (a) a carton including (i) a top panel, a bottom panel, and a plurality of walls extending between the top panel and bottom panel, wherein the top panel, bottom panel, and walls define an interior space, and(ii) a first microwave energy interactive element overlying at least a portion of the top panel facing the interior space; and(b) a microwave energy interactive tray dimensioned to be received within the carton, the microwave energy interactive tray including a second microwave energy interactive element at least partially overlying a dimensionally stable base,at least one support element for elevating the base from the bottom panel of the carton, andat least one flanged receiving element including a plurality of hingeable flange segments, wherein the hingeable flange segments are defined by a plurality of radially arranged slits that extend through the microwave energy interactive heating element and dimensionally stable base.

32. The system of claim 31, wherein the first microwave energy interactive element comprises a susceptor.

33. The system of claim 31, wherein the first microwave energy interactive element comprises a microwave energy interactive material supported on a polymeric film.

34. The system of claim 31, wherein the first microwave energy interactive element comprises a microwave energy interactive insulating material.

35. The microwave energy interactive heating system of claim 34, wherein the microwave energy interactive insulating material comprises: (a) a microwave energy interactive material supported on a first polymeric film layer;(b) a moisture-containing layer superposed with the microwave energy interactive material; and(c) a second polymeric film layer joined to the moisture-containing layer in a predetermined pattern, thereby forming one or more closed cells between the moisture-containing layer and the second polymeric film layer.

36. The system of claim 35, wherein the closed cells expand in response to being exposed to microwave energy, and wherein the expanded cells cause the microwave energy interactive material to bulge toward the microwave energy interactive tray.

37. The system of claim 34, wherein the microwave energy interactive insulating material comprises: (a) a susceptor; and(b) a plurality of expandable cells that inflate in response to being exposed to microwave energy.

38. The system of claim 31, wherein the second microwave energy interactive element comprises a microwave energy interactive material supported on a microwave energy transparent substrate.

39. The system of claim 31, wherein the radially arranged slits extend from an physical aperture through the microwave energy interactive element and the base.

40. The system of claim 31, wherein each flange segment is defined by a pair of adjacent slits terminating at respective end points, and wherein the tray further comprises a fold line extending between the respective end points.

41. A method of heating, browning, and crisping a food item in a microwave oven comprising: (a) providing a microwave energy interactive heating tray, the tray including a dimensionally stable base having at least one elevating support element extending from a first surface thereof,a microwave energy interactive element at least partially overlying a second surface opposed to the first surface, andat least one flanged receiving element including a plurality of hinged flange segments, the flange segments being defined by a plurality of radially arranged slits extending through the microwave energy interactive element and dimensionally stable base;(b) urging the food item against the flanged receiving element, thereby causing the flange segments to deflect in a direction toward the support element;(c) lodging the food item between the deflected flange segments, such that at least a portion of the food item is in intimate contact with the microwave energy interactive element; and(d) exposing the food item lodged within the receiving element to microwave energy.