Patent Application
20220371808
The present disclosure generally relates to a moisture absorbing device; and more particularly, to a moisture absorbing device configured for coupling to a food container; and more particularly to a moisture absorbing device configured for coupling to an inside surface of a food container, and a method of using the device to reduce the humidity and moisture inside of a food container containing food being transported inside the food container.
When warm or hot food, including crispy or crunchy food, is delivered to a consumer, or taken away from a restaurant by the consumer, the recently cooked food produces steam (water vapor) that can increase the humidity and atmospheric moisture inside of the food container. By the time the consumer is ready to eat the food, even when the period since cooking is brief, the texture and taste of the food will likely have been modified by the moisture inside the food container. Fried foods, including French fries, for example, are often soggy instead of crispy after being transported from a restaurant to the consumers destination. Consumers, therefore, may order specific food items from a menu and not others because certain foods are not appetizing after transport/delivery. Cold food and produce (e.g., berries, lettuce, microgreens) can also create moisture inside of a food container. For example, droplets of condensation can form on the interior surface and then effect the texture and/or taste of food items inside the container. Accordingly, there is a need for an improved method and device for reducing the humidity inside a food container to keep food appetizing after it has been delivered from the restaurant to the location where the consumer will eat it.
In various embodiments, a moisture absorbing device for reducing moisture inside of a food container during use is provided. The device can comprise: a carrier layer having a bottom surface and a top surface separated from the bottom surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a bottom surface in continuous contact with the top surface of the carrier layer, and a top surface separated from the bottom surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; and wherein the absorbent layer comprises a hydrogel composition.
In some embodiments, the absorbent layer further comprises an adhesive.
In some embodiments, the moisture absorbing device further comprises a ventilation layer having a bottom surface in non-continuous contact with the top surface of the absorbent layer and a top surface separated by a third spaced distance from the bottom surface.
In some embodiments, the moisture absorbing device can further comprise an attaching layer having a bottom surface in non-continuous contact with the top surface of the ventilation layer and a top surface separated by a fourth spaced distance from the bottom surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the top surface for attaching the device to a surface of the food container.
In some embodiments, the moisture absorbing device can further comprise a removable sheet covering the top surface of the attaching layer, wherein the adhesive material on the top surface is exposed upon removal of the removeable sheet.
In some embodiments, the moisture absorbing device can further comprise a removeable liner covering the bottom surface of the carrier layer, wherein the bottom surface of the carrier layer is exposed to the moisture inside of the food container upon removal of the removeable liner.
In some embodiments, the hydrogel composition can comprise a polyacrylic acid, polyacrylamide, polyvinyl alcohol, ethylene, maleic anhydride copolymers, polyvinyl ethers, methyl cellulose, carboxymethyl cellulose, hydroxypropylcellulose, polyvinylmorpholinone, or a salt thereof.
In some embodiments, the hydrogel composition can comprise a polyacrylic acid or an alkali metal salt of a polyacrylic acid.
In some embodiments, the hydrogel composition can comprise a polyvinyl alcohol or an alkali metal salt of a polyvinyl alcohol.
In some embodiments, the hydrogel composition is present in an amount from about 5 to about 98 weight percent based on total weight of the absorbent layer.
In some embodiments, the hydrogel composition can absorb at least 10 times its weight in moisture.
In some embodiments, the ventilation layer comprises a fluted structure having a first plurality of open channels extending along the top surface of the absorbent layer.
In some embodiments, the ventilation layer comprises a fluted structure having a first plurality of open channels extending along the top surface of the absorbent layer and a second plurality of open channels extending along the bottom surface of the attaching layer.
In some embodiments, the ventilation layer is comprised of corrugated paper, paperboard, cardboard, and processed into a fluted, wavy, convoluted, accordion, or honeycomb design.
In some embodiments, the carrier layer is comprised of a porous material, a fibrous textile, a non-woven fabric, a tight-weaved material, or a combination thereof; and wherein the carrier layer is configured to allow moisture-containing air from the food container to reach the absorbent layer.
In some embodiments, the removable sheet is comprised of an acrylic-based pressure-sensitive adhesive.
In various embodiments, a method of reducing the moisture inside of a food container containing food is provided. In some embodiments, the food is cooked food having a temperature above room temperature. In some embodiments, the method comprises: adding the food to a first surface of the food container; attaching a moisture absorbing device to a second surface of the food container, the device comprising: a carrier layer having a bottom surface and a top surface separated from the bottom surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a bottom surface in continuous contact with the top surface of the carrier layer, and a top surface separated from the bottom surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; wherein the absorbent layer comprises a hydrogel composition; and closing the food container.
In some embodiments, the absorbent layer in the device of the method further comprises an adhesive; and the method comprises a roll-to-roll assembly of the device, including: providing the carrier layer, depositing the absorbent layer onto the top surface of the carrier layer; and adhering the top surface of the absorbent layer to an interior surface of a food container.
In some embodiments, the device of the method further comprises a ventilation layer having a bottom surface in non-continuous contact with the top surface of the absorbent layer and a top surface separated by a third spaced distance from the bottom surface.
In some embodiments, the device in the method further comprises: an attaching layer having a bottom surface in contact with the top surface of the ventilation layer and a top surface separated by a fourth spaced distance from the bottom surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the top surface for attaching the device to a surface of the food container; and a removable sheet covering the top surface of the attaching layer, wherein the adhesive material on the top surface is exposed upon removal of the removeable sheet.
In some embodiments, the method further comprises, prior to attaching the moisture absorbing device to the second surface of the food container, removing the removable sheet from the attaching layer.
In some embodiments, the device in the method further comprises a removeable liner covering the bottom surface of the carrier layer, wherein the bottom surface of the carrier layer is exposed to the moisture inside of the food container upon removal of the removeable liner.
In some embodiments, the method further comprises, prior to closing the food container, removing the removeable liner from the carrier layer.
In various embodiments, a method of preparing a moisture absorbing device, comprising: a carrier layer having a bottom surface and a top surface separated from the bottom surface by a first spaced distance, wherein the first spaced distance defines a thickness of the carrier layer; and an absorbent layer having a bottom surface in continuous contact with the top surface of the carrier layer, and a top surface separated from the bottom surface by a second spaced distance, wherein the second spaced distance defines a thickness of the absorbent layer; and wherein the absorbent layer comprises a hydrogel composition.
In some embodiments, the absorbent layer in the device of the method further comprises an adhesive; and the method comprises: a roll-to-roll assembly of the device, including: providing the carrier layer, depositing the absorbent layer onto the top surface of the carrier layer; and joining the top surface of the absorbent layer to an interior surface of a food container.
In some embodiments, the device of the method further comprises a ventilation layer having a bottom surface in non-continuous contact with the top surface of the absorbent layer and a top surface separated by a third spaced distance from the bottom surface; and an attaching layer having a bottom surface in non-continuous contact with the top surface of the ventilation layer and an top surface separated by a fourth spaced distance from the bottom surface, wherein the fourth spaced distance defines a thickness of the attaching layer; wherein the attaching layer comprises an adhesive material on the top surface for attaching the device to a surface of the food container; and the method comprising a roll-to-roll assembly of the device, including: providing the carrier layer, depositing the absorbent layer onto the top surface of the carrier layer; adhering the bottom surface of the ventilation layer to the top surface of the absorbent layer; adhering the bottom surface of the attaching layer to the top surface of the ventilation layer; and adhering the top surface of the attaching layer to an interior surface of a food container.
It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein and, together with the description, explain the principles and operations of the claimed subject matter.
A complete understanding of the present embodiments and the advantages and features thereof will be more readily understood by reference to the following detailed description, appended claims, and accompanying drawings, wherein:
The drawings are not necessarily to scale, and certain features and certain views of the drawings may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
Reference will now be made in detail to the exemplary embodiment(s), examples of which is/are illustrated in the examples. Before describing the exemplary embodiments, it is noted the embodiments reside primarily in combinations of components and procedures related to the moisture absorbing device. Accordingly, the composition and method components have been represented where appropriate, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
The specific details of the various embodiments described herein are used for demonstration purposes only, and no unnecessary limitation or inferences are to be understood therefrom.
In various embodiments, a moisture absorbing device and method of using the device to reduce the moisture present inside of a food container are provided. The device is configured to be attached to various food containers, including disposable food containers. The disposable food containers can be paper, paperboard, corrugated fiberboard, plastic- or wax-coated paper, wood, thermoforming (plastics), molded pulp, chip board, or other materials. Examples of disposable food containers include corrugated cardboard pizza boxes, foam (e.g., Styrofoam) clamshells, paperboard clamshells, insulated paper containers, or other existing food containers currently available for packaging food for delivery. In some embodiments, the disposable food container is produced using in-line machinery.
In various embodiments, as shown in
The moisture absorbing device 100 can have any suitable three-dimensional shape, including, for example, shapes that are generally cuboid, rectangular cuboid, cylinder, hemisphere, prism, etc. In such embodiments, the moisture absorbing device 100 has a predetermined height H, as shown in
The moisture absorbing device 100 can have any suitable length L and width W. In some embodiments, the length and width are identical (e.g., square); in other embodiments, the length and width are different (e.g., rectangle). When the length and width are different, as shown in
In some embodiments, the moisture absorbing device 100 has a substantially flat and planar shape so that it can be applied in a manner similar to how a label would be attached to a food container. For example, in some embodiments, the moisture absorbing device 100 can be rolled onto the food container C during a manufacturing step in, for example, a roll-to-roll fabrication process. In such embodiments, the moisture absorbing device 100 has a predetermined height H, as shown in
In some embodiments, during use, the carrier layer 110 comprises a bottom surface 109 that faces the food F located on the lower interior surface B of the food container C, and a top surface 111 that faces the upper interior surface D of the food container C, as shown in
In some embodiments, the carrier layer 110 comprises a water vapor transmission rate that is efficient enough to permit the steam S emanating from the food F, as shown in
In some embodiments, the carrier layer 110 comprises a top surface 111 that faces the absorbent layer 115. In some embodiments, the top surface 111 is in contact with a bottom surface 114 of the absorbent layer 115. In some embodiments, the carrier layer 110 serves as a base upon which the absorbent layer 115 may be carried, casted, and/or established on. In such embodiments, the absorbent layer 115 can be deposited on the carrier layer 110, which will carry the absorbent layer 115 during the manufacturing process. In such embodiments, the carrier layer 110 and the absorbent layer 115 are fused together through physical and/or chemical bonding. In some embodiments, the physical and/or chemical bonding is optionally facilitated, catalyzed, or created by an adhesive material.
In some embodiments, the absorbent layer 115 is positioned between the carrier layer 110 and the ventilation layer 120. In some embodiments, the absorbent layer 115 comprises one or more materials or components that are capable of absorbing moisture, whether in a liquid or gas state, or in the form of a droplet, vapor, steam, etc. The one or more absorbing materials can absorb the moisture by physical means, chemical means, or a combination thereof. Suitable absorbent materials for the absorbent layer 115 include organic materials, such as fibrous materials and polymeric materials, and inorganic materials. Organic fibrous materials include woody or non-woody pulp such as cotton, combined cotton, rayon, recycled paper, and pulp fluff. Organic polymeric materials include superabsorbent materials. In this context, a “superabsorbent” material refers to a water-swellable, water-soluble organic or inorganic material capable, under favorable conditions, of absorbing at least about 10 times its weight, or at least about 20 times its weight, in an aqueous solution containing 0.9 weight percent sodium chloride. Suitable organic superabsorbent materials include natural materials such as guar gum, agar, gelatin, collagen, pectin and the like, and synthetic materials, such as hydrogel polymers.
In some embodiments, the absorbent layer 115 comprises a hydrogel composition that is capable of absorbing moisture, whether in a liquid or gas state, or in the form of a droplet, vapor, steam, etc. In such embodiments, the hydrogel composition can include, for example, one or more of the following: alkali metal salts of polyacrylic acids, polyacrylamides, polyvinyl alcohol, ethylene, maleic anhydride copolymers, polyvinyl ethers, cellulose, okara cellulose, methyl cellulose, carboxymethyl cellulose, hydroxypropylcellulose, polyvinylmorpholinone, and polymers and copolymers of vinyl sulfonic acid, polyacrylates, polyacrylamides, polyvinylpyrridine, and the like. Other suitable superabsorbent materials include hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, hyaluronic acid, chitosan, alginate, and isobutylene maleic anhydride polymers and mixtures thereof.
In some embodiments, the hydrogel composition comprises polymers that are crosslinked to render the materials substantially water insoluble. In such embodiments, the crosslinking may be accomplished, for example, by irradiation or by covalent, ionic, van der Waals, or hydrogen bonding. The superabsorbent materials may be in any form suitable for use in the absorbent layer 115, including, for example, particles, fibers, flakes, spheres, etc. In some embodiments, the absorbent layer 115 comprises the superabsorbent material in an amount from about 5 to about 98 weight percent based on total weight of the absorbent layer, whereby the stated range includes any intermediate endpoints and subranges (e.g., from about 10 to about 95 weight percent, about 15 to about 90 weight percent, about 20 to about 85 weight percent, etc.).
In some embodiments, the absorbent layer 115 comprises a hydrogel composition that is stable enough to be dried during the manufacturing and/or assembly process for the moisture absorbing device 100. In such embodiments, for example, the absorbent layer 115 or the moisture absorbing device 100 may be inserted into an oven to fully remove any moisture residing in the hydrogel, the absorbent layer 115, the carrier layer 110, and/or the ventilation layer 120.
In some embodiments, the absorbent layer 115 further comprises one or more absorption enhancers that increase the rate of condensation (droplet formation) and/or moisture absorption in the absorbent layer 115 or in the superabsorbent hydrogel contained therein. In some embodiments, the absorption enhancer is a salt or salt mixture. In some embodiments, the salt is calcium chloride (CaCl2)) or the like. In various embodiments, the combination of the one or more absorbing materials and the absorption enhancer allows the device to absorb and hold substantially more moisture (e.g., water) than if the absorbent layer 115 were comprised only of a fabric or a similar textile-based absorbent material.
In some embodiments, the absorbent layer 115 further comprises one or more adhesives configured to attach the moisture absorbing device 100 to an inside surface of a food container. In such embodiments, the adhesive can be a synthetic rubber-based or water-borne acrylic-based pressure-sensitive adhesive (PSA) material. In some embodiments, the adhesive is a hot-melt adhesive configured for application via a hot glue gun or the like. Existing hot-melt adhesives that can be utilized include, for example, tackifying resins, waxes, plasticizers, fugitive glues, etc.
In some embodiments, absorbent layer 115 comprises a sheet that is removably attached to and configured to cover the top surface 116. The removable sheet be any suitable material, whereby the suitability is based on its ability to be readily released from the absorbent layer 115 while allowing the absorbent layer 115 to maintain its ability to be attached to a food container. For example, in some embodiments, the absorbent layer 115 comprises an adhesive or other fastening material that can facilitate the coupling of the moisture absorbing device 100 to a food container, but the removable sheet must be non-reactive and allow the absorbent layer 115 to maintain its adhesive and fastening properties. In some embodiments, the absorbent layer 115 includes a synthetic rubber-based or water-borne acrylic-based pressure-sensitive adhesive (PSA) material.
In some embodiments, the moisture absorbing device 100 further comprises the ventilation layer 120. In such embodiments, the ventilation layer 120 is secured to the top surface 116 of the absorbent layer 115. In some embodiments, the ventilation layer 120 is in continuous contact with the top surface 116 of the absorbent layer 115. In other embodiments, the ventilation layer 120 is in non-continuous contact with the top surface 116 of the absorbent layer 115. In some embodiments, ventilation layer 120 comprises a fluted, wavy, convoluted, accordion, or honeycomb design that is designed to increase the exposed surface area of the top surface 116 of the absorbent layer 115. In some embodiments, as shown in
The ventilation layer 120 can be comprised of any suitable material. For example, in some embodiments, the ventilation layer 120 is corrugated paper, paperboard, cardboard, or a similar material that can be processed into a fluted, wavy, convoluted, accordion, or honeycomb design. In some embodiments, the ventilation layer 120 comprises a single layer of material, and in other embodiments, the ventilation layer 120 comprises a plurality of material layers. Single face corrugated paper, for example, generally comprises a medium layer that includes the three-dimensional design (fluted, wavy, etc.), and a liner material having flat surfaces attached to the same. In embodiments comprising a single layer of material, the medium layer of the corrugated paper can be utilized as the ventilation layer 120; i.e., without the liner layer.
In some embodiments, the moisture absorbing device 100 further comprises an attaching layer 125, as shown in
As shown in
In some embodiments, the attaching layer 125 comprises a sheet that is removably attached to and configured to cover the top surface 126. The removable sheet be any suitable material, whereby the suitability is based on its ability to be readily released from the attaching layer 125 while allowing the attaching layer 125 to maintain its ability to be attached to a food container. For example, in some embodiments, the attaching layer 125 comprises an adhesive or other fastening material that can facilitate the coupling of the moisture absorbing device 100 to a food container, but the removable sheet must be non-reactive and allow the attaching layer 125 to maintain its adhesive and fastening properties. In some embodiments, the attaching layer 125 includes a synthetic rubber-based or water-borne acrylic-based pressure-sensitive adhesive (PSA) material. In some embodiments, the adhesive is a hot-melt adhesive configured for application via a hot glue gun or the like. Existing hot-melt adhesives that can be utilized include, for example, tackifying resins, waxes, plasticizers, fugitive glues, etc.
In some embodiments, the moisture absorbing device 100 further comprises a removable liner 105, as shown in
During use, the moisture absorbing device described herein is configured to remove moisture from the inside space of a food container. The function of absorbing moisture in this context must be initiated quickly and last for the amount of time that is typical for food delivery or take out, which ranges about from 5 to 60 minutes, or from about 10 to 45 minutes, or from about 15 to 30 minutes. During such a time period, the moisture absorbing device functions by absorbing the moisture present in the atmosphere, which in turn results in more appetizing food (e.g., dried or fried hot foods).
The adjacent layers of the multilayer construction of the moisture absorbing device 100 can be assembled using any suitable method, including, for example, double-sided tape, glue or another liquid adhesive, or an aerosol adhesive. The moisture absorbing device 100 can be manufactured manually or mechanically. In some embodiments, for example, the moisture absorbing device 100 can be assembled in a roll-to-roll process. In some embodiments, the assembly of the moisture absorbing device 100 can be coupled to the manufacturing process of a food container. In such embodiments, the food container can be manufactured using mechanical systems and then sent to a machine that uses a roll-to-roll process to adhere the device to the food container. In the roll-to-roll process, the moisture absorbing device 100 may be applied to a food container with or without adhesive. In some embodiments, the moisture absorbing device 100 comprises an adhesive material to join the device to a food container. In other embodiments, the adhesive material is absent from the moisture absorbing device 100 and the process utilizes roll-to-roll machines that are configured to apply an adhesive layer to the device before joining it to a food container. And in further embodiments, the moisture absorbing device 100 is joined to a food container without adhesive. In such embodiments, the device is joined to the food container mechanically. For example, the lid of the food container can include slits or tabs that are configured to receive the moisture absorbing device 100.
The following examples are provided to aid in the understanding of the present disclosure, the true scope of which is set forth in the appended claims. One of skill in the art would appreciate that modifications can be made in the procedures set forth without departing from the spirit of the disclosure.
Example 1. A moisture absorbing device comprising an absorbent layer, a carrier layer, a ventilation layer, and an attaching layer, configured in a manner consistent with the device shown in
Example 2. A moisture absorbing device comprising a carrier layer and an absorbent layer which is a modified version of the device shown in
A recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. As will be understood by one skilled in the art, ranges disclosed herein encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art, language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a component provided in 1-3 grams refers to the component being provided in 1, 2, or 3 grams.
As used herein, the use of examples, or exemplary language (e.g., “such as”), is intended to illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.
As used herein, the terms “about” and “substantially” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” and “substantially” will mean up to plus or minus 10% of the particular term.
Exemplary embodiments of the methods are described above in detail. The methods are not limited to the specific embodiments described herein, but rather, steps of the method may be utilized independently and separately from other steps described herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.
This written description uses examples to disclose the present embodiments, including the best mode, and also to enable any person skilled in the art to practice the present embodiments, including making and using the moisture absorbing device or performing any methods. The patentable scope of the present embodiments is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have elements that do not differ from the literal language of the claims, or if they include equivalent elements with insubstantial differences from the literal language of the claims.
This claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 63/191,876 filed on May 21, 2021, the content of which is relied upon and incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63191876 | May 2021 | US |
