Packaging and food suitable for use in a microwave oven

Abstract

In some embodiments, the apparatus and methods disclosed herein are useful in providing a convenient, microwaveable package for cooking and crisping food in a microwave oven. In some embodiments, the microwaveable packaged food includes an outer package and a quantity of food contained within the outer package. By one method, the package has a multi-layered microwaveable tray having at least three layers including a susceptor layer having a plurality of discrete openings disposed thereon and therein of a material that interacts with microwave energy, an absorbent pad layer having a flexible paper-based material adapted to absorb moisture and grease, and a paperboard base layer providing structure to support the susceptor layer and the absorbent paperboard base layer. In this manner, the microwaveable tray or support has at least three macroscopic layers including a susceptor, an absorbent pad, and a paperboard support, some of which layers can also include additional layers as discussed below.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 62 / 428,314, filed November 30, 2016, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] This invention generally relates to packaged foods, and packaging for the transport, retail display, storage and microwave cooking of convenience foods.

[0004] background

[0005] Convenience foods require consumers to cook minimally and can be consumed immediately after purchase or heating in a microwave oven. One of the problems associated with the use of microwave energy (i.e., electromagnetic radiation with frequencies of approximately 0.3–300 GHz, typically around 2.45 GHz) for cooking food in a microwave oven is the uneven heating of the food. Significant temperature variations can occur where uniform temperature is desired. This problem is partly due to the often uneven power distribution within the oven cavity. Uneven power density creates "hot spots" and "cold spots" within the cavity.

[0006] Another reason for this problem is that, during a typical heating cycle, food does not usually exhibit a uniform temperature response to microwave radiation throughout its entire volume. In particular, when microwave radiation is applied to food, some parts of the food cook before others and may become overcooked while other parts remain uncooked.

[0007] Numerous efforts have been made to address the problem of uneven heating. Various types of turntables, sensors, reflectors, and shields have been proposed as solutions. However, due to variations in power, cavity size, and magnetic field configuration, devices suitable for some commercially available microwave ovens may exhibit unacceptable performance in others. Furthermore, some devices that could improve cooking are unacceptable because they are prone to arcing or sparking. Additionally, devices that shield food and / or reflect radiation away from it prolong cooking time. Typical foods possess heterogeneous thermal resistance and heterogeneous dielectric properties. Moreover, the dielectric properties of these foods often change during cooking. These factors further complicate efforts to improve cooking speed and uniformity. Among the factors considered when developing new convenience foods, the ability of packaging to address these issues while also facilitating microwave heating is one.

[0008] One particularly challenging popular food is bacon, due to the unevenness of bacon strips, the oil and moisture retained during and after cooking, and the fact that bacon strips change size and shape during cooking. Brief description of the attached diagram

[0010] This document discloses embodiments of systems, apparatus, and methods relating to microwave-safe packaging and food. The description includes accompanying drawings.

[0011] Figure 1 This is a top perspective view of food packaging in some implementations.

[0012] Figure 2 It is a flat configuration Figure 1 A top view of a portion of the packaging.

[0013] Figure 3 It is an unopenable configuration. Figure 1 Top perspective view of the packaging.

[0014] Figure 4 This is a top perspective view of another food package according to several embodiments.

[0015] Figure 5 It is an unopenable configuration. Figure 4 A portion of the top perspective view.

[0016] Figure 6 yes Figure 4 A portion of the top perspective view.

[0017] Figure 7 yes Figure 4 A top view of a portion of it.

[0018] Figure 8 This is a top view of another food package according to several embodiments.

[0019] Figure 9 yes Figure 8 A cross-sectional view of a portion of it.

[0020] Figure 10 It is shown Figure 9 A schematic cross-sectional view showing additional details of the layers.

[0021] Figure 11 This is a top view of another food package according to several embodiments.

[0022] Figure 12 This is a top view of another food package according to several embodiments.

[0023] Figure 13 yes Figure 12 A cross-sectional view of a portion of it.

[0024] Figure 14 It is shown Figure 13 A schematic cross-sectional view of multiple layers of additional details.

[0025] Figure 15 This is a top view of another food package according to several embodiments.

[0026] Figure 16 This is a top view of another food package according to several embodiments.

[0027] Figure 17 This is a top perspective view of another food package according to several embodiments.

[0028] Figure 18 yes Figure 17 A portion of the top perspective view.

[0029] For the sake of simplicity and clarity, the elements are illustrated in the accompanying drawings, and these elements are not necessarily drawn to scale. For example, the dimensions and / or relative positions of some elements in the drawings may be enlarged relative to other elements to aid in understanding the various embodiments of the invention. Similarly, to facilitate less obstructed observation of these various embodiments of the invention, common but well-known elements that are useful or necessary in commercially feasible embodiments are often not shown. Certain actions and / or steps may be described or depicted in a specific sequence of occurrence, but those skilled in the art will understand that such specificity regarding the sequence is not actually necessary. The terms and expressions used herein have their usual technical meaning as those skilled in the art would use in light of the above description, unless otherwise set forth herein.

[0030] Detailed Explanation

[0031] Generally, this document describes convenient microwave-safe packaging for cooking and crisping foods (such as raw bacon or other meats) in a microwave oven, according to various embodiments. In some embodiments, the microwave-safe packaged food includes an outer packaging and a quantity of food contained therein, wherein the packaged food can be heated in a microwave oven. One method involves a flat, multi-layered microwave-safe support or tray having at least three layers, including a sensor layer, an absorbent pad layer, and a cardboard base layer; the sensor layer contains a microwave energy-interacting material thereon and a plurality of discrete openings therein; the absorbent pad layer has a flexible paper-based material suitable for absorbing moisture and grease; and the cardboard base layer provides a structure supporting the sensor layer and the absorbent pad layer. In this way, the microwave-safe tray or support has at least three macroscopic layers including a sensor layer, an absorbent pad, and a cardboard support, some of which may include additional layers as described below. In one embodiment, the sensor is adhered to a cardboard base (on the side of the sensor opposite its product contact surface), and the cardboard base is adhered to the absorbent pad. In another embodiment, an absorbent pad is disposed between the sensor and the cardboard base. As used herein, the cardboard base typically supports the weight of the food on it, and the sensor is a support or macro layer of the tray that comes into contact with the product.

[0032] In one exemplary method, the receptor is a metallized multilayer film with multiple layers on the bottom laminated onto a paper layer. More specifically, in one example, the receptor layer comprises a multilayer flexible structure having at least one top product contact layer with a metallized material, thereon having a microwave energy-interacting material, and a paper layer (which may include functional additional paper layers or multiple layers). In another example, the multilayer flexible structure of the receptor layer also includes additional polymer layers. As used herein, the multilayer flexible structure of the receptor layer may have a receptor thickness between about 0.002 inches and about 0.020 inches. Furthermore, the basis weight of the receptor layer may be between about 40 and about 60 pounds per 3000 square feet.

[0033] In some configurations, the top surface area of ​​a multi-layered microwave oven support is approximately 50 square inches to approximately 80 square inches. Alternatively, a microwave oven support may have a total support width of approximately 9.0 inches, a total support length of approximately 6.5 inches, and a support thickness of approximately 0.03 inches to approximately 0.07 inches. Therefore, in one configuration, the support occupies approximately 9 inches × approximately 6.5 inches.

[0034] As described above, the receptor material or layer may have perforations, holes, or openings therein to facilitate the drainage of grease and / or moisture from the food contact surface of the receptor. Furthermore, in some configurations, the discrete openings have a higher density at the center of the tray or support suitable for microwave ovens. For example, in one exemplary configuration, the discrete openings are arranged in a radial pattern or configuration emanating from the center of the receptor layer. In some embodiments, the support includes about 30 to about 80 discrete openings, each with a diameter of about 0.125 inches to about 0.25 inches. In one exemplary embodiment, the microwave-safe support has a receptor layer area to opening area ratio of about 40:1 to about 80:1. A method is used to provide a greater number of discrete openings at or near the center of the receptor layer, which is typically used when cooking bacon and other meats to achieve a uniform distribution of grease and moisture in meat products. In one exemplary method, the receptor layer includes about 65 to about 85 discrete openings with diameters between about 0.1 inches and about 0.3 inches, and a surface area ratio of about 60:1 to about 70:1. In another configuration, the receptor layer has approximately 73 discrete openings, each with a diameter of approximately 0.125 inches, resulting in a receptor layer area ratio of approximately 64:1 to approximately 65:1. By having a perforated pattern within these ranges, a certain amount of grease is removed during cooking and crisping of foods, avoiding a chewy and / or greasy result or significant shrinkage. These ranges are particularly suitable for cooking bacon in a manner very similar to deep-frying bacon.

[0035] In operation, the cardboard base layer functions as a carrier or support for the receptor layer and absorbent pad, thus providing the necessary rigidity for supporting food on it. The cardboard layer may (or may not) be multi-coated on one or both sides to repel grease and / or moisture. In some constructions, the base thickness of the cardboard base layer is between about 0.010 inches and about 0.030 inches. In some embodiments, the base weight of the cardboard layer is about 50 to about 80 pounds per 1000 square feet. In one method, the cardboard base layer has a thickness of about 12 to about 16 points. In another method, the cardboard base layer is a solid bleached sulfate cardboard base layer of about 14 or about 16 points. In yet another method, the cardboard base is about 0.019 inches to about 0.022 inches thick. Furthermore, while the receptor layer and absorbent pad can have a multi-layer construction, the cardboard base layer can have a single-layer construction.

[0036] As described above, in some constructions, the absorbent pad is a multi-layered flexible structure for absorbing grease and / or moisture, and may include a paper layer, a transparent polyethylene layer, and a nonwoven paper base layer. In one method, the absorbent pad thickness is between about 0.010 inches and about 0.040 inches, with a basis weight of about 135 pounds per ream (1000 square feet). In another method, the absorbent pad thickness is about 0.023 inches.

[0037] As described above, the layers of a microwave oven support can be configured in various ways. For example, although the sensor layer is typically disposed on the food contact surface of the support, the order of these layers can vary. Additionally, the dimensions of these layers can vary relative to each other. In one method, the sensor layer, absorbent pad layer, and cardboard base layer can extend together. In another method, the sensor layer covers a smaller surface area of ​​the microwave oven support than the cardboard base layer covers. For example, in one method, the absorbent pad may be disposed only below discrete openings in the sensor layer or only below the sensor layer. In another instance, the absorbent pad may extend together with the sensor layer and / or the cardboard layer. In one exemplary method, the sensor layer covers approximately 40% to approximately 60% of the entire support surface area. In another configuration, the cardboard base layer of the microwave oven support extends beyond the periphery of the sensor layer, allowing the consumer to grasp the cardboard base layer without touching the sensor layer. In some configurations, the sensor layer covers a smaller surface area of ​​the microwave oven support than the cardboard base layer covers, and the sensor layer has a circular configuration typically disposed within the central region of the microwave oven support. This also allows consumers to use the perimeter of the cardboard base as a safe area when removing food packaging from the microwave, as these edge areas remain relatively cool.

[0038] In some embodiments, the package may include a rectangular support. More specifically, the package may include a rectangular self-assembly support configured to lift the multi-layered microwave-safe support or tray from the bottom of the microwave oven. Furthermore, in some configurations, the microwave-safe support may have one or more upright flanges disposed along the edge of the microwave-safe support.

[0039] In some illustrative methods, microwave-safe packaged foods include an outer packaging and a certain amount of raw bacon contained within the outer packaging. In such a configuration, the packaged food facilitates heating in a microwave oven, wherein the bacon contains at least about 7.5% to about 18.5% protein, and the packaging has a flat, multi-layered microwave-safe support having at least three layers, including a sensor layer, an absorbent pad layer, and a cardboard base layer; the sensor layer has a microwave-interacting material and has a plurality of discrete openings arranged radially therein; the absorbent pad layer has a flexible paper-based material for absorbing moisture and grease; the cardboard base layer supports the sensor layer and the absorbent pad layer. In such a configuration, the amount of grease not absorbed by the support during microwave cooking of the bacon is less than about 10%. In one configuration, less than about 8% of the grease is not absorbed by the support. In another configuration, less than about 6% of the grease is not absorbed by the support.

[0040] In another exemplary configuration, raw meat packaging configured to cook raw meat in a microwave oven includes an angled structure or V-bracket of cardboard with receptors and an absorbent pad. By one method, microwave-safe packaged food includes a multi-layered microwave-safe support having a top support surface and a lower support surface connected by side support walls and an absorbent pad between the top and lower support surfaces, the top support surface, the side support surfaces, and the side support walls being formed of cardboard material; additionally, in such a configuration, the top support surface has a receptor layer disposed thereon, the receptor layer having a microwave-interacting material thereon and a plurality of discrete openings disposed in the receptor layer; and the top support surface has an angled structure having a plurality of discrete openings in the receptor layer configured to allow moisture and grease to drain. Furthermore, by one method, the absorbent pad layer has a flexible paper-based material suitable for absorbing moisture and grease, which drains through the openings in the receptor layer into the absorbent pad below the top support surface.

[0041] In a package with an angled top surface, the receptor layer may comprise a multilayer flexible structure having at least one top product contact layer with a metallized material and a microwave energy-interacting material thereon, a paper layer, and an angled top support surface; the angled top support surface has a V-shape and a centrally located lowest discharge port. Furthermore, in some configurations, at least some of a plurality of discrete openings are disposed in recesses of the angled top support surface. Similar to some embodiments discussed above, in some configurations, the discrete openings are arranged in a radial configuration.

[0042] The packaging outlined in this article provides a quick way to cook and crisp meat in the microwave by using a sensory layer that cooks raw meat (or other foods) quickly and evenly, and an absorbent pad to control any oil, grease, or moisture (byproducts of the cooking process). In short, the packaged food comprises a cardboard base connected (e.g., by lamination) to a metallized sensory material and an integrated absorbent material. The combination of these elements is ideally configured to balance the removal of grease from the food contact surface from the sensory layer with the simultaneous provision of sufficient oil or grease (e.g., a minimum amount of grease on the surface) to achieve proper crispness. This packaging may be particularly appealing to consumers who wish to enjoy fried bacon (or other foods that may produce oil or grease during cooking, such as sausages, cold cuts, or deli meats) but want to avoid the mess and odors associated with frying these foods, or who prefer a one-time serving of such food.

[0043] Figure 1 A microwave-safe packaged food 10 is shown, having raw meat 12 (e.g., raw bacon) on it. Besides raw bacon 12, the packaged food may contain, for example, meatballs, potato chips, baked goods, vegetable chunks or flakes, processed foods and / or other meats, as well as unprocessed, previously or partially cooked foods, and other options. As shown, the packaged food 10 includes a multi-layered microwave-safe tray or support 14 having a top support surface 16 and a lower support surface 18 connected by side support walls 20. Between the top support surface 16 and the lower support surface 18, the microwave-safe support 14 has an absorbent pad 22 configured to absorb grease and / or moisture from the raw meat 12 or other foods during microwave cooking.

[0044] To cook, heat, crisp, and / or brown the food 12, a microwave oven-safe support 14 has a sensor layer 24. In one configuration, the sensor layer 24, having a microwave energy-interacting material, is disposed on a top support surface 16. Furthermore, as shown, the sensor layer 24 has a plurality of discrete openings 26 disposed therein. The plurality of discrete openings 26 extend through the sensor layer 24 and the top support surface 16 to allow moisture and grease to drain or be removed. Additionally, an absorbent pad layer 22 disposed between the top support surface 16 and the lower support surface 18 absorbs at least some of the moisture and grease that separates from the bacon 12 during cooking in the microwave oven. In one configuration, the absorbent pad layer 22 (located below the top support surface 16) has a flexible paper-based material suitable for absorbing moisture and grease flowing through the sensor layer 24 and the discrete openings 26 in the top support surface 16.

[0045] In one configuration, the top support surface 16 has an angled configuration. In another configuration, at least some of the plurality of discrete openings 26 are disposed in the recesses 30 of the angled top support surface 16. In some embodiments, the sensor layer 24 is a multilayer flexible structure having at least one top product contact layer with a metallized material, thereon a microwave energy interaction material, and a paper layer. Furthermore, in one method, the angled top support surface 16 has a V-shaped configuration with a centrally located lowermost discharge port 28.

[0046] In some embodiments, a plurality of discrete openings 26 are arranged primarily along the recesses of the angled top support surface 16. In other configurations, some of the discrete openings may be located at other locations on the sensor layer 24 and the top support surface 16. Various configurations can be employed, as discussed in more detail below. For example, the discrete openings may be arranged at a higher density at the center of the support surface or tray suitable for a microwave oven. In one exemplary method, the plurality of discrete openings are configured in a radial configuration (which may also include a higher density of openings at the center of the support suitable for a microwave oven).

[0047] In one method, the top support surface 16, the lower support surface 18, and the side support wall 20 are made of cardboard material. Figure 2 A cardboard blank 32 is shown for forming a portion of a microwave-safe support surface 14 made of cardboard. The cardboard blank 32 includes a top support surface 16, sidewalls 20, and a lower support surface 18. Furthermore, the top support surface 16 has a plurality of discrete openings 26 disposed therein. As described above, the discrete openings 26 are also provided in the sensor layer 24 (in such a way that the discrete openings in the sensor layer and the discrete openings of the top surface 16 are aligned with each other to facilitate efficient drainage of moisture and grease from the product contact surface of the sensor layer 24). Although the discrete openings 26 extend through the top support surface 16, in other configurations discussed below, the support surface or tray may not have any openings in the cardboard layer. Figure 2 Also shown is a tongue or extension 34 extending from the support surface 16 (which may also extend from the lower support surface 18), which can be secured to the lower support surface 18 (or the top support surface 16). In one exemplary method, the extension 34 may be secured to the other end of the cardboard blank 32 before or after the sensor layer 24 and / or absorbent pad 22 are secured thereto.

[0048] Once the sensor layer 24 and absorbent pad 22 are secured to the cardboard blank 32 and the extension 34 is secured to the reminder on the blank 32, the raw bacon 12 can be placed on the microwave-safe packaged food 10, and then wrapped, vacuum-packed, and / or sealed within a film 36 (e.g., an ethylene-vinyl alcohol barrier film). In one exemplary method, the cardboard blank 32 is placed in a film packaging material 36 with a generally flat configuration (see, for example...). Figure 3 This allows the consumer to reconfigure the cardboard blank 32 from a flat transport or delivery configuration when removing the microwave-safe packaged food 10 from the film 36. Figure 1 The configuration consists of an inclined top support surface 16 and sidewalls 20 that are generally perpendicular to and typically perpendicular to the lower support surface 18.

[0049] In operation, the consumer can open the bag or film 36 by tearing open the vacuum-sealed container, remove the packaged food 10 from the film 36 (this helps prevent the food from cooking inside the bag, which could result in a tough texture), erect the multi-layer microwave-safe support 14 (if desired), and optionally place a paper towel on top of the packaged food 10 in the microwave to prevent grease splattering, then microwave the raw bacon for about 2 to about 5 minutes. This allows the consumer to cook the raw bacon into crispy cooked bacon in minutes without the tough texture typically associated with microwaved bacon. This is achieved by allowing the absorbent pad 22 to pull the grease and moisture from the surface of the receptor layer 24 in a relatively quick manner, not too quickly, so that a small amount of grease remains on it to provide the crispy appearance of fried bacon and the texture that consumers generally prefer (without noticeably shrinking the bacon). While some consumers prefer to use a paper towel on top of the packaged food 10, the relatively quick removal of grease by the absorbent pad 22 generally results in less grease splattering during microwave cooking of bacon in a microwave oven at a capacity that cannot be accommodated. Paper towels can be included as part of packaged food.

[0050] Figure 4 Another microwave-safe packaged food 110 is shown, on which food 112 (e.g., raw bacon) is placed. Although some of the aforementioned figures include angled food-supporting surfaces, Figure 4A generally flat microwave-safe tray or support is shown. In this configuration, the microwave-safe packaged food 110 includes an outer packaging, such as film packaging and / or a box (not shown), and a portion of food 112 contained therein. The packaged food 112 is configured to be heated in a microwave oven, and the packaging facilitates heating of the food thereon. In some embodiments, the flat, multi-layered microwave-safe support 114 has at least three layers, including a sensor layer 124, an absorbent pad 112, and a cardboard base layer 116. The packaged food 110 may also include optional supports 138 in some configurations. In one exemplary configuration, the microwave-safe support has a total support width of about 9.0 inches, a total support length of about 6.5 inches, and a support thickness of about 0.03 inches to about 0.070 inches.

[0051] In one method, a microwave-interacting material is present on a receptor layer 124, and a plurality of discrete openings 126 are disposed in the receptor layer 124. As described below, the receptor layer 124 may have multiple layers. The receptor layer 124 typically has a plurality of discrete openings 126 disposed therein. In one exemplary method, the plurality of discrete openings 126 are configured to have a higher density of discrete openings 126 at the center of a support or tray suitable for a microwave oven.

[0052] As described above, like the support or tray 114 suitable for a microwave oven, the sensor layer 124 is a multilayer structure. In one method, the sensor layer 124 is a multilayer flexible structure having at least one top product contact layer with a metallized material, thereon a microwave energy interacting material, and a paper layer. In another method, the multilayer flexible structure of the sensor layer 124 also includes an additional polymer layer. Typically, the paper layer of the sensor layer 124 is not exposed, allowing for minimal absorption of grease and / or moisture. For example, in some configurations of the paper layer of the sensor layer 124, the paper layer is embedded but not exposed. In one configuration, the sensor layer 124 has a sensing thickness between about 0.002 inches and about 0.020 inches.

[0053] In one configuration, the microwave oven support 114 has a top surface area of ​​approximately 50 square inches to approximately 80 square inches. In another configuration, the discrete openings with a higher density at the center of the microwave oven tray have a radial arrangement. In some embodiments, the receptor layer 124 has approximately 30 to approximately 80 discrete openings 126 within it. Furthermore, in some configurations, the diameter of each discrete opening 126 is approximately 0.125 inches to approximately 0.25 inches. By one method, the ratio of the receptor layer area to the opening area of ​​the microwave support is between approximately 40:1 and approximately 80:1.

[0054] On the other hand, absorbent pad layer 122 comprises a flexible paper-based material suitable for absorbing moisture and grease. Similar to receptor layer 124, absorbent pad layer 122 can also be a multi-layered flexible structure. In one method, the absorbent pad has a paper layer for absorbing moisture and grease, a transparent polyethylene layer, and a nonwoven paper base layer. In some embodiments, the pad thickness of absorbent pad layer 122 is between about 0.010 inches and about 0.040 inches. The basic weight is about 135 pounds per ream (1,000 square feet).

[0055] In another aspect, the cardboard base layer 116 supports the sensor layer 124 and the absorbent pad layer 122. As described above, the cardboard base layer 116 may be a single layer and may have a base thickness between about 0.010 inches and about 0.030 inches.

[0056] like Figure 4 As shown, the microwave-safe food container 110 may have a support 138 that raises the flat, microwave-safe support 114 from the bottom or lower point of the microwave oven. Figure 6 As shown, the packaging may include a rectangular support, which may be, for example, an automatically assembling support configured to elevate the microwave-safe support 114. If the food packaging includes a support 138, the support 138 is typically located outside the vacuum-packed container containing the food 112 to reduce the amount of air in the packaging, or the support 138 may be included in a flat structure. Figure 5 A flat microwave oven-safe support 114 and food 112 disposed in a film package 136 are shown. Figure 5 A film package 136 with four side seals is shown. Many film packages can be used to transport food 112 and maintain its freshness.

[0057] In some embodiments, the receptor layer 124, the absorbent pad layer 122, and the cardboard base layer 116 do not extend together. For example, in some configurations, the surface area of ​​the receptor layer 124 covering the microwave oven support 114 is less than the surface area of ​​the cardboard base layer 116 covering the microwave oven support 114. Figure 7 A receptor layer 124 is shown, covering a surface area smaller than the entire surface of the microwave support 114. For example, the peripheral edge of the receptor layer 124 does not extend to the peripheral edge of the support 114 or the peripheral edge of the cardboard base layer 116 suitable for a microwave oven. In one method, the receptor layer covers approximately 40% to approximately 60% of the entire surface area of ​​the support. While the absorbent pad 122 may be disposed only below the discrete opening 126 or the receptor layer 124, in some configurations, the absorbent pad 122 extends together with the cardboard layer 116, even if the receptor layer 124 covers less than the entire surface area of ​​the support. In other embodiments, the receptor layer, the absorbent pad layer, and the cardboard base layer extend together with each other.

[0058] Figure 8 A top view of one embodiment is shown, in which the receptor layer 124, absorbent pad layer 122, and cardboard base layer 116 extend together in length and width. Although the receptor layer 124 is primarily visible in the top view, discrete openings 126 in the receptor layer 124 allow access to the absorbent pad 122 beneath it. Figure 9 As shown in the cross-section, in this configuration, a cardboard base layer 116 is sandwiched between the receptor layer 124 and the absorbent pad 122. Therefore, discrete openings 126 extend through the receptor layer 124 and the cardboard base layer 116 to the absorbent pad 122. While the cardboard base layer 116 absorbs only a small amount of grease and moisture, the absorbent pad 122 absorbs enough grease and moisture to allow the bacon product to cook and become crisp during microwave cooking without becoming chewy. Furthermore, the perforated pattern of discrete openings in the receptor layer is formed in a way that retains sufficient grease on the food to make it crisp without excessively shrinking the food (which would occur if there wasn't enough grease on the food positioned on the receptor layer during cooking).

[0059] Figure 10 A schematic diagram of various multilayer structures is shown for one embodiment of a support 114 suitable for a microwave oven. In some embodiments, the receptor layer 124 may include, for example, a metallized material, a paper layer, and / or a polymer layer, and the absorbent pad layer 122 may include, for example, a paper layer, a polyethylene layer, and a nonwoven paper base layer, for absorbing moisture and grease. To illustrate the combination of these layers, Figure 10 This illustrates how the winding of these different materials (i.e., the three macroscopic layers) can be combined to form a support 114 suitable for a microwave oven. These three layers can be attached together by, for example, heating, pressurizing, gluing, or adhesive bonding, or a combination thereof. Additionally, as mentioned above, the order of these layers can be varied.

[0060] Another configuration with non-common extension layers is shown in Figure 11 In this configuration, the surface area of ​​the sensor layer 124 covering the microwave-safe support 114 is less than the surface area of ​​the cardboard base layer 116 covering the microwave-safe support 114. Furthermore, the sensor layer 124 has a generally circular configuration, typically positioned at the center of the microwave-safe support 114. Additionally, discrete openings in a radial configuration are centrally located on the sensor layer 124. By means of a method, the cardboard base layer 116 extends beyond the periphery of the sensor layer 124, allowing the consumer to grasp the cardboard base layer 124 without touching the sensor layer 124, which may become hot to the touch after microwave cooking.

[0061] like Figure 7 , Figure 8 and Figure 11 As shown, the receptor layer 124 may have a radial pattern of discrete openings 126 disposed therein. Although the discrete openings shown in these figures have a generally circular structure, other structures are also possible. For example, the discrete openings may be rectangular, elliptical, or rhomboid, etc.

[0062] Figure 12 A microwave oven-safe support 214 with a sensor layer 224 having discrete openings 226 is shown. Figure 12 A radial pattern, slightly different from the previous pattern, is shown, and includes discrete diamond-shaped openings 226. Figure 13 The cross-section shows a support 214 suitable for a microwave oven, having an absorbent pad 222 sandwiched between a food-contacting sensor layer 224 and a cardboard base layer 216. Therefore, the discrete openings 226 extend only through the sensor layer 226 and not through the intermediate absorbent pad layer 222. Figure 14 A three-layer combination with a receptor layer 226 and an absorbent pad layer 222 is shown, each of which has multiple layers.

[0063] In some embodiments, discrete openings in the receptor layer (and, in some embodiments, the cardboard layer) can be formed in the receptor layer (and optionally the cardboard layer) via, for example, die-cutting or laser cutting. In one exemplary method, the discrete openings are cut into the material before the receptor layer is attached to the absorbent pad.

[0064] A microwave oven-safe tray or support can be formed by laminating three macroscopic layers (i.e., a sensor layer, an absorbent pad, and a cardboard base) together. When forming a microwave oven-safe tray or support with multiple layers that typically extend together, the three layers can usually be continuously or intermittently unrolled and laminated (or otherwise attached) together. In another construction, for example, when the sensor layer is inserted onto a cardboard base, discrete sensor films can be cut from a roll of sensor film, and then, after aligning the sensor film, the cardboard base, and / or the absorbent pad, the sensor film is laminated to the cardboard base and / or the absorbent pad by, for example, adhesive or other means. In some constructions, the sensor layer and the absorbent pad are laminated together, cut from the roll, aligned with the cardboard base, and then adhered thereto.

[0065] One method allows three macrolayers (i.e., the absorbent pad, the receptor, and the cardboard base) to be laminated together at approximately the same time. For example, as described above, the three macrolayers can be unrolled and laminated together shortly thereafter. In another construction, these macrolayers can be applied or laminated in stages. As an example, the receptor layer can be applied to the cardboard base, and the absorbent pad can then be attached to it. For example, the receptor layer and the cardboard base can be attached, with discrete openings die-cut into them, and then the absorbent pad can be attached to them.

[0066] Figure 15 Another radial configuration of discrete openings 326 in the receptor layer 324 of the support member 314 suitable for a microwave oven is shown. Furthermore, Figure 16 The diamond-shaped discrete opening 326 shown is configured through the elliptical receptor layer 324. In addition to elliptical and circular receptor layers, the discrete receptor layer can be square, diamond, star, or other shapes, but the receptor layer is typically located at the center of the support or tray suitable for a microwave oven.

[0067] Figure 17 Another embodiment of a microwave-safe packaged food 310 with raw bacon 312 disposed thereon is shown. Product 310 includes a multi-layered microwave-safe support 314 having a sensor 324, an absorbent pad 322, and a cardboard base 316. The cardboard base 316 may have one or more upright flanges 340 disposed at the edges of the microwave-safe support 314. Figure 18 As shown, the cardboard base layer 316 may have a central portion 315 and a wing or flange 340 below the absorbent pad layer 322 and the receptor layer 324. This wing or flange 340 can be transported to the consumer in a flat configuration, but it can be folded into an upright or raised configuration. It is typically perpendicular to the central portion 315 of the cardboard base layer 316. When in... Figure 17 When configured for microwaving, the flange 340 of the cardboard base 316 helps retain grease that may splatter during microwave cooking and provides consumers with an easy-to-grip cardboard section to remove the package from the microwave. While Figure 17 Includes flanges 340 on three sides of the packaging, but the flanges may be provided only on two sides. Example

[0068] The embodiments included herein illustrate this disclosure but are not intended to limit it. These embodiments are intended to illustrate the differences between more conventional packaging and packaging having some of the features described herein. For example, compared to existing stocksusceptor material (referred to as the Control in the table below), four strips of bacon were microwaved, and the weight of each component of the packaging was weighed before and after the microwave cooking operation, quantifying the absorption capacity of a microwave-safe tray or support using an absorbent pad (referred to as the Packaging Test in the table below). Figure 8 Similarly, the test package in the following embodiment includes a microwave-safe support having a sensor layer, a cardboard base layer, and an absorbent pad layer. The control package, however, only has a sensor layer and a cardboard base without any discrete openings.

[0069] More specifically, the absorbent pad (in the packaging test) was weighed, as were the receptor cards (i.e., the receptor layer and cardboard base) of both the packaging test material and the control material. The weight of four raw bacon strips was also weighed before they were placed on the packaging and microwaved for 2.5 minutes at 1100W. After removing the packaging from the microwave, the cooked bacon was weighed, as were the grease and moisture drained from the tray, the receptor tray, and the absorbent pad (in the packaging test). All data are summarized below in grams.

[0070] Table 1: List of the measurement results listed above

[0071]

[0072] Average -> 11.57

[0073]

[0074]

[0075] Average -> 0.37

[0076] Table 2: Analysis of the weight data collected in columns A through G above

[0077]

[0078] Average -> 72.31

[0079]

[0080]

[0081] Average -> 3.72

[0082] The total grease listed in Column 1 is the weight difference of the components, i.e., the receptor tray and absorbent pad (if present), before and after cooking, plus the weight of the grease that was poured out. Column 4 shows the total unabsorbed grease, which is the total grease in Column 1 minus the amount of grease absorbed by the components, i.e., the receptor tray and absorbent pad in the test package. Finally, Column 5 shows the percentage of unabsorbed grease, which is the data in Column 4 divided by the data in Column 1. This demonstrates that, in terms of grease absorption, the receptor tray with the absorbent pad is more effective than existing receptor materials without an absorbent pad.

[0083] The bacon used in the above tests included center-cut bacon with a moisture content of approximately 35.25% to approximately 62.75%, a protein content of approximately 7.5% to approximately 18.5%, a fat percentage of approximately 16.25% to approximately 52.25%, and a salt content of approximately 1.16% to approximately 2.16%. In another bacon product, the moisture content was approximately 30.75% to approximately 58.25%, the protein content was approximately 7.5% to approximately 17.75%, the fat percentage was approximately 22.5% to approximately 57.5%, and the salt content was approximately 1.16% to approximately 2.16%. In yet another product, the moisture content was approximately 30.75% to approximately 58.25%, the protein content was approximately 7.5% to approximately 17.75%, the fat percentage was approximately 22.5% to approximately 57.5%, and the salt content was approximately 0.95% to approximately 1.95%. In some embodiments, bacon may have a protein content higher than 18.5%. While these examples illustrate the use of the packaging described herein to cook some bacon products, other foods (including raw, pre-cooked, or partially cooked foods) may have protein content ranges outside of those provided above.

[0084] Those skilled in the art will recognize that various modifications, variations, and combinations can be made with respect to the above embodiments without departing from the scope of this disclosure, and such modifications, variations, and combinations are considered to be within the scope of the inventive concept.

Claims

1. A packaged food suitable for microwave ovens, comprising an outer packaging and a certain amount of food contained within the outer packaging, said packaged food being configured to be heated in a microwave oven, and comprising: A multi-layered support for microwave ovens, having at least three layers, including: The sensor layer includes a microwave energy interaction material and has a plurality of discrete openings therein, the discrete openings being arranged at a higher density at the center of the support for the microwave oven. Absorbent pad, which has a flexible paper-based material for absorbing moisture and grease; and A cardboard base layer has a top support, a lower support, and side support walls connecting the top and lower supports. A receptor layer is disposed on the top support, and an absorbent pad layer is disposed on the lower support, with the absorbent pad layer located between the top and lower supports. The cardboard base layer supports both the receptor layer and the absorbent pad layer. The microwave oven-friendly support member can be reconfigured from a first transport configuration to a second cooking configuration by moving the top support member relative to the lower support member. In the first transport configuration, the first and second portions of the receptor layer and the top support at the center of the microwave oven-compatible support are substantially flat, and In the second cooking configuration, the top support and the lower support are separated from each other at least at the side support walls, and the first and second portions of the sensor layer and the central top support of the microwave-safe support extend relative to each other at an inclined angle to form angled upward-facing surfaces to support the food and guide grease to discrete openings while retaining a sufficient amount of grease to make the food crispy when heating the packaged food. The central top support of the microwave-safe support rests on the absorbent pad layer of the lower support, and the discrete openings extend through the top support so that the absorbent pad layer drains moisture and grease from the top support through the discrete openings to the absorbent pad layer disposed on the lower support. The microwave oven-safe support has a sensor layer area to discrete opening area ratio of about 40:1 to about 80:1 to facilitate the removal of at least 90% of the grease generated on the sensor layer during microwave food processing to the absorbent pad layer.

2. The packaged food as described in claim 1, wherein, The sensor layer is a multi-layer flexible structure having at least one top product contact layer with metallized material, including microwave energy interaction material, and a paper layer.

3. The packaged food as described in claim 2, wherein, The multilayer flexible structure of the receptor layer also includes an additional polymer layer, the multilayer flexible structure of the receptor layer having a thickness of about 0.002 inches to about 0.020 inches.

4. The packaged food as described in claim 1, wherein, The microwave oven support has a top surface area of ​​about 50 to about 80 square inches and the discrete openings with a higher density at the center of the microwave oven tray are arranged in a radial configuration and include about 30 to about 80 discrete openings, each of which has a diameter of about 0.125 inches to about 0.25 inches.

5. The packaged food as described in claim 1, wherein, The base thickness of the cardboard substrate is between approximately 0.010 inches and approximately 0.030 inches.

6. The packaged food as described in claim 1, wherein, The absorbent pad is a multi-layered flexible structure for absorbing moisture and grease, and the multi-layered flexible structure has a paper layer, a transparent polyethylene layer, and a non-woven paper base layer.

7. The packaged food as described in claim 6, wherein, The absorbent pad has a thickness of about 0.010 inches to about 0.040 inches and a basis weight of about 135 pounds per ream (1,000 square feet).

8. The packaged food as described in claim 1, wherein, The support for microwave ovens has a total support width of approximately 9.0 inches, a total support length of approximately 6.5 inches, and a support thickness of approximately 0.03 inches to approximately 0.070 inches.

9. The packaged food as described in claim 1, wherein, The surface area of ​​the sensor layer covering the support member suitable for microwave ovens is smaller than the surface area of ​​the cardboard base layer covering the support member suitable for microwave ovens.

10. The packaged food as described in claim 9, wherein, The receptor layer covers approximately 40% to approximately 60% of the top support.

11. The packaged food as described in claim 9, wherein, The cardboard base of the microwave oven-compatible support extends beyond the periphery of the sensor layer, allowing the consumer to grip the cardboard base without touching the sensor layer.

12. A raw meat package configured to cook raw meat in a microwave oven, and comprising: A multi-layer microwave oven support has a top support surface and a lower support surface connected by side support walls. The multi-layer microwave oven support has an absorbent pad connected between the top support surface and the lower support surface and supported by the lower support surface. The top support surface, the lower support surface and the side support walls are made of cardboard material. and The top support surface has a sensor layer disposed thereon, the sensor layer comprising a microwave energy interaction material and a plurality of discrete openings disposed in the sensor layer and the top support surface; The top support surface has a flat transport configuration, wherein the top support surface of the first and second portions of the sensor layer and the center of the support member suitable for the microwave oven is substantially flat; and The top support surface can be reconfigured into an angled cooking configuration by moving the top support surface relative to the lower support surface such that the top support surface and the lower support surface are separated from each other at least at the side support walls, and the first and second portions of the sensor layer and the top support surface extend relative to each other at an inclined angle to form an angled, upward-facing cooking surface to support food during cooking and guide grease to the plurality of discrete openings during microwave heating while retaining a sufficient amount of grease to make the food crispy. The top support surface at the center of the microwave-safe support rests on the absorbent pad layer supported by the lower support surface, and the plurality of discrete openings extend through the top support surface such that the absorbent pad drains moisture and grease from the top support surface through the plurality of discrete openings to the absorbent pad supported by the lower support surface below the top support surface. The absorbent pad is disposed on the lower support surface and has a flexible paper-based material suitable for absorbing moisture and grease, which drain into the absorbent pad on the lower support surface through openings in the sensor layer.

13. The packaging as claimed in claim 12, wherein, The sensor layer is a multi-layer flexible structure having at least one top product contact layer with metallized material, including a microwave energy interaction material, a paper layer, and an angled top support surface; the angled top support surface has a V-shape and a centrally located lowest discharge port.

14. The packaging as claimed in claim 12, wherein, At least some of the plurality of discrete openings are disposed in the recesses of the angled top support surface.

15. The packaging as claimed in claim 14, wherein, The discrete openings are configured in a radial shape.

16. A packaged food suitable for microwave ovens, comprising an outer packaging and a quantity of raw bacon contained within the outer packaging, said packaged food being configured to facilitate heating the food in a microwave oven, wherein: The bacon contains at least about 7.5% to about 18.5% protein; The packaging also includes a multi-layered microwave oven-safe support having at least three layers, comprising: The sensor layer comprises a microwave energy-interacting material and has a plurality of discrete openings arranged in a radial configuration therein, wherein the discrete openings are located at the center of the support member suitable for microwave ovens; Absorbent padding layer, which has a flexible paper-based material suitable for absorbing moisture and grease; and A cardboard base layer having a top support, a lower support, and side support walls connecting the top and lower supports; a sensor layer disposed on the top support and an absorbent pad layer disposed on the lower support, the absorbent pad layer being located between the top and lower supports; and The microwave oven-friendly support member can be reconfigured from a first transport configuration to a second cooking configuration by moving the top support member relative to the lower support member. In the first transport configuration, the first and second portions of the receptor layer and the top support at the center of the microwave oven-compatible support are substantially flat. In the second cooking configuration, the top support and the lower support are separated from each other at least at the side support walls, and the first and second portions of the sensor layer and the central top support of the microwave-safe support extend relative to each other at an inclined angle to form an angled, upward-facing support surface to support the bacon and guide the grease to discrete openings while retaining a sufficient amount of grease to make the food crispy when the bacon is heated. The central top support of the microwave-safe support rests on the absorbent pad layer of the lower support, and the discrete openings extend through the top support so that the absorbent pad layer drains moisture and grease from the top support through the discrete openings to the absorbent pad layer disposed on the lower support. The amount of unabsorbed oil produced during microwave cooking of bacon is less than approximately 10%, and The microwave oven-safe support has a ratio of approximately 40:1 to approximately 80:1 between the area of ​​the receptor layer and the area of ​​the discrete opening to facilitate the removal of at least 90% of the grease generated on the receptor layer during microwave processing of bacon to the absorbent pad layer.

17. The microwave-safe packaged food as described in claim 16, wherein, The receptor layer and the absorbent pad layer are laminated together.

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