Blank, structure and related method for inductive heating of food products

Abstract

A structure includes at least one panel for supporting a food product, the at least one panel formed from a laminate structure having a base layer, a conductive layer, and a surface film. The structure further includes at least one spacing feature extending downward from the at least one panel for supporting the at least one panel a distance above an induction source for attenuating heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminate structure.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 052,037, filed on July 15, 2020.

[0003] By incorporating references

[0004] The disclosure of U.S. Provisional Patent Application No. 63 / 052,037, filed on July 15, 2020, is hereby incorporated by reference for all purposes as if it were described in its entirety. Background Technology

[0005] This disclosure generally relates to laminated structures / blanks for heating one or more food products by induction heating, structures formed from blanks, and related methods. More specifically, this disclosure relates to structures having at least one spacer member for supporting a base panel at a predetermined vertical distance from an induction source. Summary of the Invention

[0006] According to one aspect, this disclosure generally relates to a structure comprising: at least one panel for supporting a food product, the at least one panel being formed of a laminated structure including a base layer, a conductive layer, and a surface film. The structure further includes at least one spacer extending downward from the at least one panel to support the at least one panel at a distance above a sensing source, thereby attenuating heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminated structure.

[0007] According to another aspect, this disclosure generally relates to a blank for forming a structure, the blank including at least one panel for supporting a food product, the at least one panel being formed of a laminated structure including a base layer, a conductive layer, and a surface film. When the structure is formed from the blank, the blank also includes features for forming at least one spacer feature extending downward from the at least one panel to support the at least one panel above a sensing source at a distance, thereby attenuating heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminated structure.

[0008] According to another aspect, this disclosure generally relates to a method of forming a structure, the method comprising obtaining a blank comprising at least one panel formed of a laminated structure comprising a base layer, a conductive layer, and a surface film. The method further comprises forming at least one spacer extending downward from the at least one panel to support the at least one panel at a preselected distance above a sensing source, thereby attenuating heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminated structure.

[0009] According to another aspect, this disclosure generally relates to a method for heating a food product, the method comprising: obtaining a blank comprising at least one panel formed of a laminated structure comprising a base layer, a conductive layer, and a surface film; and forming a structure from the blank such that the structure comprises at least one panel and at least one spacer extending downward from the at least one panel. The method further comprises: positioning the structure on a sensing source, wherein the at least one spacer supports the at least one panel above the sensing source by a distance; and activating the sensing source to generate an oscillating magnetic field interacting with the conductive layer of the laminated structure to heat at least one food product supported on the at least one panel.

[0010] Those skilled in the art will understand the above advantages and other advantages and benefits of various additional embodiments by reading the following detailed description of the embodiments with reference to the accompanying drawings. Attached Figure Description

[0011] In accordance with conventional practice, the various features in the accompanying drawings discussed below are not necessarily drawn to scale. The dimensions of the various features and elements in the drawings may be enlarged or reduced to more clearly illustrate the embodiments of this disclosure.

[0012] Figure 1 It is a cross-sectional view of a laminated structure used to form a blank and a structure according to the present disclosure.

[0013] Figure 2 This is a plan view of a blank for forming a structure according to a first exemplary embodiment of the present disclosure.

[0014] Figure 3 It is positioned in the forming device Figure 2 A schematic diagram of the blank.

[0015] Figure 4 According to the first exemplary embodiment, by Figure 2 A perspective view of the structure formed from the blank.

[0016] Figure 5 It is positioned on the induction source for induction heating. Figure 4 A schematic diagram of the structure.

[0017] Figure 6 This is a plan view of a blank for forming a structure according to a second exemplary embodiment of the present disclosure.

[0018] Figure 7 According to the second exemplary embodiment, by Figure 6 A perspective view of the structure formed from the blank.

[0019] Figure 8 This is a plan view of a blank for forming a structure according to a third exemplary embodiment of the present disclosure.

[0020] Figure 9 It is based on the third exemplary embodiment of this disclosure. Figure 8 A perspective view of the structure formed from the blank.

[0021] Figure 10 This is a plan view of a blank for forming a structure according to a fourth exemplary embodiment of the present disclosure.

[0022] Figure 11 It is based on the fourth exemplary embodiment of this disclosure. Figure 10 A perspective view of the structure formed from the blank.

[0023] Figure 12 yes Figure 11 Another perspective view of the structure.

[0024] Figure 13 This is a plan view of a blank for forming a structure according to a fifth exemplary embodiment of the present disclosure.

[0025] Throughout the accompanying figures, corresponding parts are specified by the corresponding reference numbers. Detailed Implementation

[0026] Various aspects of this disclosure can be further understood by referring to the figures. For simplicity, similar numbers may be used to describe similar features. It should be understood that, in the case of depicting multiple similar features, not all of these features need to be labeled on every figure. It should also be understood that the various components used to form the structure are interchangeable. Therefore, although only certain combinations are illustrated herein, many other combinations and configurations are contemplated.

[0027] The structure according to this disclosure can be adapted to articles of various shapes. For illustrative purposes and not for limiting the scope of this disclosure, the following detailed description describes articles, such as food products, that are at least partially deployed on or within the structure embodiment.

[0028] Articles may include, but are not limited to, fast food products, takeout products, leftovers, or any combination thereof. Examples of such products include pastries (e.g., filled or frosted pastries), bread, fruit sticks, French toast sticks, fish, chicken (such as chicken nuggets, chicken strips, chicken feet, etc.), popcorn, peanuts, candy, French fries (such as waffle fries, steak fries, strip fries, French rings, etc.), sandwiches, pizzas, pies, burritos, tortillas, or any other food products intended for consumer consumption. In this specification, the terms “inner,” “internal,” “outer,” “external,” “lower,” “bottom,” “upper,” and “top” indicate an orientation defined relative to a fully upright and vertical structure.

[0029] As described herein, the structure may be formed from multiple overlapping panels, end flaps, and / or other portions of the blank. Such panels, end flaps, and / or other portions of the blank may be designated relative to each other, for example, "first," "second," "third," etc., referred to in sequence or out of sequence, without departing from this disclosure.

[0030] refer to Figure 1 Exemplary embodiments of the present disclosure illustrate methods for forming a blank 103 and / or a structure 100. Figure 4 A schematic cross-sectional view of the laminated structure 102. The structure 100 can be used to support or hold one or more food products and can include one or more conductive and / or thermally conductive materials, such that the structure 100 can generate heat when exposed to a changing / oscillating magnetic field, for example, by inducing eddy currents in the conductive material and causing heat to be generated by the resistance to such eddy currents. In this respect, the laminated structure 102, the blank 103, and / or the structure 100 are configured to be used with an induction generator or induction source (e.g., a source of a changing / oscillating magnetic field) to provide induction heating to one or more food products. In the case of ferromagnetically conductive materials, heating can be provided at least partially by hysteresis losses.

[0031] As shown, the laminate 102 includes a food contact film or surface film 104, a conductive material or conductive layer 106, and a material base layer 110. In this respect, the food contact film 104 forms the interior of the laminate 102 or the food support surface. The food contact film 104 may be formed from a polymeric material such as polyethylene terephthalate (PET). The food contact film 104 may provide at least barrier properties to the base layer 110, for example, preventing the passage of fluids such as moisture, oil, and / or food effluents, and may be suitable for heating applications as described herein. The food contact film 104 may be formed from additional or alternative materials (e.g., metals or composite materials) without departing from this disclosure.

[0032] As shown and described, the conductive layer 106 may be formed at least partially of a conductive and / or thermally conductive or semi-conductive and / or semi-thermally conductive material, such as a metal or metal alloy (e.g., an ferromagnetic / paramagnetic metal) or other material that may have properties suitable for induction heating. Such materials may include, for example, copper and copper alloys, brass, aluminum, iron, steel, stainless steel, tungsten, chromium, nickel, cobalt, carbon fiber, graphite, silicon, platinum, silver, gold, and their alloys. In the exemplary embodiment shown, the conductive layer 106 may be formed of aluminum, but additional or alternative metallic materials may be used without departing from this disclosure. The conductive layer 106 may be patterned or configured, for example, to include one or more discontinuous and / or non-conductive regions to provide a desired distribution of electrical and / or thermal conduction without departing from this disclosure.

[0033] The base layer 110 may be a composite material, such as paper or paper-based products (e.g., cardboard, etc.) and supports the conductive layer 106 and the food contact film 104, and is generally configured to have the same size, shape and / or dimensions as one or more of those components, but the base layer 110 may be configured differently without departing from this disclosure.

[0034] The laminated structure 102 can be formed by arranging the food contact film 104, the conductive layer 106, and the base layer 110 in a corresponding overlapping relationship. This arrangement can be provided by a lamination process, including, for example, rollers and chucks (nip), chemical deposition, application of one or more adhesives, etc.

[0035] It should be understood that the food contact film 104 and the conductive layer 106 can be separately formed elements. The food contact film 104 may be metallized or otherwise provided with a conductive material, and / or the conductive layer 106 may be provided with a coating or surface treatment performed similarly to that performed on the food contact film 104. In one embodiment, the conductive layer 106 may be provided without an accompanying film or film-like treatment.

[0036] In one embodiment, the laminate 102 may include a food contact layer 104 formed of 75ga PET, a conductive layer 106 formed of aluminum with a thickness of about 7 micrometers, and a base layer 110 formed of cardboard with a thickness of about 0.018 calipers. It should be understood that the laminate 102 or one or more components thereof may have different configurations without departing from this disclosure.

[0037] Additional reference Figure 2 The first exemplary embodiment of the present disclosure illustrates the outer surface 101 of a blank 103 for forming a structure 100. The blank 103 may be formed from a laminated structure 102, but it should be understood that different material arrangements may be provided to form the blank 103.

[0038] As shown, blank 103 may have a longitudinal axis L1, a transverse axis L2, and one or more panels. In the illustrated embodiment, blank 103 may include a central panel or bottom panel or main panel or base panel 121 (broadly, "first base panel" or "second base panel") that is detachably and / or foldably connected at a transverse weakening line 125 to a central panel or bottom panel or main panel or base panel 123 (broadly, "first base panel" or "second base panel").

[0039] The blank 103 may include a plurality of end flaps or flaps that are foldably / detachably attached to the respective panels, and as shown, may include a pair of positioning flaps 127 that are detachably and / or foldably attached to the opposing longitudinal free edges of the base panel 121 at the respective longitudinal weakening lines 129.

[0040] As shown, a pair of positioning flaps 131 may also be foldably and / or detachably attached to portions of the opposing longitudinal free edges of the base panels 121, 123 at respective longitudinal weakening lines 133 intersecting the weakening line 125. As further described herein, one or more of the positioning flaps 127, 131 may engage a portion of a forming tool or apparatus, or may otherwise engage, to position the base panels 121, 123 relative to the forming tool or apparatus.

[0041] Turn Figure 3 The illustration shows a schematic diagram of a forming apparatus 137 for reconfiguring a blank 103 into a structure 100. As shown, the forming apparatus 137 may include a male forming member 139, such as an anvil or other member having one or more protruding surface features, and a female forming member 141, such as a mold / cavity having one or more recessed surface features complementary to the surface features of the male forming member 141.

[0042] In the illustrated embodiment, the male forming member 139 and the female forming member 141 may be arranged to be movable relative to each other, for example, such that one or both of the male forming member 139 and the female forming member 141 may be configured to move toward and / or away from the other of the male forming member 139 and the female forming member 141.

[0043] In this respect, the blank 103 can be positioned between the male forming member 139 and the female forming member 141 of the forming device 137, and such positioning can be achieved and / or maintained via engagement of one or more of the positioning flaps 127, 131 with a portion of the forming device 137 (e.g., the edge or margin of one or both of the forming members 139, 141), a clamp, a clip, or other retaining structure. In one embodiment, the retaining structure can be mounted on or positioned near the forming device 137 and can engage one or more of the positioning flaps 127, 131 to maintain the position of the blank 103 during operation of the forming device 137.

[0044] One or more of the forming members 139, 141 can be pulled together / approached each other such that one or more of the protruding surface features of the male forming member 139 cause a portion of the blank 103 to enter into a corresponding recessed feature of the female forming member 141. This action of the forming device 137 can cause the blank 103 to be at least partially deformed and / or reconfigured into the structure 100, including at least one spacer feature forming the structure 100, as further described herein.

[0045] Additional reference Figure 4 and Figure 5 A structure 100 formed from a blank 103 is illustrated according to a first exemplary embodiment of the present disclosure. As shown, the structure 100 may include at least one of the base panels 121, 123. Thus, one or more of the positioning flaps 127, 131 and / or another of the base panels 121, 123 may be separated from one of the base panels 121, 123 at corresponding weakening lines 129, 133, 125. It should be understood that the structure 100 may include both of the base panels 121, 123 and / or one or more of the positioning flaps 127, 131 without departing from the present disclosure. For example, in one embodiment, the base panels 121, 123 may be folded at the weakening line 125 to at least partially face-to-face, such that the structure 100 is formed of panels 121, 123 arranged in a two-layer structure. Alternatively, the base panels 121, 123 may be positioned spaced apart from each other in the formed structure, or the base panels may be alternatively arranged to form, for example, separate structures or trays.

[0046] As shown, structure 100 may include spacer features, which may include a pair of spacer members 143 projecting downward from the base panels 121 / 123. The spacer members 143 may be formed via the operation of the forming device 137 described above. For example, the spacer members 143 may be formed at least partially via a reconfiguration of at least a conductive layer of the material forming the blank 103 / structure 100, such as a malleable metallic material of conductive layer 106 undergoing at least partial shape change during operation of the forming device 137. Figure 1 ).

[0047] As shown, the spacer member 143 may have the form of a generally elongated, inclined or wedge-shaped protrusion extending downward from the base panel 121 / 123. In one embodiment, the spacer member 143 may have the form of an elongated crease or fold corresponding to a corresponding notch 142 in the upper surface of the base panel 121 / 123. It should be understood that the spacer member 143 may have different configurations, such as curves, ridges, peaks, etc., and may be a continuous feature or have one or more discontinuities without departing from this disclosure.

[0048] Structure 100 in Figure 5 The image is shown supported on an induction source S, which is configured to generate one or more oscillating / changing magnetic fields B. In this regard, the induction source S may include a working coil, such as a wound / spiked configuration of metal wire or cable, and may include or be electrically coupled to a power source and activated / energized to provide alternating current to the working coil. In one embodiment, the induction source may be an induction oven, such as a glass / ceramic / composite surface, beneath which one or more copper or other magnetic coils are positioned to generate a magnetic field for induction cooking.

[0049] When the induction source S generates one or more oscillating magnetic fields B, one or more currents E, such as eddy currents, can be formed in the conductive material of the structure 100. The resistance of the conductive material of the structure 100 to such currents generates heat H that can be conducted to the food product (e.g., food product F).

[0050] As shown, the spacer members 143 of structure 100 position / support the base panels 121 / 123 (and the food products thereon) at a predetermined or pre-selected distance D above the induction source S. This distance D above the induction source S can provide a desired attenuation of the heat H supplied to the food products F in response to the oscillating magnetic field B, for example, to prevent thermal damage (e.g., cracking, peeling, etc.) to one or more parts of structure 100, to prevent scorching or overcooking of the food products F, which may occur at a distance less than D above the induction source S. In one embodiment, distance D may be approximately 1.75 mm. Alternatively, distance D may be greater than or less than 1.75 mm without departing from the scope of this disclosure. For example, distance D may be selected based on various parameters of the induction source (e.g., the size of the induction oven, the power of the induction oven, etc.).

[0051] Additional reference Figure 6 The illustration shows a method for forming a structure 200 according to a second exemplary embodiment of the present disclosure. Figure 7 The outer surface 201 of the blank 203. The blank 203 and the structure 200 may have one or more features that are the same as or similar to the features described above with respect to the blank 103 and the structure 100, and the same or similar reference numerals are used to indicate the same or similar features.

[0052] The blank 203 has a longitudinal axis L1 and a transverse axis L2, and may be formed at least partially by the laminated structure 102, but the blank 203 may be formed by one or more additional or alternative materials without departing from this disclosure.

[0053] As shown, the blank 203 includes a main panel, central panel, or base panel 221 having a pair of longitudinally spaced convex cuts 222 (e.g., cuts with a radius of curvature extending laterally downward from the longitudinal centerline of the blank 203) opposite to a pair of longitudinally spaced concave cuts 224 (e.g., cuts with a radius of curvature extending laterally upward from the longitudinal centerline of the blank 203).

[0054] The blank also includes a first end flap 223 foldably connected to the base panel 221 at a longitudinal fold line 225, and a second end flap 227 foldably connected to the base panel 221 at a longitudinal fold line 229.

[0055] As shown, the end flap 223 includes a proximal portion 231 foldably connected to the base panel 221 at a longitudinal fold line 225, and a distal portion 233 foldably connected to the proximal portion 231 at a longitudinal fold line 235.

[0056] Similarly, the end flap 227 includes a proximal portion 237 foldably connected to the base panel 221 at a longitudinal fold line 229, and a distal portion 239 foldably connected to the proximal portion 237 at a longitudinal fold line 241.

[0057] Additional reference Figure 7 In one exemplary embodiment, the structure 200 can be formed from the blank 203 by placing the outer surface 201 of the blank 203 downward on the support surface, and folding the proximal portion 231 of the end flap 223 at the fold line 225 along the direction of arrow A1 and folding the distal portion 233 of the end flap 223 at the fold line 235 along the direction of arrow A2 to insert the corresponding portion of the distal portion 233 of the end flap 223 through the opening formed by the corresponding cutout 222 in the base panel 221.

[0058] In this respect, the spacer 243 may be formed by the arrangement of the proximal portion 231 and the distal portion 233 of the end flap 223, and positioned to extend downward from the base panel 221. The spacer 243 may have a generally inclined or wedge-shaped profile formed by the arrangement of the proximal portion 231 and the distal portion 233 of the end flap 223, but the spacer 243 may have different arrangements without departing from this disclosure. In the aforementioned arrangement, the proximal portion 231 of the end flap 223 extends from the base panel 221 to the distal portion 233 of the end flap 223, and the distal portion 233 of the end flap 223 extends from the proximal portion 231 of the end flap 223 to the base panel 221.

[0059] Similarly, the proximal portion 237 of the end flap 227 can be folded at fold line 229 in the direction of arrow A3, and the distal portion 239 of the end flap 227 can be folded at fold line 241 in the direction of arrow A4. A portion of the distal portion 239 of the end flap 227 can be inserted into an opening formed by a corresponding cutout 224 to form a spacer member 245 extending downward from the base panel 221 and having a generally inclined or wedge-shaped profile formed by the arrangement of the proximal and distal portions 237 and 239 of the end flap 227. In the above arrangement, the proximal portion 237 of the end flap 227 extends from the base panel 221 to the distal portion 239 of the end flap 227, and the distal portion 239 of the end flap 227 extends from the proximal portion 237 of the end flap 227 to the base panel 221. The spacer member 245 can have different arrangements without departing from this disclosure.

[0060] In the aforementioned arrangement, a portion of the base panel 221 may be at least partially separated from the remainder of the base panel 221 at cutouts 222, 224 to form corresponding retaining tabs 220, 226 for retaining the respective end flaps 223, 227.

[0061] In this respect, the spacer members 243 and 245 of the structure 200 position the base panel 221 at the sensing source (e.g., Figure 5 At a preselected distance D above the induction source S shown, to provide a desired attenuation of the heat H supplied to the food product F in response to the oscillating magnetic field B, for example, to prevent thermal damage (e.g., cracking, peeling, etc.) to one or more parts of the structure 200, to prevent the food product F from burning or overcooking, etc., as described above with respect to the structure 100.

[0062] Additional reference Figure 8 The illustration shows a method for forming a structure 300 according to a third exemplary embodiment of the present disclosure. Figure 9 The outer surface 301 of the blank 303. The blank 303 and the structure 300 may have one or more features that are the same as or similar to the features described above with respect to blanks 103, 203 and structures 100, 200, etc., and the same or similar reference numbers are used to indicate the same or similar features.

[0063] The blank 303 has a longitudinal axis L1 and a transverse axis L2, and may be formed at least partially by the laminated structure 102, but the blank 303 may be formed by one or more additional or alternative materials without departing from this disclosure.

[0064] As shown, blank 303 includes a main / center / bottom panel or base panel 321, which is foldably connected to a first side panel 323 at a transverse fold line 325 and foldably connected to a second side panel 327 at a transverse fold line 329. Each fold line 325, 329 may be interrupted by a corresponding pair of transversely spaced curved cuts 331, 333.

[0065] The first side panel 323 can be foldably connected to the first top panel 335 at a transverse fold line 335 interrupted by a pair of corresponding curved cuts 333. Similarly, the second side panel 327 can be foldably connected to the second top panel 339 at a transverse fold line 341 interrupted by a pair of curved cuts 331, such that the cuts 331, 333 are arranged in a relatively concave / convex relationship. In one embodiment, different arrangements of the top panels may be provided, for example, a single top panel.

[0066] Additional reference Figure 9In one exemplary embodiment, structure 300 can be formed from blank 303 by placing the outer surface 301 of blank 303 downward on a support surface and folding the side panels 323, 327 upward along the directions of corresponding arrows A5 and A6 at corresponding fold lines 325, 329. Subsequently, top panels 335, 339 can be folded toward each other along the directions of corresponding arrows A7, A8 at corresponding fold lines 337, 341, such that the top panels 335, 339 are positioned in an arrangement that at least partially overlaps (e.g., at least partially face-to-face). This arrangement of structure 300 can be maintained using an adhesive such as glue G.

[0067] After the structure 300 is thus formed, portions of the respective side panels 323, 327 can be separated from the respective adjacent panels at corresponding cutouts 331, 333 to form a plurality of spacer members 343 (generally, "first spacer members") protruding from the opposite edges of the side panels 323, 327. As shown, the set of four spacer members 343 can protrude upward relative to the top panels 339, 335 and the set of four spacer members 343 can protrude downward relative to the base panel 321. It should be understood that one or more of the spacer members 343 can have different configurations or arrangements without departing from this disclosure.

[0068] In this respect, panels 321, 323, 327, 335, and 339 extend at least partially around the interior 307 of structure 300 in an open sleeve arrangement, in which food products can be at least partially contained. Although top panels 335 and 339 have been described as the uppermost panels / layers of structure 300, it should be understood that structure 300 can be inverted such that panels 335 and 339 are the lowermost or supporting panels / layers of structure 300, and panel 321 is positioned as the uppermost panel / layer of structure 300.

[0069] Structure 300 is shown as being supported on a sensing source (such as...) Figure 5 On the induction source S shown, the induction source is configured to generate one or more oscillating / changing magnetic fields B, such that when one or more oscillating magnetic fields B are generated by the induction source S, one or more currents (e.g., eddy currents) can be formed in the conductive material of the structure 300 to generate heat H that can be conducted to the food product (e.g., food product F) through resistance.

[0070] The spacer member 343 of structure 300 can therefore be configured to position the base panel 321 at a preselected distance D above the induction source S to provide a desired attenuation of the heat H supplied to the food product F in response to the oscillating magnetic field B, for example, to prevent thermal damage (e.g., cracking, peeling, etc.) to one or more parts of structure 300, to prevent the food product F from burning or overcooking, etc., as described above with respect to structures 100, 200.

[0071] Additional reference Figure 10 The illustration shows the outer surface 401 of a blank 403 for forming a structure 400 according to a fourth exemplary embodiment of the present disclosure. The blank 403 and the structure 400 may have one or more features that are the same as or similar to the features described above with respect to blanks 103, 203, 303 and structures 100, 200, 300, etc., and the same or similar reference numerals are used to denote the same or similar features.

[0072] The blank 403 has a longitudinal axis L1 and a transverse axis L2, and may be formed at least partially by the laminated structure 102, but the blank 403 may be formed by one or more additional or alternative materials without departing from this disclosure.

[0073] As shown, blank 403 includes a main / central / base panel or base panel 421, which is foldably connected to a first end panel 423 at a transverse fold line 425 interrupted by a cut 427 having one or more straight, curved, and angled portions. Similarly, base panel 421 may be foldably connected to a second side panel 429 at a transverse fold line 431 interrupted by a cut 433 having one or more straight, curved, and angled portions.

[0074] The first side panel 435 can be foldably attached to the base panel 421 at a longitudinal fold line 437 interrupted by a cut 439 having one or more straight, curved, and angled portions. Similarly, the second side panel 441 can be foldably attached to the base panel 421 at a longitudinal fold line 443 interrupted by a cut 445 having straight, curved, and angled portions.

[0075] Multiple end flaps can be foldably connected to corresponding panels among multiple panels of blank 403, and may include a first corner panel 447 foldably connected to the first end panel 423 at an inclined fold line 449, and a second corner panel 451 foldably connected to the first end panel 423 at an inclined fold line 453. As shown, corner panels 447, 451 can be separated from corresponding side panels 435, 441 at corresponding inclined cutouts 455, 457.

[0076] Similarly, the first corner panel 459 can be foldably connected to the second end panel 429 at the inclined fold line 461, and the second corner panel 463 can be foldably connected to the second end panel 429 at the inclined fold line 465. The corner panels 459 and 463 can be separated from the corresponding side panels 435 and 441 at the corresponding inclined cuts 467 and 469.

[0077] Additional reference Figure 11 and Figure 12 In one exemplary embodiment, the structure 400 can be formed from the blank 403 by placing the outer surface 401 of the blank 403 downward on the support surface and folding the end panels 423 and 429 upward at the corresponding fold lines 425 and 421 along the directions of the corresponding arrows A9 and A10, and simultaneously or subsequently folding the side panels 435 and 441 upward at the corresponding fold lines 437 and 443 along the directions of the corresponding arrows A11 and A12.

[0078] Corner panels 447 and 459 can be folded at corresponding fold lines 449 and 461 to at least partially face-to-face with side panel 435, and corner panels 451 and 463 can be folded at corresponding fold lines 453 and 465 to at least partially face-to-face with side panel 441. This arrangement of structure 400 can be maintained using an adhesive such as glue.

[0079] After the structure 400 is thus formed, portions of the corresponding end panels 423, 429 and the corresponding side panels 435, 441 can be separated from the adjacent base panel 421 at corresponding cutouts 427, 433, 439, 445 to form a plurality of corresponding spacer members 471, 473 (generally, "second spacer members"), 475, 477 (generally, "first spacer members") projecting downward from the corresponding panels 423, 429, 435, 441. In this respect, the spacer members 471, 473, 475, 477 can take the form of tabs, pillars, legs, etc., extending downward relative to the base panel 421. It should be understood that one or more of the spacer members 471, 473, 475, 477 can have different configurations or arrangements without departing from this disclosure.

[0080] As shown, structure 400 may have a generally tray-like arrangement, wherein panels 421, 423, 429, 435, 441 extend at least partially around the interior 407 of structure 400 for accommodating one or more food products.

[0081] Therefore, structure 400 can be configured to be supported on a sensing source (such as...) Figure 5On the sensing source S), the sensing source is configured to generate one or more oscillating / changing magnetic fields B, such that when one or more oscillating magnetic fields B are generated by the sensing source S, one or more currents (e.g., eddy currents) can be formed in the conductive material of the structure 400 to generate heat H that can be conducted to the food product (e.g., food product F) through resistance.

[0082] The spacer members 471, 473, 475, and 477 of the structure 400 can be arranged to position the base panel 421 at a preselected distance D above the induction source S to provide a desired attenuation of the heat H supplied to the food product F in response to the oscillating magnetic field B, for example, to prevent thermal damage (e.g., cracking, peeling, etc.) to one or more parts of the structure 400, to prevent the food product F from burning or overcooking, as described above with respect to structures 100, 200, and 300.

[0083] Additional reference Figure 13 The illustration shows the outer surface 501 of a blank 503 for forming a structure 500 according to a fifth exemplary embodiment of the present disclosure. The blank 503 and the structure 500 may have one or more features that are the same as or similar to the features described above with respect to blanks 103, 203, 303, 403 and structures 100, 200, 300, 403, and the same or similar reference numerals are used to denote the same or similar features.

[0084] Specifically, blank 503 can be substantially similar to blank 403, except that panels 421, 423, 429, 435, and 441 are provided in different dimensions / arrangements. In this respect, the structure formed from blank 503 can be formed in a manner similar to that described above regarding the formation of structure 400 from blank 403, and can be used to support the base panel 421 at a preselected distance above the sensing source, as described above regarding the foregoing embodiments.

[0085] It should be understood that additional or alternative structures for induction heating of one or more food products may be provided without departing from this disclosure. Such structures may take the form of bowls, trays, sleeves, mats, covered structures (e.g., having one or more hinged lids), and may, in accordance with the above discussion, have at least one bottom / base panel from which one or more spacer members in the form of tabs, legs, pillars, protrusions, other projections, etc., extend to support the bottom / base panel at a predetermined distance from the induction source.

[0086] Generally, the blank or base layer described herein can be constructed from cardboard with calipers, making it heavier and more rigid than ordinary paper. The base layer can also be made of other materials (such as cardboard), or any other material with properties suitable for enabling the structure to function at least substantially as described above. The base layer can be coated, for example, with a clay coating. Products, advertisements, and other information or images can then be printed on the clay coating. The base layer can then be coated with a varnish to protect the information printed on it. The base layer can also be coated with, for example, a moisture barrier on one or both sides. The base layer can also be laminated or coated with one or more sheet materials at selected panels or panel portions.

[0087] It is obvious that many other sequential steps can be used to form the structure as described herein. It is also obvious that many other materials or structures can be used to form the structure according to this disclosure. Any of these materials can be used alone or in combination and in any configuration to form the structure. In the case of using multiple materials (or multiple layers of the same material), these materials can be partially or completely bonded together, or they can remain separate from each other (i.e., unbonded).

[0088] This disclosure envisions numerous other structures and configurations. Any such structure may, if desired, include one or more regions lacking conductive material or inhibiting heat / electrical conduction. Such regions can be used to enhance the heating, browning, and / or crisping of adjacent food products or other articles, and can be sized, positioned, and / or arranged to tailor such heating.

[0089] Any such structure or body can be formed from a variety of materials, provided that these materials are substantially resistant to softening, burning, combustion, or degradation at typical surface heating temperatures (e.g., up to about 400°F, and in one embodiment up to about 425°F). Such heating temperatures can be higher without departing from this disclosure.

[0090] If desired, any of the numerous conductive materials described or envisioned herein may be substantially continuous, i.e., without noticeable cracks or breaks, or may be discontinuous, for example, by including one or more cracks or pores. The size and location of the cracks or pores may be determined for specific areas where food products or other articles are selectively heated. Cracks or pores may extend throughout the entire structure or through only one or more layers. The number, shape, size, and location of such cracks or pores may vary for a particular application, depending on the type of structure being formed, the food product or other article to be heated in or on it, the desired degree of shielding, browning, and / or embrittlement, the need to regulate temperature changes in the food product by direct heating, and whether and to what extent venting is required.

[0091] It should be understood that pores can be physical pores or voids in one or more layers or one or more materials used to form a structure, or they can be non-physical "pores" (not shown), such as areas that can be formed by simply not applying conductive material to a particular area or by removing conductive material from a particular area, for example, mechanically, chemically, etc.

[0092] In some cases, it may be beneficial to create one or more discontinuous or inactive regions to prevent overheating or scorching of the structure or one or more food products supported thereon. Such regions can be formed by forming areas of the structure without conductive material, by removing any conductive material that has been applied, or by deactivating the conductive material in these regions, as discussed above.

[0093] The conductive materials described herein can be applied to a substrate or base panel in any suitable manner, and in some cases, the conductive materials can be printed, extruded, sputtered, evaporated, or laminated onto the substrate. The conductive materials can be applied to the substrate in any pattern and using any technique to achieve the desired heating effect for food products. For example, the conductive materials can be provided as continuous or discontinuous layers or coatings, including circular, annular, hexagonal, island, square, rectangular, octagonal, and other shapes.

[0094] The laminated structures and blanks / structures disclosed herein can be formed according to a variety of processes known to those skilled in the art, including adhesive bonding, thermal bonding, ultrasonic bonding, mechanical stitching, or any other suitable process. Any of the various components used to form the package can be provided as a sheet of material, a roll of material, or a die-cut material having the shape of the structure to be formed (e.g., a blank or base layer).

[0095] All directional references (e.g., up, down, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are used for identification purposes only to aid the reader in understanding the various embodiments of this disclosure and do not impose limitations, particularly regarding the location, orientation, or use of the disclosed embodiments, unless specifically set forth in the claims. Coupling references (e.g., connection, attachment, coupling, link, etc.) should be interpreted broadly and may include intermediate members between the connections of elements and relative movement between elements. Thus, a coupling reference does not necessarily mean that two elements are directly and fixedly connected to each other. Furthermore, references to the various elements discussed in the various embodiments may be interchanged to create entirely new embodiments falling within the scope of this disclosure.

[0096] The foregoing description of this disclosure illustrates and describes various embodiments. Since various changes can be made to the above constructions without departing from the scope of this disclosure, everything contained in the foregoing description or shown in the accompanying drawings should be interpreted as illustrative rather than restrictive. Furthermore, the scope of this disclosure covers various modifications, combinations, variations, etc., of the above embodiments. Moreover, this disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of this disclosure as expressed herein, in proportion to the foregoing teachings, and / or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of this disclosure.

[0097] The foregoing description illustrates and describes various embodiments of this disclosure. Since various changes can be made to the above structures, everything contained in the foregoing description or shown in the accompanying drawings should be interpreted as illustrative rather than restrictive. Furthermore, various modifications, combinations, and variations of the above embodiments are within the scope of this disclosure. Moreover, this disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of this disclosure, commensurate with the foregoing teachings, and / or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of this disclosure.

Claims

1. A structure comprising: a base panel formed from a laminate structure, the laminate structure including a base layer, a conductive layer, and a surface film, the base panel assuming a planar arrangement for supporting a food product; and at least one spacing feature extending downwardly from the base panel for supporting the base panel at a distance above an inductive source for attenuating heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminate structure; the at least one end flap including a proximal portion foldably connected to the base panel at a fold line, and a distal portion foldably connected to the proximal portion at a fold line, the proximal portion extending downwardly from the fold line at which the proximal portion is foldably connected to the base panel, and the distal portion extending upwardly from the fold line at which the distal portion is foldably connected to the proximal portion to the base panel, such that the proximal portion and the distal portion form a sloped or wedge-shaped profile of the at least one spacing feature.

2. The structure of claim 1, wherein the base layer includes a composite material, the conductive layer includes a metallic material, and the surface film includes a polymeric material.

3. The structure of claim 2, wherein the base layer includes paperboard and the metallic material includes aluminum.

4. The structure of claim 1, wherein the at least one spacing feature is a first spacing feature, the at least one end flap includes a first end flap and a second end flap, the first spacing feature includes the first end flap, and the structure further includes a second spacing feature projecting downwardly from the base panel, the second spacing feature including the second end flap.

5. A blank for forming a structure, the blank comprising: a base panel formed from a laminate structure, the laminate structure including a base layer, a conductive layer, and a surface film, the base panel assuming a planar arrangement for supporting a food product; and when the structure is formed from the blank, the blank including a feature for forming at least one spacing feature extending downwardly from the base panel for supporting the base panel at a distance above an inductive source for attenuating heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminate structure; the at least one end flap including a proximal portion foldably connected to the base panel at a fold line, and a distal portion foldably connected to the proximal portion at a fold line, the proximal portion extending downwardly from the fold line at which the proximal portion is foldably connected to the base panel, and the distal portion extending upwardly from the fold line at which the distal portion is foldably connected to the proximal portion to the base panel, such that the proximal portion and the distal portion form a sloped or wedge-shaped profile of the at least one spacing feature. when the structure is formed from the blank, the proximal portion extends downward from a fold line at which the proximal portion is foldably connected to the base panel, and when the structure is formed from the blank, the distal portion extends upward to the base panel from a fold line at which the distal portion is foldably connected to the proximal portion, such that the proximal portion and the distal portion form a sloped or wedge-shaped profile of the at least one spacing feature.

6. The blank of claim 5, wherein the base layer comprises a composite material, the conductive layer comprises a metallic material, and the surface film comprises a polymeric material.

7. The blank of claim 6, wherein the base layer comprises paperboard and the metallic material comprises aluminum.

8. The blank of claim 5, wherein the at least one spacing feature is a first spacing feature, the at least one end flap comprises a first end flap and a second end flap, the first spacing feature comprises the first end flap, and the structure further comprises a second spacing feature formed from the second end flap.

9. A method of forming a structure, the method comprising: obtaining a blank, the blank comprising a base panel and at least one end flap foldably connected to the base panel, the base panel formed from a laminate structure, the laminate structure comprising a base layer, a conductive layer, and a surface film, the base panel assuming a planar arrangement; and forming at least one spacing feature extending downward from the base panel to support the base panel a preselected distance above an inductive source for attenuating heat transferred to a food product in response to an oscillating magnetic field interacting with the conductive layer of the laminate structure; the at least one end flap comprising a proximal portion foldably connected to the base panel at a fold line, and a distal portion foldably connected to the proximal portion at a fold line, the forming at least one spacing feature comprising arranging the proximal portion to extend downward from a fold line at which the proximal portion is foldably connected to the base panel, and arranging the distal portion to extend upward to the base panel from a fold line at which the distal portion is foldably connected to the proximal portion, such that the proximal portion and the distal portion form a sloped or wedge-shaped profile of the at least one spacing feature.

10. The method of claim 9, wherein the base layer comprises a composite material, the conductive layer comprises a metallic material, and the surface film comprises a polymeric material.

11. The method of claim 10, wherein the base layer comprises paperboard and the metallic material comprises aluminum.

12. The method of claim 9, wherein the at least one spacing feature is a first spacing feature, the at least one end flap comprises a first end flap and a second end flap, the first spacing feature comprises the first end flap, and the method of forming the at least one spacing feature comprises positioning a second spacing feature from the second end flap.

13. A method of heating a food product, the method comprising: ​ obtaining a structure as claimed in claim 1 ; positioning the structure on an induction source, wherein the at least one spacer feature supports the base panel a distance above the induction source; and activating the induction source to generate an oscillating magnetic field that interacts with the electrically conductive layer of the laminate structure, thereby heating the at least one food product supported on the base panel.

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