Blanks, structures and related methods for induction heating of food products

Abstract

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

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 052,037, filed July 15, 2020.

[0002] [Incorporated by reference] The disclosure of U.S. Provisional Patent Application No. 63 / 052,037, filed July 15, 2020, is incorporated herein by reference for all purposes as if set forth in its entirety herein.

[0003] The present disclosure relates generally to laminated structures / blanks for heating one or more food items by induction heating, structures formed therefrom, and related methods. More specifically, the present disclosure relates to structures having at least one spacing member for supporting a base panel at a predetermined vertical distance from an induction source. Summary of the Invention

[0004] According to one aspect, the present disclosure generally relates to a structure including at least one panel for supporting a food product, the at least one panel being formed from a laminated structure including a base layer, a conductive layer, and a surface film. The structure further includes at least one spacing feature extending downwardly from the at least one panel to support the at least one panel at a distance above an induction source to attenuate heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminated structure.

[0005] According to another aspect, the present disclosure generally relates to a blank for forming a construct. The blank includes at least one panel for supporting a food product, the at least one panel being formed from a laminate structure including a base layer, a conductive layer, and a surface film. The blank further includes a mechanism for forming at least one spacing mechanism extending downwardly from the at least one panel to support the at least one panel at a distance above an induction source to attenuate heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminate structure when the construct is formed from the blank.

[0006] According to another aspect, the present disclosure generally relates to a method of forming a structure, the method including obtaining a blank including at least one panel formed from a laminate structure including a base layer, a conductive layer, and a surface film, the method further including forming at least one spacing feature extending downwardly from the at least one panel to support the at least one panel a preselected distance above an induction source to attenuate heat transferred to a food product in response to an oscillating magnetic field interacting with the conductive layer of the laminate structure.

[0007] According to another aspect, the present disclosure relates to a method for heating food products, the method including obtaining a blank including at least one panel formed from a laminate structure including a base layer, a conductive layer, and a surface film, and forming a structure from the blank such that the structure includes the at least one panel and at least one spacing feature extending downwardly from the at least one panel. The method further includes positioning the structure over an induction source such that the at least one spacing feature supports the at least one panel a distance above the induction source, and activating the induction source to generate an oscillating magnetic field that interacts with the conductive layer of the laminate structure to heat at least one food product supported by the at least one panel.

[0008] Those skilled in the art will appreciate the above advantages and other benefits and advantages of various additional embodiments after reading the following detailed description of the embodiments with reference to the following drawings.

[0009] According to common practice, the various features in the drawings described below are not necessarily drawn to scale. Dimensions of the various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the present disclosure.

[0010] Corresponding parts are designated by corresponding reference numerals throughout the drawings. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a cross-sectional view of a laminate structure for use in forming blanks and structures according to the present disclosure. FIG. [Figure 2] FIG. 1 is a plan schematic view of a blank for forming a structure according to a first exemplary embodiment of the present disclosure. [Figure 3] 3 is a schematic diagram of the blank of FIG. 2 positioned in a forming apparatus. [Figure 4] 3 is a perspective view of a structure formed from the blank of FIG. 2 according to a first exemplary embodiment. [Figure 5] 5 is a schematic diagram of the structure of FIG. 4 positioned on an induction source for induction heating. [Figure 6] FIG. 10 is a plan schematic view of a blank for forming a structure according to a second exemplary embodiment of the present disclosure. [Figure 7] FIG. 7 is a perspective view of a structure formed from the blank of FIG. 6 according to a second exemplary embodiment. [Figure 8] FIG. 10 is a plan schematic view of a blank for forming a structure according to a third exemplary embodiment of the present disclosure. [Figure 9] FIG. 9 is a perspective view of a structure formed from the blank of FIG. 8 according to a third exemplary embodiment of the present disclosure. [Figure 10] FIG. 10 is a plan schematic view of a blank for forming a structure according to a fourth exemplary embodiment of the present disclosure. [Figure 11] FIG. 11 is a perspective view of a structure formed from the blank of FIG. 10 according to a fourth exemplary embodiment of the present disclosure. [Figure 12]FIG. 12 is another perspective view of the structure of FIG. [Figure 13] FIG. 10 is a plan schematic view of a blank for forming a structure according to a fifth exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012] Various aspects of the present disclosure may be further understood by reference to the figures. For simplicity, like numerals may be used to describe like features. Where multiple like features are shown, it will be understood that not all such features are necessarily labeled in each figure. It will also be understood that the various components used to form a structure may be interchanged. Thus, while only certain combinations are illustrated herein, numerous other combinations and configurations are contemplated herein.

[0013] Structures according to the present disclosure can accommodate articles of many different shapes, and for purposes of illustration, and not for purposes of limiting the scope of the disclosure, the following detailed description describes articles such as food products that are at least partially disposed on or within embodiments of the structures.

[0014] The items may include, but are not limited to, fast food products, take-out products, food waste, etc., or any combination thereof. Examples of such products include pastry (e.g., filled or frozen pastry), bread, fruit bars, French toast sticks, fish, chicken (chicken nuggets, chicken strips, chicken fingers, etc.), popcorn, peanuts, candy, French fries (waffle fries, steak fries, shoestring fries, curly fries, etc.), sandwiches, pizza, calzones, turnovers, burritos, or any other food product that may be presented for consumer consumption. As used herein, the terms "inside," "inner," "outside," "external," "lower," "bottom," "upper," and "top" refer to directions determined in relation to a fully assembled, upright structure.

[0015] As described herein, a structure may be formed by a plurality of overlapping panels, end flaps, and / or other portions of a blank, which panels, end flaps, and other portions of a blank may be designated in sequential or non-sequential reference, e.g., relative terms such as "first," "second," "third," etc., without departing from this disclosure.

[0016] Referring to FIG. 1 , a schematic cross-sectional view of a laminated structure 102 for forming a blank 103 and / or a structure 100 ( FIG. 4 ) is illustrated, according to an exemplary embodiment of the present disclosure. The structure 100 can be used to support or hold one or more food items and can include one or more electrically and thermally conductive materials such that the structure 100 can generate heat when exposed to a changing / oscillating magnetic field, e.g., such that eddy currents are induced in the electrically conductive material and electrical resistance to such eddy currents generates heat. In this regard, the laminated structure 102, blank 103, and / or structure 100 are configured for use with an induction generator or source, e.g., a source of a changing / oscillating magnetic field, to provide induction heating to one or more food items. In the case of ferromagnetically conductive materials, heating can be provided at least in part by hysteresis losses.

[0017] As shown, the laminate structure 102 includes a food contact or surface film 104, a conductive material or layer 106, and a base layer of material 110. In this regard, the food contact film 104 forms the interior or food-supporting surface of the laminate structure 102. For example, the food contact film 104 can be formed from a polymeric material such as polyethylene terephthalate (PET). The food contact film 104 can have barrier properties in at least the base layer 110, e.g., resist the passage of fluids such as moisture, oil, and food spillage, and can be suitable for use in heating applications such as those described herein. The food contact film 104 can be formed from additional or alternative materials, such as metals or composite materials, without departing from this disclosure.

[0018] As shown and described, the conductive layer 106 may be at least partially formed of an electrically and / or thermally conductive or semi-conductive material, such as a metal or metal alloy (e.g., ferrous, magnetic, or paramagnetic metal), or other material that may have properties suitable for induction heating. Examples of such materials include copper and copper alloys, brass, aluminum, iron, steel, stainless steel, tungsten, chromium, nickel, cobalt, carbon fiber, graphite, silicon, platinum, silver, gold, and alloys thereof. In the exemplary embodiment shown, the conductive layer 106 may be formed from aluminum; however, additional or alternative metallic materials may be used without departing from the present disclosure. For example, the conductive layer 106 may be patterned or configured to include one or more discontinuities and / or non-conductive regions to provide a desired profile for electrical and / or thermal conduction without departing from the disclosure.

[0019] The base layer 110 may be a composite material such as paper or a paper-based product (e.g., paperboard, etc.) that supports the conductive layer 106 and the food contact film 104 and is generally configured to be the same size, shape, and / or dimensions as one or more of these components, although the base layer 110 may be configured differently without departing from this disclosure.

[0020] The laminated structure 102 can be formed by placing one on top of the other a food contact film 104, a conductive layer 106, and a base layer 110. Such placement can be provided by a lamination process including, for example, roller and nip, chemical vapor deposition, application of one or more adhesives, etc.

[0021] It will be understood that the food contact film 104 and the conductive layer 106 may be separately formed elements, that the food contact film 104 may be metallized or otherwise provided with a conductive material, and / or that the conductive layer 106 may be provided with a coating or surface treatment that functions similarly to the food contact film 104. In one embodiment, the conductive layer 106 may be provided without an associated film or film-like treatment.

[0022] In one embodiment, laminate structure 102 may include a food contact layer 104 formed from 75 ga (0.019 mm) PET, a conductive layer 106 formed from aluminum having a thickness of about 7 microns, and a base layer 110 formed from paperboard having a thickness of about 0.018 caliper. It will be understood that laminate structure 102 or one or more components thereof may have different configurations without departing from this disclosure.

[0023] 2, there is illustrated an exterior surface 101 of a blank 103 for forming a structure 100 in accordance with a first exemplary embodiment of the present disclosure. The blank 103 may be formed from a laminate structure 102, although it will be understood that different material arrangements may be provided to form the blank 103.

[0024] As shown, blank 103 can have a longitudinal axis L1, a transverse axis L2, and one or more panels. In the illustrated embodiment, blank 103 can include a central or bottom or main or base panel 121 (broadly, a “first base panel” or a “second base panel”) separably and / or foldably connected to a central or bottom or main or base panel 123 (broadly, a “first base panel” or a “second base panel”) at a transverse line of weakness 125.

[0025] The blank 103 may include a plurality of end flaps or flaps foldably / separably connected to the respective panels, and may include a pair of positioning flaps 127 detachably and / or foldably connected to opposing free longitudinal edges of the base panel 121 at respective longitudinal lines of weakness 129, as shown.

[0026] As shown, a pair of positioning flaps 131 may be foldably and / or separably connected to a portion of each opposing free longitudinal edge of the base panels 121, 123 at respective longitudinal lines of weakness 133 that intersect with the line of weakness 125. As described further herein, one or more of the positioning flaps 127, 131 may engage with a portion of a forming tool or apparatus or otherwise engage to position the base panels 121, 123 relative to the forming tool or apparatus.

[0027] 3, a schematic diagram of a forming apparatus 137 for reconstructing blank 103 into structure 100 is shown. As shown, forming apparatus 137 can include a male forming member 139, e.g., an anvil or other member having one or more protruding surface features, and a female forming member 141, e.g., a mold / cavity of another member having one or more concave surface features complementary to the surface features of male forming member 139.

[0028] In the illustrated embodiment, the male forming member 139 and the female forming member 141 can be arranged to be movable relative to each other, for example, so that one or both of the male forming member 139 and the female forming member 141 can be configured to move toward and / or away from the other of the male forming member 139 and the female forming member 141.

[0029] In this regard, the blank 103 may be positioned between the male forming member 139 and the female forming member 141 of the forming apparatus 137, and such position may be achieved and / or maintained through engagement of a portion of the forming apparatus 137, such as a rim or edge of one or both of the forming members 139, 141, a clamp, clip, or other retaining structure, with one or more positioning flaps 127, 131. In one embodiment, a retaining structure may be attached to or positioned near the forming apparatus 137 and engage with one or more positioning flaps 127, 131 to maintain the position of the blank 103 during operation of the forming apparatus 137.

[0030] One or more of the forming members 139, 141 may be drawn / approached toward one another such that one or more of the protruding surface features of the male forming member 139 urges a portion of the blank 103 into a corresponding recessed feature of the female forming member 141. As further described herein, such action of the forming device 137 may cause at least a partial deformation and / or reconfiguration of the blank 103 into the structure 100, including forming at least one spacing feature of the structure 100.

[0031] 4 and 5, a structure 100 formed from a blank 103 is shown in accordance with a first exemplary embodiment of the present disclosure. As shown, the structure 100 can include at least one of the base panels 121, 123. Accordingly, one or more of the positioning flaps 127, 131 and / or another of the base panels 121, 123 can be separated from one of the base panels 121, 123 at respective lines of weakness 129, 133, 125. It will be understood that the structure 100 can include both 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 can be folded to at least partially face-to-face contact at the line of weakness 125 such that the structure 100 is formed from the panels 121, 123 arranged in a two-layer configuration. Alternatively, the base panels 121, 123 may be positioned spaced apart from one another in the formed structure, or the base panels may alternatively be arranged to form separate structures or trays.

[0032] As shown, structure 100 may include a spacing feature that may include a pair of spacing members 143 projecting downwardly from base panels 121 / 123. Spacing members 143 may be formed through the action of forming device 137 described above. For example, spacing members 143 may be formed at least in part through reconfiguration of at least the conductive layer of material forming blank 103 / structure 100, e.g., malleable metallic material of conductive layer 106 (FIG. 1), which undergoes at least a partial shape change during operation of forming device 137.

[0033] As shown, spacing members 143 can have the form of generally elongated, diagonal, or wedge-shaped protrusions extending downwardly from base panel 121 / 123. In one embodiment, spacing members 143 can have the form of elongated folds or pleats corresponding to respective depressions 142 in the upper surface of base panel 121 / 123. It will be understood that spacing members 143 can have different configurations, e.g., curves, bumps, peaks, etc., and can be a continuous feature or have one or more discontinuities, without departing from this disclosure.

[0034] The structure 100 is shown in FIG. 5 and is supported on an induction source S configured to generate one or more oscillating / changing magnetic fields B. In this regard, the induction source S may include an actuation coil, e.g., a wound / spiral 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 actuation coil. In one embodiment, the induction source may be an induction cooker, e.g., a glass / ceramic / composite surface under which copper or other magnetic coil(s) are disposed to generate the magnetic field for induction cooking.

[0035] Upon generation of one or more oscillating magnetic fields B by induction source S, one or more electrical currents E, e.g., eddy currents, may form in the conductive material of structure 100. The electrical resistance of the conductive material of structure 100 to such currents generates heat H, which may be conducted to the food product, e.g., food product F.

[0036] As shown, the spacing member 143 of the structure 100 positions / supports the base panel 121 / 123 (and food thereon) above the induction source S by a predetermined or preselected distance D. Such distance D of the base panel 121 / 123 above the induction source S can provide a desired attenuation of heat H supplied to the food F in response to the oscillating magnetic field B, for example, to prevent thermal damage (e.g., cracking, delamination, etc.) of one or more portions of the structure 100, charring or overcooking of the food F, etc., that may occur at a distance less than D above the induction source S. In one embodiment, the distance D can be approximately 1.75 mm. Alternatively, the distance D can be greater than or less than 1.75 mm without departing from the scope of the present disclosure. For example, the distance D can be selected based on various parameters of the induction source (e.g., the size of the induction cooker, the power of the induction cooker, etc.).

[0037] 6, there is illustrated an exterior surface 201 of a blank 203 for forming a structure 200 (FIG. 7) according to a second exemplary embodiment of the present disclosure. The blank 203 and structure 200 may have one or more features that are the same or similar to those described above with respect to the blank 103 and structure 100, and like or similar reference numbers are used to indicate like or similar features.

[0038] The blank 203 has a longitudinal axis L1 and a transverse axis L2 and may be at least partially formed from the laminated structure 102, although the blank 203 may be formed from one or more additional or alternative materials without departing from the disclosure.

[0039] As shown, the blank 203 includes a main or central or base panel 221 having a pair of longitudinally spaced convex cuts 222 (e.g., cuts having a radius of curvature extending laterally upward from the longitudinal centerline of the blank 203) opposite a pair of longitudinally spaced concave cuts 224 (e.g., cuts having a radius of curvature extending laterally downward from the longitudinal centerline of the blank 203).

[0040] 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 .

[0041] 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.

[0042] Similarly, end flap 227 includes a proximal portion 237 foldably connected to base panel 221 at longitudinal fold line 229 and a distal portion 239 foldably connected to proximal portion 237 at longitudinal fold line 241 .

[0043] 7, in one exemplary embodiment, construct 200 can be formed from blank 203 by placing outer surface 201 of blank 203 face down on a support surface, folding proximal portions 231 of end flaps 223 at fold lines 225 in the direction of arrow A1, folding distal portions 233 of end flaps 223 at fold lines 235 in the direction of arrow A2, and inserting respective portions of distal portions 233 of end flaps 223 through openings in base panel 221 formed by respective cuts 222.

[0044] In this regard, spacing member 243 is formed by the arrangement of proximal and distal portions 231, 233 of end flaps 223 and is positioned to extend downwardly from base panel 221. Spacing member 243 may have a generally diagonal or wedge-shaped profile formed by the arrangement of proximal and distal portions 231, 233 of end flaps 223, although spacing member 243 may have a different arrangement without departing from this disclosure. In the aforementioned arrangement, proximal portion 231 of end flap 223 extends from base panel 221 to distal portion 233 of end flap 223, and distal portion 233 of end flap 223 extends from proximal portion 231 of end flap 223 to base panel 221.

[0045] Similarly, proximal portion 237 of end flap 227 can be folded in the direction of arrow A3 at fold line 229, and distal portion 239 of end flap 227 can be folded in the direction of arrow A4 at fold line 241. A portion of distal portion 239 of end flap 227 can be inserted into the opening formed by each cut 224 to extend downwardly from base panel 221, forming spacing member 245 having a generally diagonal or wedge-shaped profile formed by the arrangement of proximal portion 237 and distal portion 239 of end flap 227. In the foregoing arrangement, proximal portion 237 of end flap 227 extends from base panel 221 to distal portion 239 of end flap 227, and distal portion 239 of end flap 227 extends from proximal portion 237 of end flap 227 to base panel 221. Spacing members 245 may have different configurations without departing from this disclosure.

[0046] In the foregoing arrangement, a portion of the base panel 221 may be at least partially separated from the remainder thereof at cuts 222, 224 to form respective retention tabs 220, 226 for retaining respective end flaps 223, 227.

[0047] In this regard, spacing members 243, 245 of structure 200 position base panel 221 a preselected distance D above an induction source, e.g., induction source S shown in FIG. 5 , to provide a desired attenuation of heat H supplied to food product F in response to oscillating magnetic field B, e.g., to prevent thermal damage (e.g., cracking, delamination, etc.) of one or more portions of structure 200, to prevent charring or overcooking of food product F, etc., as described above with respect to structure 100.

[0048] 8, there is illustrated an exterior surface 301 of a blank 303 for forming a structure 300 (FIG. 9) according to a third exemplary embodiment of the present disclosure. The blank 303 and structure 300 may have one or more features that are the same or similar to those described above with respect to the blanks 103, 203 and structures 100, 200, and like or similar reference numbers are used to indicate like or similar features.

[0049] The blank 303 has a longitudinal axis L1 and a transverse axis L2 and may be at least partially formed from the laminated structure 102, although the blank 303 may be formed from one or more additional or alternative materials without departing from the disclosure.

[0050] As shown, blank 303 includes a main / center / bottom or base panel 321 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 respective pair of laterally spaced curved cuts 331, 333.

[0051] The first side panel 323 can be foldably connected to the first top panel 335 at a transverse fold line 337 interrupted by a respective pair of 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, with the cuts 331, 333 disposed in opposing convex and concave relationship. In one embodiment, different arrangements of top panels can be provided, for example, a single top panel.

[0052] 9, in one exemplary embodiment, structure 300 can be formed from blank 303 by placing outer surface 301 of blank 303 face down on a support surface and folding side panels 323, 327 upwardly at respective fold lines 325, 329 in the directions of arrows A5 and A6. Top panels 335, 339 can then be folded toward each other at respective fold lines 337, 341 in the directions of respective arrows A7, A8, so that top panels 335, 339 are in at least a partially overlapping arrangement, e.g., in at least partial face-to-face contact with each other. This arrangement of structure 300 can be maintained with an adhesive, such as adhesive G.

[0053] In forming the structure 300 in this manner, a portion of each side panel 323, 327 may be separated from its respective adjacent panel at a respective cut 331, 333 to form a plurality of spacing members 343 (broadly "first spacing members") that protrude from opposing edges of the side panels 323, 327. As shown, a set of four spacing members 343 may protrude upward relative to the top panels 339, 335, and a set of four spacing members 343 may protrude downward relative to the base panel 321. It will be understood that one or more spacing members 343 may have different configurations or arrangements without departing from this disclosure.

[0054] In this regard, panels 321, 323, 327, 335, 339 extend at least partially around interior 307 of structure 300 in an open sleeve-like arrangement capable of at least partially receiving food products. Although top panels 335, 339 have been described as the uppermost panels / layers of structure 300, it will be understood that structure 300 can be inverted, with panels 335, 339 being the lowermost or support panels / layers of structure 300 and panel 321 being positioned as the uppermost panel / layer of structure 300.

[0055] The structure 300 is shown supported by an induction source, such as induction source S shown in FIG. 5, which is configured to generate one or more oscillating / changing magnetic fields, such that when the one or more oscillating magnetic fields B are generated by induction source S, one or more electrical currents, e.g., eddy currents, are formed in the conductive material of the structure 300, which, by electrical resistance, generate heat H that can be conducted to a food item, e.g., food item F.

[0056] In this manner, spacing member 343 of structure 300 can be configured to position base panel 321 above induction source S by a preselected distance D to provide a desired attenuation of heat H supplied to food product F in response to oscillating magnetic field B, for example, to prevent thermal damage (e.g., cracking, delamination, etc.) of one or more portions of structure 300, prevent charring or overcooking of food product F, etc., as described above with respect to structures 100, 200.

[0057] 10, there is shown an exterior 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 structure 400 may have one or more features that are the same or similar to those described above with respect to the blanks 103, 203, 303 and structures 100, 200, 300, and like or similar reference numbers are used to indicate like or similar features.

[0058] The blank 403 has a longitudinal axis L1 and a transverse axis L2 and may be at least partially formed from the laminated structure 102, although the blank 403 may be formed from one or more additional or alternative materials without departing from the disclosure.

[0059] As shown, blank 403 includes a main / central / base panel or base panel 421 foldably connected to a first end panel 423 at a transverse fold line 425, which may be 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 end panel 429 at a transverse fold line 431, which may be interrupted by a cut 433 having one or more straight, curved, and angled portions.

[0060] A first side panel 435 may be foldably connected to the base panel 421 at a longitudinal fold line 437 that is interrupted by a cut 439 having one or more straight, curved, and angled portions. Similarly, a second side panel 441 may be foldably connected to the base panel 421 at a longitudinal fold line 443 that is interrupted by a cut 445 having one or more straight, curved, and angled portions.

[0061] The plurality of end flaps may be foldably connected to each of the plurality of panels of the blank 403 and may include a first corner panel 447 foldably connected to the first end panel 423 at a diagonal fold line 449 and a second corner panel 451 foldably connected to the first end panel 423 at a diagonal fold line 453. As shown, the corner panels 447, 451 may be separated from the respective side panels 435, 441 at respective diagonal cuts 455, 457.

[0062] Similarly, the first corner panel 459 can be foldably connected to the second end panel 429 at a diagonal fold line 461, and the second corner panel 463 can be foldably connected to the second end panel 429 at a diagonal fold line 465. The corner panels 459, 463 can be separated from the respective side panels 435, 441 at respective diagonal cuts 467, 469.

[0063] 11 and 12, in one exemplary embodiment, structure 400 can be formed from blank 403 by placing outer surface 401 of blank 403 facing downward on a support surface and folding end panels 423, 429 upward at respective fold lines 425, 431 in the directions of respective arrows A9, A10, and simultaneously or subsequently folding side panels 435, 441 upward at respective fold lines 437, 443 in the directions of respective arrows A11, A12.

[0064] Corner panels 447, 459 can be folded into at least partial face-to-face contact with side panel 435 at respective fold lines 449, 461, and corner panels 451, 463 can be folded into at least partial face-to-face contact with side panel 441 at respective fold lines 453, 465. This arrangement of structure 400 can be maintained with an adhesive, such as glue.

[0065] In forming the structure 400 in this manner, a portion of each end panel 423, 429 and each side panel 435, 441 may be separated from the adjacent base panel 421 at respective cuts 427, 433, 439, 445 to form a plurality of respective spacing members 471, 473 (broadly "second spacing members"), 475, 477 (broadly "first spacing members") projecting downwardly from the respective panels 423, 429, 435, 441. In this regard, the spacing members 471, 473, 475, 477 may take the form of tabs, posts, legs, etc., that extend downwardly relative to the base panel 421. It will be understood that one or more of the spacing members 471, 473, 475, 477 may have different configurations or arrangements without departing from this disclosure.

[0066] As shown, the structure 400 can have a generally tray-like configuration with panels 421, 423, 429, 435, 441 extending at least partially around the interior 407 of the structure 400 for receiving one or more food items.

[0067] 5 configured to generate one or more oscillating / changing magnetic fields B. And, upon generation of one or more oscillating magnetic fields B by the induction source S, one or more electrical currents, e.g., eddy currents, form in the conductive material of the structure 400, generating heat H that can be resistively conducted to the food product, e.g., food product F.

[0068] Spacing members 471, 473, 475, 477 of structure 400 can be arranged to position base panel 421 above induction source S by a preselected distance D to provide a desired attenuation of heat H supplied to food product F in response to oscillating magnetic field B, for example, to prevent thermal damage (e.g., cracking, delamination, etc.) of one or more portions of structure 400 and to prevent charring or overcooking of food product F, as described above with respect to structures 100, 200, 300.

[0069] 13, there is shown an exterior 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 structure 500 may have one or more features that are the same as or similar to those described above with respect to blanks 103, 203, 303, 403 and structures 100, 200, 300, 400, and like or similar reference numbers are used to indicate like or similar features.

[0070] In particular, blank 503 may be generally similar to blank 403, except that panels 421, 423, 429, 435, 441 are provided in different sizes / arrangements. In this regard, a structure formed from blank 503 may be formed in a manner similar to that described above with respect to forming structure 400 from blank 403, and may be used to support base panel 421 at a predetermined distance above an induction source, as described above with respect to the previous embodiment.

[0071] It will be appreciated that additional or alternative structures for induction heating one or more food products may be provided without departing from this disclosure. Such structures may have the form of a bowl, tray, sleeve, mat, lidded structure (e.g., having one or more hinged lids), etc., and may have at least one bottom / base panel having one or more spacing members in the form of tabs, legs, posts, ridges, other protrusions, etc. extending therefrom for supporting the bottom / base panel at a predetermined distance from the induction source, in accordance with the discussion above.

[0072] Generally, the blanks or substrates described herein may be constructed from paperboard having a thickness that is heavier and more rigid than ordinary paper. Alternatively, the substrate may be constructed from cardboard or any other material having suitable properties to enable the structure to function at least substantially as described above. The substrate may be coated with, for example, a clay coating. The clay coating may then be printed with merchandise, advertising, and other information or images. The substrate may then be coated with a varnish to protect the information printed on the substrate. The substrate may also be coated on one or both sides with, for example, a moisture barrier. In selected panels or panel portions, the substrate may also be laminated or coated with one or more sheet-like materials.

[0073] It will be apparent that numerous other sequences of steps can be used to form structures as described herein. It will also be apparent that numerous other materials or structures can be used to form structures in accordance with the present disclosure. Any of such materials can be used alone or in combination, and in any configuration, to form a structure. When multiple materials (or multiple layers of the same material) are used, the materials may be partially or completely bonded to each other, or may remain separate from each other (i.e., unbonded).

[0074] Countless other structures and configurations are contemplated by the present disclosure. If desired, any such structure may include one or more regions lacking conductive material or having reduced thermal / electrical conduction. Such regions may be used to enhance heating, browning, and / or crisping of adjacent food or other items, and may be sized, positioned, and arranged to vary such heating as desired.

[0075] Any such configuration or structure may be formed from a variety of materials, provided the materials are substantially resistant to softening, scorching, burning, or deterioration at typical surface heating temperatures, e.g., up to about 400° F., and in one embodiment, up to about 425° F. Such heating temperatures may be higher without departing from this disclosure.

[0076] If desired, any of the numerous conductive materials described or contemplated herein may be substantially continuous, i.e., without substantial breaks or interruptions, or may be discontinuous, for example, by including one or more breaks or openings. The breaks or openings may be sized and positioned to selectively heat specific areas of a food item or other item. The breaks or openings may extend throughout the entire structure or may extend only through one or more layers. The number, shape, size, and location of such breaks or openings may vary for a particular application depending on the type of structure being formed, the food item or other item to be heated therein or thereon, the degree of shielding, browning, and / or crisping desired, the need to regulate temperature changes in the food item due to direct heating, and the presence and degree of ventilation required.

[0077] It will be understood that the openings may be physical openings or voids in one or more layers or materials used to form the structure, or may be non-physical "openings" (not shown), such as areas that may be formed by simply not applying conductive material to a particular area or by removing, e.g., mechanically, chemically, or the like, conductive material in a particular area.

[0078] In some cases, it may be beneficial to create one or more discontinuities or inactive areas to prevent overheating or charring of the structure or one or more food items supported thereon. Such areas may be created by forming these areas of the structure without conductive material, by removing any applied conductive material, or by inactivating the conductive material in these areas, as described above.

[0079] The conductive materials described herein can be applied to a base layer or substrate by any suitable method, and in some examples, the conductive material can be printed, extruded, sputtered, vapor-deposited, or laminated to the substrate. The conductive material can be applied to the substrate in any pattern and using any technique to achieve the desired heating effect of the food product. For example, the conductive material can be provided as a continuous or discontinuous layer or coating, including circles, rings, hexagons, islands, squares, rectangles, octagons, etc.

[0080] The laminate structures and blanks / constructs disclosed herein can be formed according to a number of processes known to those skilled in the art, including using 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 sheets of material, rolls of material, or die-cut material in the shape of the structure to be formed.

[0081] All directional references (e.g., up, down, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise) are used for identification purposes only to aid the reader in understanding the various embodiments of the present disclosure and do not imply any limitations on the position, orientation, or use of the disclosed embodiments, unless specifically defined in the claims. Joint references (e.g., coupled, attached, connected, connected, etc.) should be interpreted broadly and may include intermediate members between the connection of elements and relative movement between the elements. As such, joint references do not necessarily imply that two elements are connected in a direct and fixed relationship. Furthermore, various elements described with reference to various embodiments may be interchanged to create entirely new embodiments within the scope of the present disclosure.

[0082] The foregoing description of the present disclosure illustrates and describes various embodiments. Because various changes can be made in the above configurations without departing from the scope of the present disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Moreover, the scope of the present disclosure includes various modifications, combinations, alterations, etc. of the above-described embodiments. Moreover, while the present disclosure illustrates and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of the disclosure expressed herein, commensurate with the above teachings, and / or within the skill or knowledge of the relevant art. Furthermore, specific features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and unillustrated embodiments of the present disclosure.

[0083] The foregoing description illustrates and describes various embodiments of the present disclosure. Because various modifications may be made to the above configurations, it is intended that all matter contained in the above description or shown in the accompanying drawings be interpreted as illustrative and not limiting. Moreover, various modifications, combinations, and alterations of the above-described embodiments are within the scope of the present disclosure. Furthermore, while the present disclosure illustrates and describes only selected embodiments, various other combinations, modifications, and environments are within the scope of the present disclosure, commensurate with the above teachings, and / or within the skill or knowledge of the relevant art. Furthermore, specific features and characteristics of each embodiment may be selectively substituted for and applied to other illustrated and unillustrated embodiments without departing from the scope of the present disclosure.

Claims

1. A structure comprising: a base panel and at least one end flap foldably connected to the base panel, the base panel being formed from a laminated structure including a base layer, a conductive layer, and a surface film, the base panel being in a planar configuration for supporting a food item, 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; at least one spacing feature extending downwardly from the base panel to support the base panel at a distance above an induction source to attenuate heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminated structure; Equipped with the proximal portion extends downward from the fold line where the proximal portion is foldably connected to the base panel, and the distal portion extends upward to the base panel from the fold line where the distal portion is foldably connected to the proximal portion, the proximal portion and the distal portion forming a diagonal or wedge-shaped profile of the at least one spacing feature; The structure further comprises at least one cut in the base panel at least partially forming at least one retention tab, the distal portion of the at least one end flap being at least partially received between the at least one retention tab and the base panel.

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

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

4. 10. The structure of claim 1, wherein the at least one spacing feature is a first spacing feature, the at least one end flap is a first end flap, and the structure further comprises: a second end flap foldably connected to the base panel; and a second spacing feature extending downwardly from the base panel and consisting of the second end flap.

5. A blank for forming a structure, comprising: a base panel and at least one end flap foldably connected to the base panel, the base panel being formed from a laminated structure including a base layer, a conductive layer, and a surface film, the base panel being in a planar configuration for supporting a food item, 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; and a mechanism for forming at least one spacing feature extending downwardly from the base panel to support the base panel at a distance above an induction source to attenuate heat transferred to the food product in response to an oscillating magnetic field interacting with the conductive layer of the laminated structure when the structure is formed from the blank; when the construct is formed from the blank, the proximal portion extends downward from the fold line where the proximal portion is foldably connected to the base panel, and the distal portion extends upward to the base panel from the fold line where the distal portion is foldably connected to the proximal portion, and when the construct is formed from the blank, the proximal portion and the distal portion form a diagonal or wedge-shaped profile of the at least one spacing feature; The blank further comprises at least one cut in the base panel that at least partially forms at least one retention tab, such that when the construct is formed from the blank, the distal portion of the at least one end flap is at least partially received between the at least one retention tab and the base panel.

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 metal material comprises aluminum.

8. 6. The blank of claim 5, wherein the at least one spacing feature is a first spacing feature, the at least one end flap is a first end flap, and the blank further comprises a second end flap foldably connected to the base panel to at least partially form a second spacing feature that projects downwardly from the base panel when the construct is formed from the blank.

9. 1. A method of forming a structure, comprising: obtaining a blank including a base panel and at least one end flap foldably connected to the base panel, the base panel being formed from a laminate structure including a base layer, a conductive layer, and a surface film, the base panel being in a planar configuration, 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; forming at least one spacing feature extending downwardly from the base panel to support the base panel a preselected distance above an induction source to attenuate heat transferred to a food item in response to an oscillating magnetic field interacting with the conductive layer of the laminated structure; forming the at least one spacing feature includes: positioning the proximal portion so that the proximal portion extends downward from the fold line foldably connected to the base panel; and positioning the distal portion so that the distal portion extends upward from the fold line foldably connected to the proximal portion to the base panel, whereby the proximal portion and the distal portion form a diagonal or wedge-shaped profile of the at least one spacing feature; The blank includes at least one cut in the base panel that at least partially forms at least one retention tab, the method further comprising positioning the distal portion of the at least one end flap between the at least one retention tab and the base panel.

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 substrate comprises paperboard and the metallic material comprises aluminum.

12. 10. The method of claim 9, wherein the at least one spacing feature is a first spacing feature, the at least one end flap is a first end flap, the blank further comprising a second end flap foldably connected to the base panel, the method further comprising positioning the second end flap to form a second spacing feature extending downwardly from the base panel.

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