Venting microwaveable packaging product

Abstract

A microwavable package designed to enhance food preparation efficiency. The package having a flexible bottom web and a flexible top web, encasing a support member. This support member featuring an upper surface treated with a grease-resistant barrier and includes multiple channels through the barrier. The top and bottom webs extend beyond the support member's perimeter and are sealed together, forming a perimeter seal with varying thicknesses. The package's innovative design provides a controlled venting area by ensuring the secondary thickness at the vent area is less than the primary thickness, thereby enhancing microwave cooking results.

Description

VENTING MICROWAVEABLE PACKAGING PRODUCTCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No.63 / 777,211, filed March 25, 2025 and entitled “Venting Microwaveable Packaging Product” and U.S. Provisional Patent Application No. 63 / 886,157, filed September 23, 2025 and entitled “Venting Microwaveable Packaging Product”, the entirety of each are incorporated herein by reference.BACKGROUND

[0002] The subject matter disclosed herein relates to food packaging. More particularly to microwavable food packaging having venting features and a support member.

[0003] In the developments of food packaging, microwaveable food slices, such as bacon, packaged with an absorbent pad has gained attention. This packaging allows the food to be cooked directly in the microwave while also containing the mess typically associated with grease. The absorbent pad inside the package soaks up the grease, providing a cleaner and more convenient cooking process.

[0004] Vacuum skin packaging (also known as “VSP”) is a process well known in the art for using a thermoplastic packaging material to enclose a food product. The vacuum skin packaging process in which an article to be packaged serves as the mold for the forming web. A product is placed on a support and then passed to a chamber where a top web is drawn upward against a heated dome and the softened top w eb is then draped over the product. The movement of the w-eb is controlled by vacuum and or air pressure, and in a vacuum skin packaging arrangement, the interior of the container is vacuumized before final welding of the top w eb to the support web. In a vacuum skin package, the upper heated film thus forms a tight skin around the product and is sealed to the support. Support members may be flat or have a shape for the particular purpose, such as tray-shaped, bowl-shaped or cup-shaped.

[0005] Typically, when a packaged food product needs to be cooked before eating, this is generally done by using a microw aveable support member and removing, either partially or completely, the top skin web just before putting the package in the oven. Food treated in this way tends to have inconsistent results and often becomes dry in texture and consistency.Furthermore, during the cooking process, grease or other fluids tend to splatter on the inner surfaces of the microwave oven.

[0006] While cooking a sealed package within a microwave oven considerable water vapor pressure is generated within the package during the heating cycle. This can result in a sudden explosion of the package within the oven. This particularly with VSP packages as the top and bottom webs are sealed together over a wide area (corresponding to the whole support surface not occupied by the product) and because the skin top web is highly formable and will stretch under pressure caused by the excess vapor. This allows the package to inflate in a ballon-like fashion over the product before either bursting of the film or a failure of the seal in an unpredictable way to release the excess pressure.

[0007] The packaging ty pically consists of a microwave-safe container and an absorbent pad. The absorbent pad being placed beneath the food slices, to capture and absorb the rendered grease. This type of packaging not only reduces splatter but also minimizes the need for additional cleaning after cooking, offering a practical solution for consumers seeking quick and efficient meal preparation. In exchange for ease of preparation and clean up, the absorption of grease-results in a loss of flavor and increased potential of dry ing out the meat.

[0008] The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter.BRIEF DESCRIPTION

[0009] A microwavable package designed to enhance food preparation efficiency. The package having a flexible bottom web and a flexible top web, encasing a support member. This support member featuring an upper surface treated with a grease-resistant barrier and includes multiple channels through the barrier. The top and bottom webs extend beyond the support member's penmeter and are sealed together, forming a perimeter seal with varying thicknesses. The package's innovative design provides a controlled venting area by ensuring the secondary7thickness at the vent area is less than the primary' thickness, thereby enhancing microwave cooking results.

[0010] An advantage that may7be realized in the practice of some disclosed embodiments of the microyvavable package is that it alloyvs for enhanced flavor retention yvhile ensuring an easy clean-up process. The self-venting plastic package, combined with a support board tohold the bacon, effectively captures and drains the excess grease, minimizing mess and splatter. This feature not only preserves the bacon's succulence and taste but also offers a practical solution for consumers who seek convenience without compromising on quality. The support board further ensures that the bacon maintains its shape and cooks evenly, resulting in perfectly crispy slices every time.

[0011] In one exemplary embodiment, a microwavable package is disclosed. The microwavable package comprises a flexible bottom web; a flexible top web; and a rigid or semi-rigid support member having an upper surface and a lower surface. The support member being disposed between the flexible bottom web and the flexible top web. The upper surface of the support member having a grease-resistant barrier. The support member having a plurality of channels extending through the grease-resistant barrier. The top web and bottom web extending beyond the perimeter of the support member, the top web and bottom web being sealed to each other along a perimeter which is outside of the perimeter of the support member creating a perimeter seal. The perimeter seal having a primary thickness and a secondary thickness proximate to a vent area. The secondary thickness being less than the primary thickness forming a controlled venting area.

[0012] In another exemplary embodiment, a microwavable packaged food product is disclosed. The microwavable packaged food product comprises a flexible bottom web; a flexible top web; and a rigid or semi-rigid support member having an upper surface and a lower surface. At least one food product situated on the support member. The support member being disposed between the flexible bottom web and the flexible top web. The upper surface of the support member having a grease-resistant barrier. The support member having a plurality of channels extending through the grease-resistant barrier. The top web and bottom web extending beyond the perimeter of the support member, the top web and bottom web being sealed to each other along a perimeter which is outside of the perimeter of the support member creating a perimeter seal. The perimeter seal having a primary thickness and a secondary thickness proximate to a vent area. The secondary thickness being less than the primary thickness forming a controlled venting area.

[0013] In another exemplary embodiment, a method of for packaging food slices is disclosed. The method comprises the steps of forming a package by: providing a flexible bottom web; and situating a rigid or semi-rigid support member on the flexible bottom web; the support member having an upper surface and a low er surface; the upper surface of thesupport member having a grease-resistant barrier; the support member having a plurality of channels extending through the grease-resistant barrier. Situating at least one food product on the support member. Providing a flexible top web over the flexible bottom web, support member and food product. The top web and bottom web extending beyond the perimeter of the support member. Heat sealing the top web and bottom web being to each other in a vacuum chamber along a perimeter which is outside of the perimeter of the support member creating a perimeter seal. The perimeter seal having a primary thickness and a secondary thickness proximate to a vent area; and the secondary thickness being less than the primary thickness forming a controlled venting area.

[0014] This brief description of the invention is intended only to provide a brief overview of subject matter disclosed herein according to one or more illustrative embodiments, and does not serve as a guide to interpreting the claims or to define or limit the scope of the invention, which is defined only by the appended claims. This brief description is provided to introduce an illustrative selection of concepts in a simplified form that are further described below in the detailed description. This brief description is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] So that the manner in which the features of the invention can be understood, a detailed description of the invention may be had by reference to certain embodiments, some of which are illustrated in the accompanying drawings. It is to be noted, however, that the drawings illustrate only certain embodiments of this invention and are therefore not to be considered limiting of its scope, for the scope of the invention encompasses other equally effective embodiments. The drawings are not necessarily to scale, emphasis generally being placed upon illustrating the features of certain embodiments of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views. Thus, for further understanding of the invention, reference can be made to the following detailed description, read in connection with the drawings in which:

[0016] Fig. 1 is a sectional view of a package according to embodiments; and

[0017] Figs. 2A - 2B is section view of a vacuum chamber for forming packages according to embodiments;

[0018] Figs. 3 is a section view of a vacuum chamber for forming packages according to another embodiment;

[0019] Fig. 4 is a top view of a formed package according to embodiments;

[0020] Fig. 5 is a top view of a formed package according to alternative embodiments;

[0021] Fig. 6 is a top view of a seal mechanism according to embodiments;

[0022] Fig. 7 is a top view of a seal mechanism according to alternative embodiments;

[0023] Fig. 8 is a top view of a support member according to embodiments;

[0024] Fig. 9 is a cross-sectional view of the support member as shown in Fig. 8;

[0025] Figs. 10A - 10H are alternative channel patterns for use on support members according to embodiments;

[0026] Figs. 1 lA-11C are isometric views of food slices being cooked in a package according to embodiments;

[0027] Fig. 12 is a top view of a package after being cooked according to embodiments;

[0028] Fig. 13 is a depiction of various support members post cooking;

[0029] Fig. 14 is a top view of a support member according to alternative embodiments; andDETAILED DESCRIPTION

[0030] Fig. 1 illustrates a package containing bacon slices. The package is ideal for packaging and cooking bacon slices. In other embodiments it can also be used to package other types of food slices, such as, e.g., slices of luncheon meat, sausage, cheese, produce, egg, etc. Foods having high fat content are well suited for the package described herein.

[0031] Package 10 includes a substantially flat support member 14 which supports thereon a group of food slices 12. Flexible top web 16 encloses food slices 12 on support member 14. Flexible top web 16 is sealed, to flexible bottom web 15 outside the periphery of the support member 18, i.e., between the periphery of the support member 18 and the periphery of the package 22 to create perimeter seal 20. Such a seal is known as a “perimeter seal.” In this manner, food slices 12 are completely enclosed by flexible top web 16 and the flexible bottom web 15 while be supported by the support member 14. The remaining portion of the flexible top web 1 that is in contact with the flexible bottom web 15 and the support member 14 creates a tack seal. The strength of the tack seal being less than that of the perimeter seal. The package having an upper outer surface 24 and lower outer surface 26.

[0032] As the package is cooked in a microw ave, vapor within the package causes the flexible top w eb to expand. The force being sufficient to overcome the tack seal. As the force increases, a portion of the perimeter seal fails allowing the package to vent in a controlled manner. This perimeter seal failure happening at the secondary thickness of the perimeter seal. Once cooking is complete, and the product sufficiently cooled, the top web can be at least partially, or completely removed and the product removed from the package. The entire package may then be discarded, allowing for easy clean up. Cooking in this manner reduces the potential for grease spatter within the microwave oven and aids in convenience and clean up.

[0033] As used herein, the term “film” is inclusive of plastic web, regardless of whether it is film or sheet. The film can have a thickness of 0.25 mm or less, or a thickness of from 0.5 to 30 mils, or from 0.5 to 15 mils, or from 1 to 10 mils, or from 1 to 8 mils, or from 1.1 to 7 mils, or from 1.2 to 6 mils, or from 1.3 to 5 mils, or from 1.5 to 4 mils, or from 1.6 to 3.5 mils, or from 1.8 to 3.3 mils, or from 2 to 3 mils, or from 1.5 to 4 mils, or from 0.5 to 1.5 mils, or from 1 to 1.5 mils, or from 0.7 to 1.3 mils, or from 0.8 to 1.2 mils, or from 0.9 to 1.1 mils.

[0034] The multi-layer films described herein may comprise at least, and / or at most, any of the following numbers of layers: 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 and 15. As used herein, the term “layer” refers to a discrete film component which is substantially coextensive with the film and has a substantially uniform composition. Where tw o or more directly adjacent layers have essentially the same composition, then these two or more adjacent layers may be considered a single layer for the purposes of this application. In an embodiment, themultilayer film utilizes microlayers. A microlayer section may include between 10 and 1,000 microlayers in each microlayer section.

[0035] An “oxygen barrier polymer,” as used herein, is any polymer known in the art which, when formed into a film consisting essentially of the polymer, exhibits low oxygen permeance, herein defined as an oxygen transmission rate of a 1.0 mil thickness film equal to or less than about 500 cubic centimeters (at standard temperature and pressure) per square meter per day per 1 atmosphere of oxygen pressure differential measured at 0% relative humidity and 23°C. All references to oxygen transmission rate in this application are measured at these conditions according to ASTM D-3985. In one embodiment, the oxygen barrier polymer has an oxygen transmission rate of a 1.0 mil thickness film of less than about 50 cubic centimeters (at standard temperature and pressure) per square meter per day per 1 atmosphere of oxygen pressure differential measured at 0% relative humidity and 23°C.

[0036] Exemplary' oxygen barrier polymers include modified or ethylene / vinyl alcohol copolymers (EV OH), polyvinyl alcohols (PVOH), vinylidene chloride polymers (PVdC), polyvinyl chlorides (PVC), polyalkylene carbonates, polyethylene furanoates (PEF), polyesters (e.g., PET, PEN), polyacrylonitriles (PAN), polyamides, and blends thereof.

[0037] A barrier layer has a thickness and composition sufficient to impart to a film, or laminate, incorporating the barrier film an oxygen transmission rate of no more than about any of the following values: 25, 20, 15, 10, and 5 cubic centimeters (at standard temperature and pressure) per square meter per day per 1 atmosphere of oxygen pressure differential measured at 0% relative humidity and 23 °C measured at these conditions and according to ASTM D-3985. (A reference to the oxygen transmission attributes of a film that is a component of a laminate refers to the oxygen transmission attributes of the film itself, which can be measured by separating the film from the laminate - for example, by using an appropriate solvent to dissolve the adhesive that bonds the films together to form the laminate.)

[0038] The term “vacuum skin packaging” (hereinafter “VSP”) as used herein indicates that the product is packaged under vacuum and the space containing the product is at least partially evacuated from gases. It is therefore desirable that both the top skin film formed around the product and that used for the support member present a barrier to oxygen, air, andother gases detrimental to the shelf or storage life of a food product. The top web of vacuum skin packaging material has a high degree of formability / stretchability to avoid the occurrence of wrinkles and other irregularities in the final packaged product.

[0039] As used herein the term “microwaveable’', as well as the term “microwavecompatible”, when referred to the structures useful for the manufacture of VSP packages, include those structures that are “substantially microwave-transparent” as well as those that are “microwave-active”. While the structures substantially microwave-transparent are those capable of being crossed by at least 80%, and in some embodiments, at least 90% of the microwaves generated by a microwave oven without any sort of interference therewith, the microwave-active are those that incorporate microwave reflective components intended to modify the energy deposition within the adjacent foodstuff. In practice, packaging materials that withstand a heat treatment at 121° C. for ! hour (conditions that are drastic enough not to be reached normally in microwave cooking) without deforming and releasing less than 60 ppm of contaminants, are generally considered to be “microwaveable” according to most of the food compliance laws. Examples of resins suitable for use in the manufacture of the package of the invention include polyolefins (such as propylene-based polymers or preferably cross-linked polyethylene-based polymers), polyesters, nylons and any other thermoplastic material that under the conditions of use will not be altered by microwaves.

[0040] The flexible top web and flexible bottom web may be, but are not required to be of the same material. The flexible webs are multilayer film structures which include a barrier layer and a heat seal layer. Suitable films for use as the flexible top web and flexible bottom web include T7230B (Barrier Web, 3.0 Mil ) T2230BZ (EZO Barrier Web. 3.0 Mil) or T7230BZ (HFFS package) all available from Cryovac. For the package to vent and to have easy open functionality, at least one of the webs should include what is known in the art as an “easy open” sealant. Films having an easy open sealant layer include, but are not limited to T2230BZ available from Cryovac. In embodiments, both the top web and the bottom web have an easy open sealant layer. In other embodiments, one of the top web or the bottom web has an easy open sealant layer and the other web has a lock down sealant layer.

[0041] In embodiments, the flexible top web and flexible bottom web have a free shrink of less than any of 15%, 20%, 25%, or 30% at 85°C measured in accordance with ASTM D2732. As used herein, the phrase “free shrink” refers to the percent dimensional change in a 10 cm x 10 cm specimen of film, when shrunk at 85°C, with the quantitative determinationbeing carried out according to ASTM D2732 “Standard Test Method for Unrestrained Linear Thermal Shrinkage of Plastic Film and Sheeting.” Unless otherwise indicated, all free shrink values disclosed herein are, of course, “total” free shrink values, which represent a sum of (a) the percent free shrink in the longitudinal (i.e., “machine”) direction dimension and (b) the percent free shrink in transverse direction.

[0042] In embodiments, the flexible top web and flexible bottom web exhibit a transparency of at least 15 percent, or at least 20 percent, or at least 25 percent, or at least 30 percent, measured using ASTM D 1746-97. Film transparency (also referred to herein as film clarity) is measured in accordance with ASTM D 1746-97 “Standard Test Method for Transparency of Plastic Sheeting”, published April. 1998. which is hereby incorporated, in its entirety, by reference thereto.

[0043] In embodiments, the flexible top web and flexible bottom web exhibit a haze of less than any of 20%, 18%, 16%, 14%, 12% or less than 10%, measured using ASTM D 1003-00. Film haze values are measured in accordance with ASTM D 1003-00 “Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics”, published July 2000, which is hereby incorporated, in its entirety, by reference thereto.

[0044] In embodiments, the flexible top web and flexible bottom web exhibit a gloss, as measured using ASTM D 2457 - 97, of from 60% to 100%, or from 70% to 90%. Film gloss values are measured in accordance with ASTM D 2457-97 “Standard Test Method for Specular Gloss of Plastic Films and Solid Plastics”, published January 10, 1997, which is hereby incorporated, in its entirety, by reference thereto.

[0045] As used herein, the term “easy open sealant layer” refers to any suitable polymer or polymer blend that forms at least a part of a film layer or is applied to a film layer, wherein the peelable sealant exhibits a seal strength that is less than the seal strength of a lock down sealant as described herein. In some embodiments, the peelable sealant can comprise a food grade material. In embodiments, the easy open sealant layer has a seal strength of between 1-6 Ibf / in measured in accordance with Technique A - Unsupported of ASTM F88 when sealed at a temperature throughout any of the ranges of 135-140°C at a pressure of 63 psi with a seal time of 1.0 seconds tested at a rate of 10 in / min with a 1-inch wide sample sealed to ridged PET substrate. In embodiments, the films provide a sufficient seal when sealed within the range of 110-180°C at a pressure of 63 psi with a seal time of between 0.5 and 3.0 seconds.

[0046] As used herein, the term “lock down sealant layer” and the like refer to any suitable polymer or polymer blend that forms at least a part of a film layer or is applied to a film layer, wherein the permanent layer exhibits a seal strength that is greater than the seal strength of the peelable sealant as described herein. Typical seal strengths for the permanent sealant can range from 6 pounds / inch to 15 pounds / inch in accordance with Technique A -Unsupported of ASTM F88.

[0047] In embodiments the support member 14 includes a cardboard base. Support members are known in the art and may be a paper board or cardboard structure, including but not limited to, single wall, double wall, triple wall construction, compressed fiber, fiber paperboard, corrugated, flute, micro-flute or the like. The support member further contains a grease-resistant barrier, such as a coating or film (laminated or extruded), applied to its upper surface to prevent grease from penetrating the cardboard during cooking. These coatings or films enhance the microwaveability of the package by maintaining structural integrity and minimizing grease leakage. The grease-resistant barrier is typically applied to the top surface of the cardboard support member, ensuring that the food slices remain in direct contact with a non-absorbent surface. This restricts the underlying board material from degrading over time. In a high moisture environment, such as with food packaging, direct contact of board material without a coating would cause the board material to degrade over time. In an alternative embodiment, the support member is a plastic corrugate having a plurality of channels. Since plastic corrugated is grease-resistant, a distinct grease-resisting coating is unnecessary.

[0048] The term flexible is understood to mean a material having a flexural modulus, or the ability of a material to bend, of less than 1.5 GPa measured in accordance with ASTMD790. A semi-rigid material has a flexural modulus of between 1.5 and 4.0 GPa measured in accordance with ASTMD790. A rigid material has a flexural modulus of greater than 4.0 GPa measured in accordance with ASTMD790.

[0049] The coatings can be made from various materials, including polyethylene, polypropylene, or specialized grease-resistant polymers, which provide a durable and effective barrier against grease. Laminated or extrusion coated films include microwavable FDA compliant plastics such as polypropylenes, polyamides or polyethylene terephthalates. In embodiments, mono-layer or multi-layer films are used to enhance grease resistance. This not only helps to keep the microwave clean but also ensures that the food slices are cookedevenly and maintain their intended presentation. Films can have any suitable thickness to form an effective grease-resistant surface. For example, from 0.2 to 2.5 mils. Thicker films can be used as well with the understanding that such thicker films will increase costs and require additional materials. It is understood that multi-layer films can be utilized that have a sealant layer to aid in the bonding to the substrate.

[0050] Suitable grease-resistant coatings include, but are not limited acrylic emulsions such as Rovene® 6114, Tykote® 6160, Tykote® 6161, and Tykote® 6152 available from Mallard Creek Polymers carboxy lated styrene-butadiene emulsion such as Tykote® 1004, Tykote® 1014. Tykote® 1019 and Tykote® 1015 available from Mallard Creek Polymers. Further grease-resistant coatings include Ulterion” 5125 OGB, Ulterion® 5150 OGB, Ultenon® 535 OPV, Ulterion® 537 OPV, Ulterion® 560 FLEX, Ultenon® 560 HV, and Ulterion® 757 OPV all available from Jain Chem, Ltd. Additional grease-resistant coatings include TopScreen oil and grease-resistant barrier coatings available from Solenis and Michem® Coat available from Michelman, Inc. Other food compliant, grease-resistant coatings may be used. Coatings are typically applied at a weight of 2 - 6 grams per square meter.

[0051] The grease-resistant coating or laminated film contains a plurality of channels that extend through the grease-resistant barrier and into the support or through the support member. These channels allow from grease rendered during the cooking process to pass through the grease-resistant coating and into the support member and / or the bottom of the package. In embodiments, the support member absorbs at least some of the grease. The sizing and concentration of channels allows for the food product to have time to cook in the grease before the grease migrates through the channels. In embodiment, the surface area of channels in the support member account for between 0.5 - 5% of the surface area of the support member. In other words, 0.5 - 5% of the surface of the grease-resistant barrier is removed or punctured. In other embodiments, the surface area of channels in the support member account for between 1 -3% of the surface area of the support member. In other embodiments, the surface area of channels in the support member account for between 1 -20% of the surface area of the support member. In other embodiments, the surface area of channels in the support member account for between 5 - 20% of the surface area of the support member. In other embodiments, the surface area of channels in the support member account for between 10 - 20% of the surface area of the support member.

[0052] Forming a package with VSP process typically utilizes a sealing station having an upper sealing dome and a die bottom with a forming plate. A gasket is arranged at the edge of either one or both the upper sealing dome and the die bottom. Both the upper sealing dome and the bottom die can be provided with slits for drawing vacuum and ventilating when the upper dome and the bottom die are closed.

[0053] The operation of the sealing station is as follows. Before closing the upper dome and the bottom die, one or more bottom web having support members with products thereon are introduced. A length of top web, possibly pre-heated by a pre-heating plate, is also drawn by the upper dome. When the upper dome and the bottom die are closed, vacuum forms above draws the web into the dome while vacuum from below draws the tray(s) into a mold. The top web is heated up to a certain temperature (for instance, about 200° C.) in the dome and air in the package is evacuated through slits. When the vacuum from above ends, gentle ventilation from above causes the top web to detach from the dome. Through full ventilation from above, the top web is sealed to the bottom web and support member, including all around the product. A gasket presses the top and bottom webs together with increased pressure forming a perimeter seal in the shape of the gasket. The heat plate is retracted and the package is then cooled. The die bottom is ventilated and the top is ventilated to help the upper film retain its desired shape. The sealing station is opened in order to move the sealed packages to the cross and longitudinal cutting stations, thus leaving the sealing station ready for sealing a new- set of trays.

[0054] Alternatively, a sealing station may operate as follows. A pre-formed bottom web containing the support member with product thereon indexes into the sealing station in parallel with an unattached top web. The die box closes fully containing the top and bottom webs with the product and support member encapsulated. A vacuum is applied to the top web to hold it to the sealing plate. Vacuum is pulled from below the formed bottom web to secure it. Vacuum is then pulled between the top and bottom webs removing oxygen and gases harmful to the shelflife of the product. When the appropriate vacuum level is reached, the seal plate pushes the top w eb down and wields it to the bottom web creating a perimeter seal where the plate presses against the gasket material under the bottom web. While maintaining the vacuum level between the top and bottom webs, the die box is vented back to atmospheric pressure. The sealing station die box opens and the vacuum sealed package is advanced out of the die box as the next package is advanced into the sealing station.

[0055] Referring now to Figs. 2A-2B, a method of preparing a package is described. Food slices 12. arranged on support member 14. The support member 14 is placed on a flexible bottom web 15 which placed on platform 28 which is carried by platform supports 29 in vacuum chamber 30. Vacuum chamber 30 includes upper vacuum chamber section 32 and lower vacuum chamber section 34. Inwardly sloping walls 36 and the horizontal wall portion containing ports 38 define a concave space or cavity 40 within upper section vacuum chamber 32. Above the ports 38 is manifold space 42 having an exterior port 44. Lower vacuum chamber section 34 has a manifold or cavity region 46 which has an exterior port 48. Lower vacuum chamber section 34 further has a passageway to cavity 40 in upper vacuum chamber section 32 as defined by the space 50 between lower vacuum chamber section 34 and platform 28.

[0056] A sheet of flexible top web 16 is stretched across the lower opening to upper vacuum chamber section 32 and a vacuum, as shown by the arrow and the abbreviation “vac.,” is applied to upper vacuum chamber section 32 via exterior port 44. manifold space 42, and ports 38, thereby drawing flexible top web 16 into a concave form against walls 36 and ports 38 as shown in Figs. 2 and 3. Any conventional vacuum pump can be used to apply the vacuum. In embodiments, flexible top web 16 is pre-heated prior to the foregoing operation to render it more pliable and thus better able to assume a concave shape in upper vacuum chamber section 32.

[0057] As shown in Fig. 2A, flexible top 16 shaped into a concave form is positioned over food slices 12 on support member 14 and flexible bottom web 15. At this point, vacuum chamber 30 has not yet been closed. Closing of the chamber is accomplished by moving upper vacuum chamber section 32 down onto lower vacuum chamber section 34 as indicated by the arrow s in Fig. 2. During this whole sequence of operation as illustrated in Figs. 2 and 3, vacuum is constantly applied through exterior port 44, manifold space 42, and ports 38 to retain the concave shape of flexible top web 16.

[0058] In Fig. 2B, w ith the vacuum chamber closed, vacuum is applied through exterior port 48 in lower vacuum chamber section 34, as indicated by the downwardly pointing arrow- and the abbreviation “vac.” Arrows on either side of platform 28 are used to illustrate the evacuation of the gas (air) from the space between flexible bottom web 15 and flexible top w eb 16. The path of the evacuated gas is from the vicinity of food slices 12, around the peripheral space 50 between lower vacuum chamber section 34 and platform 28, into cavity7region 46, and out through exterior port 48. As noted above, during this evacuation of vacuum chamber 30. the concave shape of flexible top 16 is retained by continued application of vacuum through exterior port 44, manifold space 42, and ports 38.

[0059] As flexible top web 16 collapses around and formed on food slices 12 and in contact with support member 14 and flexible bottom web, vacuum is maintained through exterior port 48 and the vacuum through exterior port 44 is released and atmospheric pressure is admitted to the vacuum chamber 30. The atmospheric pressure through port 44 and vacuum through port 48 serves to cooperatively push and pull, respectively, flexible top web 16 into position wherein flexible top web 16 substantially conforms to the shape of food slices 12 on support member 14.

[0060] The end result is the product containing package 10 shown in Fig. 1. The package having a full or at least partial vacuum. Full vacuum improves the optical appearance and tack seal. The gasket 62 is provided in vacuum chamber 30 for heat-sealing flexible top web 16, as indicated at 20 in Fig. 1, to flexible bottom web 15 between the periphery of the support member 18 and the peri phery of the package 22. Such gasket applies pressure and in combination with heating from the heat plate or heated dome forms the perimeter seal 20. The layers of flexible top web 16 and flexible bottom web 15 which are to be in contact with one another are selected to be heat-sealable to one another. In embodiments, a homogeneous ethylene / alpha-olefm copolymer is present in one or both contacting layers of flexible top web 16 and flexible bottom web 15. Such copolymer has been found to provide excellent heat seals.

[0061] If desired, vacuum chamber may be expanded in size to allow multiple packages to be produced simultaneously, including simultaneous evacuation and sealing. In this instance, implementation can be introduced to reduce the incidence of webbing (folds of excess flexible web around the package). Such methods include vertically moveable rib members to take up excess fdm as disclosed in U.S. Pat. No. 4,537,011.

[0062] Fig. 3 depicts another process for forming vacuum skin packages. Sealing a vacuum packaging involves the use of a gasket 72 to create a perimeter seal around the flexible top web 16 and flexible bottom web 15 that encapsulate the food slices 12 on the support member 14. Once the vacuum chamber is closed and the air is evacuated, and a heating plate 33 heats the flexible top web 16. After heating, one side of the vacuumchamber is vented allowing for the heated flexible web to press against the other flexible web forming a tack seal along surfaces of the support member not containing the packaged product. The flexible webs are compressed tightly around the food slices. The gasket applies pressure along a perimeter where the flexible webs overlap, forming a strong, airtight perimeter seal. This ensures that the contents are securely packaged and protected from external elements.

[0063] Turning to Fig. 4 is a top view of a package according to certain embodiments. The package includes a flexible bottom web 15 and a flexible top web 16 sealed to each other via a perimeter seal 20. Between the flexible bottom web 15 and a flexible top web 16 is support member 14 having food slices 12 disposed thereon. The food slices being laid flat onto the support member for consistent cooking. Shingling of the food slices is minimized to avoid uneven cooking and inconsistency. The support member 14 includes a number of channels 58 which help drain the grease that results from cooking through the grease-resistant barrier (shown in Fig. 5). The perimeter seal 20 has a thickness proximate the periphery of the package 22. The perimeter seal 20 being generally rectangular in shape to match that of the periphery of the package. The primary thickness 52 is utilized for the majority of the perimeter seal. A secondary thickness 54, which is less thick than the primary thickness 52 is utilized to create a controlled venting area at indent portion 56. In embodiments the secondary thickness 54 is located within the middle third of the length of package 10. As package 10 is heated and the gases expand, pressure builds within the package 10. One the pressure is sufficient, the seal in the secondary' thickness 54 in the controlled venting area at the indent portion 56 fails. This failure allows the pressure to escape the package in a desired location in a controlled manner. To further aid the success of a controlled vent, the perimeter seal 20 in the area of the secondary thickness 54 comprises an indent portion 56that extends away from the periphery7of the package 22 and towards the support member 14. The indent portion 56 increases the weaker, secondary7thickness 54 area in a more condensed portion of the package. While the indent portion 56 is shown as being V-shaped in Fig. 5, other shapes are contemplated. In embodiments, the indent portion 56 is located within the middle third of the length of package 10. In embodiments, the secondary7thickness is less than any of 25%, 30%, 40%, or 50% the thickness of the primary7thickness. In embodiments, the surface area of the secondary thickness of the perimeter seal is less than 25%, 20%, 15% or 10% of the total surface area of the perimeter seal.

[0064] Turning to Fig. 5 is a top view of a package according to another embodiments. The package includes a flexible bottom web 15 and a flexible top web 16 sealed to each other via a perimeter seal 20. Between the flexible bottom web 15 and a flexible top web 16 is support member 14 having food slices 12 disposed thereon. The food slices being laid flat onto the support member for consistent cooking. Shingling of the food slices is minimized to avoid uneven cooking and inconsistency. The support member 14 includes a number of channels 58 which help dram the grease that results from cooking through the grease-resistant barrier (shown in Fig. 5). The perimeter seal 20 has a thickness proximate the periphery of the package 22. The primary thickness 52 is utilized for the majority of the perimeter seal. A secondary' thickness 54, which is less thick than the primary thickness 52 is utilized to create a controlled venting area at the secondary thickness 54 area. As package 10 is heated and the gases expand, pressure builds within the package 10. One the pressure is sufficient, the seal in the secondary thickness 54 in the controlled venting area at the secondary' thickness 54 fails. This failure allow s the pressure to escape the package in a desired location in a controlled manner. In embodiments, the secondary thickness is less than any of 25%, 30%, 40%, or 50% the thickness of the primary thickness. In embodiments, the surface area of the secondary thickness of the perimeter seal is less than 25%, 20%, 15% or 10% of the total surface area of the perimeter seal.

[0065] The penmeter seal is formed by the use of a gasket. Figs. 6 and 7 depict tooling that is utilized to form the perimeter seal shown in Figs. 5 and 4 respectively. As shown in Fig. 6, the sealing mechanism 60 includes a gasket 62 positioned along the periphery' of the sealing mechanism 60. The gasket 62 contains a thin portion 64 used to create the secondary' thickness. The thin portion 64 being thinner than the remaining portions of the gasket 62. Likewise, in Fig. 7 an alternative sealing mechanism 70 is shown. The sealing mechanism 70 includes a gasket 72 w ith a thin indent portion 74 being positioned near the middle third of each side of the sealing mechanism. This thin indent portion forming the indent portion 56 as shown in Fig. 4. In embodiments the thickness of the secondary thickness is less than any of 25%, 30%, 40%, or 50% the thickness of the primary thickness of the perimeter seal. In embodiments the primary thickness of the perimeter seal is between 4.25 and 8.5 mm and the secondary' thickness of the perimeter seal is betw een 1.5 and 4 mm.

[0066] The seal strength of the perimeter seal remains constant with respect to width since the composition of the seal area is the same. Since the secondary^ thickness is less thanthe primary thickness, the effective seal strength becomes less. As such, as pressure increases within the package during cooking, the perimeter seal fails in the secondary¬ thickness area. Thus, resulting in a predictable and controlled vent location.

[0067] Figs. 8-9 depicts an exemplary- support member 14 having a plurality of channels 58. While anCLX-shape” is depicted, other channel shapes are contemplated, such as 1-shape, o-shape, holes, circles, slits, custom designs, logos and the like. Non-limiting channel shapes are depicted in Figs. 10A - 10H. The channels allow for the grease to pass through the grease-resistant barrier 78 of the support member 14 during the cooking process. In some embodiments, the channels further extend through the support base 76. In other embodiments, the channels extend into the support base 76.

[0068] The channels are designed to allow the grease created during the cooking process to flow through the grease-resistant barrier (coating, film or laminate) and into and / or through the support member. In the instance of a corrugated cardboard support member, the support member can then absorb the grease that has permeated through the grease-resistant barrier. In embodiments, the perforations have a size and density sufficient to absorb sufficient grease from the food product after cooking and a 2-minute cool dow n period. In embodiments, the support member absorbs a total of 10-40% of the initial weight of the food product, the support member be weighed after cooking and a 2-minute cool down period. In embodiments, the support member absorbs a total of 15-30% of the initial weight of the food product, the support member be weighed after cooking and a 2-minute cool down period.

[0069] A process for cooking bacon in an exemplary package is shown in Figs. 11 A-11C. Depicted in Fig. 11 A a package 10 is placed in a microwave (not shown). Food slices 12 (in this case bacon) are disposed on the support member. As the micro wave is operated, the food slices 12 begin to cook and the package 10 expands as shown in Fig. 1 IB. As the package expands, the support member 14 is deformed into a bowl -like shape. The bacon grease from the cooked bacon can gather, allowing the bacon to cook in its grease. Once the pressure inside the package 10 is sufficient, the secondary- thickness 54 of the perimeter seal 20 fails, allowing the package to vent in a controlled location in a controlled manner. By the venting being within the middle third of the length of the package, the flexible bottom web 15 and flexible top web 16 hold the support member 14 in the bow l-like shape while the package 10 is able to vent.

[0070] Once the cooking is complete, the support member 14 remains deformed in a bowl-like shape as depicted in Fig. 11. Excess grease can drain through the channels 58 as the food cools. A user can then open the package 10, remove the food slices 12 and discard the remaining package, making for a quick and efficient clean up. In embodiments, the package further includes opening features such as grip assistors, tear initiations, or tabs which are known to be used for easy open packages. Tabs are especially beneficial as they provide a location away from the package seal for the user to grip and open the package.

[0071] The package is designed to be user-friendly and easy to open after the cooking process is complete. Once the micro wave cooking is finished, the support member 14 remains deformed in a bowl-like shape, and excess grease drains through the channels. The user can then peel back the flexible top web 16. In embodiment, the flexible top web further includes a designated tab or comer, which is typically provided for easy access. This opening process allows the user to remove the cooked bacon slices easily without spilling the accumulated grease. The package's design ensures that the flexible webs peel apart smoothly, maintaining the integrity of the package and its contents. After removing the bacon slices, the user can dispose of the packaging, including the support member 14, which has served to aid in both cooking and cleanup, making the entire process quick and efficient.

[0072] As shown in Fig. 13 the density and size of the channels have an effect on the grease absorption. The type of food slice has different amounts of fat which renders into grease. Typically, bacon contains 10-50% fat by weight. For example, 170 grams of bacon (typically about 3 slices) will typically contain between 17 and 85 grams of fat. While not all fat is rendered during the cooking process, a substantial portion of the fat will render into grease.

[0073] As shown in Fig. 14 an alternative support member is depicted. The support member includes a number of interlocking detents.

[0074] In embodiments, the package may be printed upon. For example, via trap or surface printing.

[0075] Examples

[0076] A number of packages containing bacon were made and cooked for the examples below. Film is loaded into forming station and pockets are formed. Three strips of baconwere placed on the support member and loaded into the formed pocket. The filled formed pockets move into the sealing station. The pockets have a vacuum pulled to the set point and are then sealed. Filled / Sealed packages are moved into the cutting station to have excess film trimmed. Packages are then ready to be microwaved. Each package was microwaved for 2 minutes in a Kenmore 2 cook plus, 1250 Watt at full power. The package was allowed to cool for 2 minutes and measurements were taken as reported in Tables I-V.

[0077] A comparative example was prepared utilizing and absorbent pad instead of a support member. The results are reported in Table I.

[0078] Table IAbsorbentpadWeight of Baconuncooked (g) 55.0% Protein 26%% FAT + Moisture 74%% absorbed grease by pad 28%% of residual grease inpackage 0%% total grease 28%% steam moisture / other 46%

[0079] The absorbent paid was successful in absorbing all of the residual grease. The results were a bacon that was dry in texture and consistency and also lacking in flavor. It is believed that the grease is absorbed quickly by the pad and that by the bacon not being cooked in its own grease, flavor of the bacon is limited. Further, the lack of grease likely contributes adversely to effects regarding texture and consistency of the bacon.

[0080] A series of first examples were made as described above utilizing a 15pt white board coated 1 side with a grease-resistant coating. Perforations size and density were varied, and the results are reported in Table II. For perforation density', medium density' was performed by using 105 x-shaped perforations and for high density 218 x-shaped perforations were used. Perforations were made through the grease-resistant barrier and completely through the support member. The support members having a size of 9.875” x 5.625”. Theperorations were made with a blade having a thickness of 0.4mm and a length in inches as shown in the Table below. The perforation ratio can be calculated by determining the number of perforations multiplied by the area of perforation and divided by the surface area of the support member. To report as a percentage, the perforation ratio is multiplied by 100. For example, if a single perforation has a surface area of 0.005 in2and there are 218 perforations in a support member having a surface area of 55.45 in2, the total surface area of the perforations would be 0.005 in2x 218 = 1.09 in2. The perforation ratio being 1.09” / 55.45” = 0.01966. The perforations being 1.966% of the surface area of the support member.

[0081] Table II15pt white board coated 1 side Perforation size 0.1” 0.1” 0.15” 0.15” 0.2” 0.2” Perforation density med hi med hi med hi Weight of Baconuncooked (g) 29.3 31.1 31.2 33.5 31.3 31.6 % Protein 32% 30% 36% 35% 33% 33% % FAT + Moisture 68% 70% 64% 65% 67% 67% % absorbed grease byBoard 8% 10% 8% 9% 9% 10% % of residual grease inpackage 20% 20% 12% 11% 12% 10% % total grease 28% 30% 20% 19% 21% 21%% steam moisture / other 40% 40% 45% 46% 46% 47%

[0082] A series of second examples were made as described above utilizing a 24pt white board coated 1 side with a grease-resistant coating. Perforations size and density were varied, and the results are reported in Table III. For perforation density, medium density was 105 x-shaped perforations and hi density is x-shaped 218 perforations. Perforations were made through the grease-resistant barrier and completely through the support member. The support members having a size of 25.4 cm by 14 cm (10” x 5.5”). The perorations were made with a blade having a thickness of 0.4mm and a length in inches as shown in the Table below.

[0083] Table III24pt white board coated 1 side Perforation size 0.1” 0.1” 0.15” 0.15” 0.2” 0.2”Perforation density med hi med hi med hiWeight of Baconuncooked (g) 29 29.1 27.6 34.6 33.8 37.2 % Protein 36% 35% 32% 35% 32% 36% % FAT + Moisture 64% 65% 68% 65% 68% 64% % absorbed grease byBoard 7% 10% 13% 9% 12% 13% % of residual grease inpackage 13% 9% 14% 10% 10% 9% % total grease 20% 18% 27% 19% 22% 22%% steam moisture / other 44% 47% 41% 46% 46% 42%

[0084] For the bacon cooked in the packages according to the first and second series of examples, flavor was noticeably improved. The bacon was tender and moist when compared to the bacon cooked in a package using an absorbent pad.

[0085] A series of third examples were made as described above utilizing a 24pt white board coated 1 side with a grease-resistant coating. The board having a length of 9.875” and a width of 7” resulting in a surface area of 69.125 in2. 218 circular cut perforations having a diameter of 0.25 inches were cut into the board. Perforations were made through the greaseresistant barrier and completely through the support member. The perforation ratio can be calculated by determining the number of perforations multiplied by the area of perforation and divided by the surface area of the support member. To report as a percentage, the perforation ratio is multiplied by 100. For example, if a single perforation has a surface area of 0.0491 in2(0.1252in x 3.14 = 0.0491 in2) and there are 218 perforations in a support member having a surface area of 69.125 in2, the total surface area of the perforations would be 0.0491 in2x 218 = 10.704 in2The perforation ratio being 10.704 in2 / 69.125 in2= 0.15485. The perforations being 15.485% of the surface area of the support member. Three samples were prepared and the average results reported in Table IV below.

[0086] Table IV24pt white board coated 1 side Perforation size 0.25” circlePerforation density hiWeight of Baconuncooked (g) 157.1% Protein 43%% FAT + Moisture 57%% absorbed grease byBoard 10%% of residual grease inpackage 6%% total grease 17%% steam moisture / other 40%

[0087] Similar to the first and second series of examples, the third series of examples produced improved bacon taste, texture and appearance with a pleasant packaging experience.

[0088] A series of fourth and fifth examples were made as described above utilizing a 24pt white board coated 1 side with a grease-resistant coating. The fourth examples having a ty pical fat content for bacon while the fifth examples had a high amount of fat content. The board having a length of 9.875" and a width of 7" resulting in a surface area of 69.125 in2.218 circular cut perforations having an area of 0.0225 in2each were cut into the board. Perforations were made through the grease-resistant barrier and completely through the support member. Five samples for each data set were prepared and the average results reported in Table V below.

[0089] Table VRegular fat High fat Perforation area 0.0225 in2circle 0.0225 in2circle Perforation density7hi hi Weight of Baconuncooked (g) 115.6 173.2% Protein 38% 28%% FAT + Moisture 62% 72%% absorbed grease byBoard 14% 16%% of residual grease inpackage 15% 12%% total grease 39% 28%% steam moisture / other 23% 44%

[0090] Similar to the first through third series of examples, the fourth and fifth series of examples produced improved bacon taste, texture and appearance with a pleasant packagingexperience. The product varied in fat content between the two sample sets and performed well even with the variable fat content.

[0091] All references to (and incorporations by reference of) ASTM protocols are to the most-recently published ASTM procedure as of the priority (i.e., original) filing date of this patent application in the United States Patent Office unless stated otherwise.

[0092] Embodiments:

[0093] Embodiment A. A microwavable package comprising:a. a flexible bottom web;b. a flexible top web;c. a rigid or semi-rigid support member having an upper surface, a lower surface, and a perimeter, the support member being disposed between the flexible bottom web and the flexible top web;the upper surface of the support member having a grease-resistant barrier; the support member having a plurality of channels extending through the grease-resistant barrier;the top web and bottom web extending beyond the perimeter of the support member, the top web and bottom web being sealed to each other along a perimeter which is outside of the perimeter of the support member creating a perimeter seal;the perimeter seal having a primary thickness and a secondary thickness proximate to a vent area; andthe secondary thickness being less than the primary thickness forming a controlled venting area.

[0094] Embodiment B. The microwavable package according to embodiment A, wherein the grease-resistant barrier of the support member is a film adhered to the upper surface.

[0095] Embodiment C. The microwavable package according to any of the previous embodiments, wherein the grease-resistant barrier of the support member is a coating applied to the upper surface of the support member.

[0096] Embodiment D. The microwavable package according to any of the previous embodiments, wherein at least some of the plurality of channels extend through the lower surface of the support member.

[0097] Embodiment E. The microwavable package according to any of the previous embodiments, wherein the secondary thickness is less than any of 25%, 30%, 40%, or 50% of the primary thickness.

[0098] Embodiment F. The microwavable package according to any of the previous embodiments, wherein the primary thickness is between 4.25 and 8.5 mm and the secondary thickness is between 1.5 and 4 mm.

[0099] Embodiment G. The microwavable package according to any of the previous embodiments, wherein the perimeter seal further comprises an indent portion, at least a portion of the secondary thickness being within the indent portion.

[0100] Embodiment FI. The microwavable package according to any of the previous embodiments, further comprising a plurality of food slice products disposed on the support member.

[0101] Embodiment I. The microwavable package according to embodiment H, wherein the plurality of food slices are disposed on the support member in a single layer.

[0102] Embodiment J. The microwavable package according to any of the previous embodiments, wherein the support member is primarily cardboard.

[0103] Embodiment K. The micro wav able package according to any of the previous embodiments, wherein the support member has a thickness of between 0.4 and 1.5 mm.

[0104] Embodiment L. The microwavable package according to any of the previous embodiments, wherein the grease-resistant barrier is a coating having a weight of 2-6 grams per square meter.

[0105] Embodiment M. The microwavable package according to any of the previous embodiments, wherein the grease-resistant barrier is a film laminated to the upper surface of the support member.

[0106] Embodiment N. The microwavable package according to any of the previous embodiments, wherein the flexible bottom web and the flexible top web each comprise at least one barrier polymer.

[0107] Embodiment O. The microwavable package according to any of the previous embodiments, wherein the flexible bottom web and the flexible top web are each multilayer films comprising a barrier layer comprising a major proportion of at least one barrier polymer.

[0108] Embodiment P. The microwavable package according to any of the previous embodiments, wherein the flexible bottom web and the flexible top web have an oxygen transmission rate of less than any of 25, 20, 15, 10, or 5 cubic centimeters (at standard temperature and pressure) per square meter per day per 1 atmosphere of oxygen pressure differential measured at 0% relative humidity and 23°C, and according to ASTM D-3985.

[0109] Embodiment Q. The microwavable package according to any of the previous embodiments, wherein the surface area of the secondary thickness of the perimeter seal is less than 25% of the total surface area of the perimeter seal.

[0110] Embodiment R. The microwavable package according to any of the previous embodiments, wherein the perimeter seal in the area of the secondary thickness comprises an indent portion that extends away from the periphery of the package and towards the support member.[OHl] Embodiment S. The microwavable package according to any of the previous embodiments, wherein the package is a vacuum skin package.

[0112] Embodiment T. A microwavable packaged food product comprising:a. a flexible bottom web;b. a flexible top web;c. a rigid or semi-rigid support member having an upper surface, a lower surface, and a perimeter, the support member being disposed between the flexible bottom web and the flexible top web; the upper surface of the support member having a grease-resistant barrier;d. at least one food product situated on the support member;the support member having a plurality of channels extending through the grease-resistant barrier;the top web and bottom web extending beyond the perimeter of the support member, the top web and bottom web being sealed to each other along a perimeter which is outside of the perimeter of the support member creating a perimeter seal;the perimeter seal having a primary thickness and a secondary thickness proximate to a vent area; andthe secondary thickness being less than the primary thickness forming a controlled venting area.

[0113] Embodiment U. The microwavable packaged food product according to embodiment T, wherein the food product is a plurality of strips of bacon.

[0114] Embodiment V. The microwavable packaged food product according to embodiment U, wherein the plurality of strips of bacon are 3-5 strips of bacon.

[0115] Embodiment W. A method for packaging food slices, comprising forming a package by:a. providing a flexible bottom web;b. situating a rigid or semi-rigid support member on the flexible bottom web;the support member having an upper surface, a lower surface, and a perimeter; the upper surface of the support member having a greaseresistant barrier; the support member having a plurality of channels extending through the grease-resistant barrier;c. situating at least one food product on the support member; d. providing a flexible top web over the flexible bottom web. support member and food product;e. the top web and bottom web extending beyond the perimeter of the support member,f. heat sealing the top web and bottom web being to each other in a vacuum chamber along a perimeter which is outside of the perimeter of the support member creating a perimeter seal; the perimeter seal having a primary thickness and a secondary' thickness proximate to a vent area; and thesecondary thickness being less than the primary thickness forming a controlled venting area.

[0116] Embodiment X. The method according to embodiment W, wherein the package is a vacuum skin package.

[0117] Embodiment Y. The method according to embodiments W or X, further comprising microwaving the package, the microwaving causing the support member to deform into a bowl-like shape.

[0118] This written description uses examples to disclose the invention and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.PARTS LIST:• 10 - Package• 12 - Food slices• 14 - Support member• 15 - Flexible bottom web• 16 - Flexible top web• 18 - Periphery of the support member • 20 - Perimeter Seal• 22 - Periphery of the package• 24 - Upper outer surface• 26 - Lower outer surface• 28 - Platform• 29 - Platform supports• 30 - Vacuum chamber• 32 - Upper vacuum chamber section • 33 - Heating plate• 34 - Lower vacuum chamber section • 36 - Inwardly sloping walls• 38 - Ports• 40 - Cavity• 42 - Manifold space• 44 - Exterior port• 46 - Cavity region• 48- Exterior port• 50 - Space• 52 - Primary thickness• 54 - Secondary thickness• 56 - Indent portion• 58 - Channels• 60 - Sealing mechanism• 62 - Gasket• 64 - Thin portion• 70 - Sealing mechanism• 72 - Gasket• 74 - Thin indent portion• 76 - Support base• 78 - Grease-resistant barrier

Claims

What is claimed is:

1. A microwavable package comprising:a. a flexible bottom web;b. a flexible top web;c. a rigid or semi-rigid support member having an upper surface, a lower surface, and a perimeter, the support member being disposed between the flexible bottom web and the flexible top web;the upper surface of the support member having a grease-resistant barrier; the support member having a plurality of channels extending through the grease-resistant barrier;the top web and bottom web extending beyond the perimeter of the support member, the top web and bottom web being sealed to each other along a perimeter which is outside of the perimeter of the support member creating a perimeter seal;the perimeter seal having a primary thickness and a secondary thickness proximate to a vent area; andthe secondary thickness being less than the primary thickness forming a controlled venting area.

2. The microwavable package of claim 1 wherein the grease-resistant barrier of the support member being a film adhered to the upper surface.

3. The micro wav able package of claim 1 wherein the grease-resistant barrier of the support member being a coating applied to the upper surface or the support member.

4. The microwavable package of claim 1 wherein at least some of the plurality of channels extend through the lower surface of the support member.

5. The microwavable package of claim 1 wherein the secondary thickness is less than any of 25%, 30%, 40%, or 50% the thickness of the primary thickness.

6. The microwavable package of claim 1 wherein the primary' thickness is between 4.25 and 8.5 mm and the secondary thickness is between 1.5 and 4 mm.

7. The microwavable package of claim 1 wherein the perimeter seal further comprises an indent portion with at least a portion of the secondary thickness being within the indent portion.

8. The microwavable package of claim 1 further comprising a plurality of food slices products disposed on the support member.

9. The microwavable package of claim 8 wherein the plurality of food slices are disposed on the support member in a single layer.

10. The microwavable package of claim 1 wherein the support member is primarily cardboard.

11. The microwavable package of claim 1 wherein the support member has a thickness of between and 0.4 and 1.5 mm.

12. The microwavable package of claim 1 wherein the grease-resistant barrier is a coating having a weight of 2 - 6 grams per square meter.

13. The microwavable package of claim 1 wherein the grease-resistant barrier is a film laminated to the upper surface of the support member.

14. The microwavable package of claim 1 wherein the flexible bottom web and the flexible bottom web each comprise at least one barrier polymer.

15. The microwavable package of claim 1 wherein the flexible bottom web and the flexible bottom web are each multilayer films comprising a barrier layer comprising a major proportion of at least one barrier polymer.

16. The microwavable package of claim 1 wherein the flexible bottom web and the flexible bottom web have an oxygen transmission rate of less than any of 25, 20, 15, 10, or 5 cubic centimeters (at standard temperature and pressure) per square meter per day per 1 atmosphere of oxygen pressure differentialmeasured at 0% relative humidity and 23°C measured at these conditions and according to ASTM D-3985.

17. The microwavable package of claim 1 wherein the surface area of the secondary thickness of the perimeter seal is less than 25% of the total surface area of the perimeter seal.

18. The microwavable package of claim 1 wherein the perimeter seal in the area of the secondary' thickness comprises an indent portion that extends away from the periphery of the package and towards the support member.

19. The microwavable package of claim 1 wherein the package is a vacuum skin package.

20. A microwavable packaged food product comprising:a. a flexible bottom web;b. a flexible top web;c. a rigid or semi-rigid support member having an upper surface, a lower surface, and a perimeter, the support member being disposed between the flexible bottom web and the flexible top web; the upper surface of the support member having a grease-resistant barrier;d. at least one food product situated on the support member;the support member having a plurality of channels extending through the grease-resistant barrier;the top web and bottom web extending beyond the perimeter of the support member, the top web and bottom web being sealed to each other along a perimeter which is outside of the perimeter of the support member creating a perimeter seal;the perimeter seal having a primary thickness and a secondary thickness proximate to a vent area; andthe secondary thickness being less than the primary thickness forming a controlled venting area.

21. The microwavable packaged food product of claim 20 wherein the food product is a plurality of strips of bacon.

22. The microwavable packaged food product of claim 21 wherein the plurality of strips of bacon are 3 - 5 strips of bacon.

23. A method for packaging food slices comprising the steps of forming a package by:a. providing a flexible bottom web;b. situating a rigid or semi-rigid support member on the flexible bottom web;the support member having an upper surface, a lower surface, and a perimeter; the upper surface of the support member having a greaseresistant barrier; the support member having a plurality of channels extending through the grease-resistant barrier;c. situating at least one food product on the support member;d. providing a flexible top web over the flexible bottom web, support member and food product;e. the top web and bottom web extending beyond the perimeter of the support member,f. heat sealing the top web and bottom web being to each other in a vacuum chamber along a perimeter which is outside of the perimeter of the support member creating a perimeter seal; the perimeter seal having a primary' thickness and a secondary thickness proximate to a vent area; and the secondary- thickness being less than the primary thickness forming a controlled venting area.

24. The method of claim 23 yvherein the package is a vacuum skin package.

25. The method of claim 23 further comprising the step of micro vaving the package, the microwaving step causing the support member to deform into a bowl-like shape.

Images