Embossed Flexible Package Liquid Containment Cells
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flexible packaging for microwave cooking of food products, especially high-fat items like bacon, struggles with excessive liquid exudate pooling, which impedes browning and crisping, and requires separate absorbent pads that are inconvenient and messy.
Innovation Solution
A flexible packaging system comprising a top sheet sealed to an embossed bottom sheet with reduced food-contact surface area and a high density of polygon-shaped liquid containment cells, enhancing liquid retention capacity without the need for absorbent pads, and being heat-resistant for microwave use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate absorbent pad is used to collect liquid exudate, then liquid pooling is reduced, but the package complexity and ease of operation deteriorate due to additional components and messy handling
Solution Approach 1:
The patent combines the liquid collection function directly into the bottom sheet by embossing liquid containment cells, merging the previously separate absorbent pad function into the package structure itself. This eliminates the need for additional components while maintaining liquid management capabilities.
Solution Approach 2:
The patent uses embossed patterns in the flexible bottom sheet to create three-dimensional liquid containment cells. The embossed structure forms peaks and valleys that define cell boundaries, utilizing the flexibility of the sheet material to create effective liquid retention without rigid components.
2Ease of operation
If the bottom sheet has a large food-contact surface area, then cooking comfort is improved, but liquid retention capacity deteriorates due to excessive liquid pooling
Solution Approach 1:
The patent applies local quality by creating embossed liquid containment cells at specific locations on the bottom sheet where liquid pooling occurs. The embossed pattern is concentrated in areas prone to liquid accumulation while leaving other areas smooth for food contact, providing localized liquid management without compromising overall cooking comfort.
Solution Approach 2:
The patent segments the bottom sheet surface into multiple liquid containment cells with defined boundaries. Each cell is formed by embossed peaks and valleys that create individual compartments, dividing the liquid collection function into discrete units that prevent excessive pooling while maintaining adequate food-contact surface area.
3Ease of manufacture
If conventional packaging materials are used, then manufacturing cost is reduced, but heat resistance and microwave compatibility deteriorate at high cooking temperatures
Solution Approach 1:
The patent employs composite material structures for the flexible sheets that combine heat-resistant properties with flexibility. The materials are selected to withstand microwave cooking temperatures while maintaining the embossed structure integrity and food-contact safety, balancing manufacturing feasibility with thermal performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively captures and retains water and grease during cooking, enhancing browning and crisping of food products while maintaining package integrity at high temperatures, making it suitable for microwavable and heat-and-serve applications.
Implementation Method 1
The flexible bottom sheet comprises a plurality of embossed peaks and valleys wherein each valley has a defined perimeter with a valley base integrally connected to a valley wall which thereby defines an individual liquid containment cell
Implementation Method 2
The flexible top sheet may be sealed to the flexible embossed bottom sheet by forming a permanent or peelable heat seal between the peripheral edges of each sheet
Data Source
AI summary
The present invention is directed to packages having a flexible top sheet sealed to a flexible embossed bottom sheet The flexible bottom sheet comprises a plurality of embossed peaks and valleys wherein each valley has a defined perimeter with a valley base integrally connected to a valley wall which thereby defines an individual liquid containment cell. The packages according to the present invention are heat resistant to allow food packaged therein to be cooked in a microwave oven such that a substantial amount of water and/or grease released by the food during the cooking process is captured beneath a food contact surface in a plurality of embossed individual liquid containment cells, in preferred embodiments, the package of the present invention is a microwavable form-fill-seal package or microwavable vacuum package for storing and cooking a precooked or cured food product with substantial water and/or fat content.