U.S. patent application number 11/334808 was filed with the patent office on 2006-08-31 for microwavable container with sleeve.
Invention is credited to Richard L. Mace, George A. Tuszkiewicz.
Application Number | 20060191935 11/334808 |
Document ID | / |
Family ID | 36931126 |
Filed Date | 2006-08-31 |
United States Patent
Application |
20060191935 |
Kind Code |
A1 |
Tuszkiewicz; George A. ; et
al. |
August 31, 2006 |
Microwavable container with sleeve
Abstract
A container for use in microwave heating. The container includes
a bottom, a sidewall extending upwardly from the bottom and
terminating at a top end, and a flange extending from the sidewall
opposite the bottom. The flange includes a rim section configured
to receive a sealing film and a recessed section including a
plurality of handles. A pair of catch members are located between
the plurality of handles. The catch members extend radially
outwardly on opposed sides of the container.
Inventors: |
Tuszkiewicz; George A.;
(Plymouth, MN) ; Mace; Richard L.; (Seneca,
IL) |
Correspondence
Address: |
PATTERSON, THUENTE, SKAAR & CHRISTENSEN, P.A.
4800 IDS CENTER
80 SOUTH 8TH STREET
MINNEAPOLIS
MN
55402-2100
US
|
Family ID: |
36931126 |
Appl. No.: |
11/334808 |
Filed: |
January 18, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60646093 |
Jan 21, 2005 |
|
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Current U.S.
Class: |
220/258.5 |
Current CPC
Class: |
B65D 1/34 20130101; B65D
71/20 20130101; B65D 25/2888 20130101; B65D 81/3453 20130101 |
Class at
Publication: |
220/258.5 |
International
Class: |
B65D 51/20 20060101
B65D051/20 |
Claims
1. A container for use in microwave heating, the container
comprising: a bottom; a sidewall extending upwardly from the bottom
and terminating at a top end; a flange extending from the sidewall
opposite the bottom, the flange including: a rim section configured
to receive a sealing film; a recessed section including: a
plurality of handles, and pair of catch members located between the
plurality of handles, the catch members extending radially
outwardly on opposed sides of the container.
2. The container of claim 1, wherein the sidewall includes a base
section, an intermediate section, and an upper section, the upper
section including a collar and a stacking wall.
3. The container of claim 2, wherein the base section defines a
transverse, cross-sectional radius of from about 0.25 to about 1.0
inches.
4. The container of claim 3, wherein the intermediate section is
linear in transverse cross-section.
5. The container of claim 4, wherein the intermediate section
defines an angle relative to the horizontal plane of from about 70
to about 89 degrees.
6. The container of claim 1, wherein the recessed section includes
two opposed linear edges.
7. The container of claim 1, wherein each of the handles includes a
grip that defines a plane that is lower than the plane defined by
the surface of the rim section.
8. The container of claim 1, wherein the recessed section includes
a pair of opposed lateral sides and a pair of opposed longitudinal
sides, the union of a lateral side and a longitudinal side defining
a corner wherein each of the plurality of catch members radially
extend from the lateral sides.
9. The container of claim 8, wherein a handle is located at each of
the corners.
10. A food package kit comprising: a first tray including; a
bottom; a sidewall extending upwardly from the bottom and
terminating at a top end; a flange extending from the sidewall
opposite the bottom, the flange including: a rim section configured
to receive a sealing film; a recessed section extending from the
rim section, the recessed section terminating in a pair of opposed
lateral edges and a pair of opposed longitudinal edges, wherein
each of the opposed longitudinal edges intersect with a lateral
edge at a corner, wherein each corner contains a handle; an
outwardly extending catch member disposed between the handles on
each of the lateral edges; a sealing film adapted to be attached to
the rim section; a sleeve adapted to hold the tray therein, the
sleeve including a sleeve top and a sleeve base, wherein the sleeve
base contains an aperture having a port, the catch member disposed
through the port.
11. The kit of claim 10, wherein the sleeve includes a first side
disposed between the sleeve top and the sleeve base, wherein the
port is defined by the portion of the aperture on the first
side.
12. The kit of claim 11, wherein the sleeve includes a flap for
securing the sleeve base to the sleeve top.
13. The kit of claim 12, wherein the sleeve includes a second side
disposed between the sleeve base and the flap, wherein a second
port is defined by the portion of the aperture on the second
side.
14. The kit of claim 13, wherein the sleeve includes a second
aperture having a plurality of ports, wherein a perforation line is
located on the sleeve between the first aperture and the second
aperture.
15. The kit of claim 14, further comprising a second tray
including; a bottom; a sidewall extending upwardly from the bottom
and terminating at a top end; a flange extending from the sidewall
opposite the bottom, the flange including: a rim section configured
to receive a sealing film; a recessed section extending from the
rim section, the recessed section terminating in a pair of opposed
lateral edges and a pair of opposed longitudinal edges, wherein
each of the opposed longitudinal edges intersect with a lateral
edge at a corner, wherein each corner contains a handle; a catch
member disposed on each of the lateral edges, between the handles;
and a sealing film adapted to be attached to the rim section;
wherein the catch member of the second tray is at least partially
disposed through a port of the second aperture.
16. The kit of claim 10, wherein the sleeve top comprises an easy
open and re-close partition.
17. A method of preparing food for subsequent sale, the method
comprising the steps of: providing a container including; a bottom;
a sidewall extending upwardly from the bottom and terminating at a
top end, the sidewall defining an interior; a flange extending from
the sidewall opposite the bottom, the flange including: a rim
section configured to receive a sealing film; a recessed section
extending from the rim section, the recessed section terminating in
a pair of opposed lateral edges and a pair of opposed longitudinal
edges, wherein each of the opposed longitudinal edges intersect
with a lateral edge at a corner, wherein each corner contains a
handle; a catch member disposed on each of the lateral edges,
between the handles; dispensing food in the interior of the
container; attaching a sealing film to the rim section; providing a
sleeve including a sleeve top and a sleeve base, wherein the sleeve
base contains an aperture having a port; and placing the tray in
the sleeve so that the catch member is at least partially disposed
through the port.
18. The method of claim 17, further comprising the step of
fastening the sleeve top to the sleeve base.
19. The method of claim 17, further comprising the step of placing
a second tray in the sleeve, the second tray including: a rim
section configured to receive a sealing film; a recessed section
extending from the rim section, the recessed section terminating in
a pair of opposed lateral edges and a pair of opposed longitudinal
edges, wherein each of the opposed longitudinal edges intersect
with a lateral edge at a corner, wherein each corner contains a
handle; a catch member disposed on each of the lateral edges,
between the handles, such that the catch member of the second tray
is at least partially disposed in the port.
20. The method of claim 19, wherein the step of placing a second
tray in the sleeve further comprises orienting the second tray such
that the rim section of the second tray is in contact with the rim
section of the first tray.
21. A food package kit comprising: a first tray and a second tray,
the first tray and second tray each including; a bottom; a sidewall
extending upwardly from the bottom and terminating at a top end; a
flange extending from the sidewall opposite the bottom, the flange
including: a rim section configured to receive a sealing film; a
recessed section extending from the rim section, the recessed
section terminating in a pair of opposed lateral edges and a pair
of opposed longitudinal edges, wherein each of the opposed
longitudinal edges intersect with a lateral edge at a corner,
wherein each corner contains a handle; an outwardly extending catch
member disposed between the handles on each of the lateral edges; a
sleeve adapted to hold the first tray and the second tray therein
such that the rim section of the first tray and the rim section of
the second tray are each between the bottom of the first tray and
the bottom of the second tray, the sleeve including a sleeve top, a
sleeve base, a first sleeve side and a second sleeve side, wherein
the first sleeve side contains an aperture having a generally
hourglass shape having a narrow portion between two wide portions
and the second sleeve side contains an aperture having a generally
hourglass shape having a narrow portion between two wide portions.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 60/646,093, filed Jan. 21, 2005, entitled
"MICROWAVABLE CONTAINER WITH SLEEVE", which is incorporated herein
by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to the packaging of edible
products. More particularly, the invention relates to a packaging
assembly adapted for microwave oven cooking that reduces material
requirements, optimizes space, and facilitates handling of the
microwavable container by the consumer when the contents of the
container are hot.
BACKGROUND OF THE INVENTION
[0003] Consumers often prefer to cook food in a microwave oven
rather than conventional ovens because of the reduced cooking time
required to heat foods in a microwave oven. As a result, a wide
variety of food items have been designed for heating in a microwave
oven. Popular examples of these items include lasagna, cheese
macaroni dishes and vegetable casseroles.
[0004] Microwave ovens do not transfer heat to a material in the
same manner as conventional ovens. Rather, the material is induced
to heat itself as the microwave oven generates a continually
changing electrical field. Accordingly, microwave cooking requires
containers that are transparent to microwave energy.
[0005] A variety of trays and containers have been developed
specifically for microwave heating. For example, Matsui U.S. Pat.
No. 4,704,510 discloses a container for food service which is
adapted to withstand heating in a microwave oven. The container is
formed from a laminate sheet material consisting of a non-stretched
polyethylene terephthalate film laminated to the interior of a
foamed plastic sheet. The bottom of the container is raised to
curve concavely towards the center thereof to distribute the
container contents and improve upon the heat distribution within
the container during the heating or cooking of the contents with
microwave radiation. However, the laminated container material
utilized is relatively expensive to construct.
[0006] Bowen, et al. U.S. Pat. No. 4,486,640 relates to a utensil
for cooking and/or baking foods in a microwave oven in which a
generally flat-bottomed container base incorporates a removable
tray and a closure lid possessing apertures to enable the escape of
steam which is generated during cooking. This microwaveable
container structure is relatively complex and expensive, while not
facilitating the optimum distribution of foods or comestibles
within the container to allow for a more uniform temperature
distribution therethrough during cooking with microwave energy.
[0007] Watkins U.S. Pat. No. 4,416,906 discloses a microwave food
heating container having a central raised core in the container
bottom to essentially distribute the food contained therein about
an annulus to improve upon the uniform heating thereof. As in the
other above-mentioned patents, there is no optimum distribution of
the food within the container so as to allow for a greater
efficiency during cooking and a degree in the uniformity of the
temperature which will meet the demands of the technology for
cooking with microwave energy.
[0008] Isakson, et al. U.S. Pat. No. 4,640,838 describes a
vapor-tight microwave oven package incorporating a vent enabling
the escape of steam or vapor which is generated during cooking, and
does not provide for an optimum distribution of foods within a
generally rigid microwaveable container to attain uniform
temperatures during microwave cooking or heating of the food
contents of a container.
[0009] Levendusky, et al. U.S. Pat. No. 4,560,850 discloses a
microwave container with a cover incorporating a port for the
release of steam, and with a raised container bottom to distribute
the foods therein for more even cooking or heating. This structure
also fails to provide for the optimum dispersion of a food within a
specially configured container and does not allow for an adequately
uniform temperature distribution through the food as it is cooked
by microwave energy with a resultant higher degree of
efficiency.
[0010] Although various measures have been undertaken to improve
upon efficiency and temperature uniformity of microwave cooking,
they have not proven to be entirely adequate, especially when used
for prepackaged, single-serve applications. Many single-serve
microwavable trays are relatively flimsy, making it difficult for a
consumer to remove a tray containing hot items from the microwave
without experiencing some discomfort. Moreover, many prior art
trays require expensive container constructions.
[0011] Single-serve containers often require specially designed
wrappers or packaging cartons to display nutritional information,
ingredients, and heating instructions. These wrappers and packaging
cartons can become destroyed or separated from the carton upon use,
requiring separate packaging materials and instructions for each
microwave serving. This extraneous packaging material increases the
cost to the consumer. Prior art trays also incorporate inefficient
designs which do not adequately utilize the retail shelf space or
the volume of the shipping cube.
SUMMARY OF THE INVENTION
[0012] In view of the shortcomings set forth above, it is an object
of the invention to provide an improved microwave food package,
which minimizes material requirements, locks multiple containers in
a paperboard sleeve, and optimizes the shipping cube and retail
shelf space. It is also an object of the invention to facilitate
removal of the tray from the microwave when the tray contains hot
materials.
[0013] The invention includes a container for use in microwave
heating. The container includes a bottom, a sidewall extending
upwardly from the bottom and terminating at a top end, and a flange
extending from the sidewall opposite the bottom. The flange
includes a rim section configured to receive a sealing film and a
recessed section including a plurality of handles. A pair of catch
members are located between the plurality of handles. The catch
members extend radially outwardly on opposed sides of the
container.
[0014] In another embodiment, the invention includes a food package
assembly comprising a first tray including a bottom, a sidewall
extending upwardly from the bottom and terminating at a top end and
a flange extending from the sidewall opposite the bottom. The
flange includes a rim section configured to receive a sealing film
and a recessed section extending from the rim section. The recessed
section terminates in a pair of opposed lateral edges and a pair of
opposed longitudinal edges, wherein each of the opposed
longitudinal edges intersect with a lateral edge at a corner,
wherein each corner contains a handle. An outwardly extending catch
member is disposed between the handles on each of the lateral
edges. A sealing film is attached to the rim section. A sleeve for
holding the tray including a sleeve top and a sleeve base. The
sleeve base contains an aperture having a port, wherein the catch
member is disposed through the port.
[0015] Yet another aspect of the invention includes a method of
preparing food for subsequent sale. The method includes the steps
of providing a container including a bottom, a sidewall extending
upwardly from the bottom and terminating at a top end, the sidewall
defining an interior, and a flange extending from the sidewall
opposite the bottom. The flange includes a rim section configured
to receive a sealing film, and a recessed section extending from
the rim section. The recessed section terminates in a pair of
opposed lateral edges and a pair of opposed longitudinal edges,
wherein each of the opposed longitudinal edges intersect with a
lateral edge at a corner, wherein each corner contains a handle. A
catch member is disposed on each of the lateral edges, between the
handles. The method also includes the steps of positioning food in
the interior of the container, attaching a sealing film to the rim
section, providing the sleeve including a sleeve top and a sleeve
base, wherein the sleeve base contains an aperture having a port
and placing the tray in the sleeve so that the catch member is at
least partially disposed through the port.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in connection with the accompanying
drawings, in which:
[0017] FIG. 1 shows an isometric view of a microwaveable container
pursuant to the invention.
[0018] FIG. 2 shows a top plan view of a microwaveable container
pursuant to the invention.
[0019] FIG. 3 shows a side elevational view of the microwaveable
container pursuant to the invention.
[0020] FIG. 4 shows a cross sectional front elevational view of the
microwaveable container pursuant to the invention.
[0021] FIG. 5 shows a top plan view of a packaging sleeve pursuant
to the invention.
[0022] FIG. 6 shows an isometric view of the packaging assembly
pursuant to the invention.
[0023] FIG. 7 shows an isometric view of a single tray packaging
assembly pursuant to the invention.
[0024] FIG. 8 shows an isometric view of the packaging assembly
pursuant to the invention incorporating a full overwrap sleeve.
[0025] FIG. 9 shows a top plan view of a full overwrap sleeve
pursuant to the invention.
[0026] FIG. 10 shows an isometric view of an alternative embodiment
of the packaging assembly pursuant to the invention.
[0027] FIG. 11 shows a top plan view of an alternative embodiment
of the packaging sleeve pursuant to the invention.
[0028] FIG. 12 shows a top plan view of an alternative embodiment
of the full overwrap sleeve pursuant to the invention.
[0029] FIG. 13 shows an isometric view of another alternative
embodiment of the packaging assembly pursuant to the invention
incorporating an alternative embodiment of the full overwrap
sleeve.
[0030] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the invention
as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] A microwavable food container 10 in accordance with the
invention is shown in FIG. 1. Container 10 is generally defined by
a bottom 12, a sidewall 14, a flange 16 and handles 18. Container
10 is an integrally thermoformed plastic material, such as
polyolefins (e.g., polypropylene, polyethylene), blends of
polyolefins, polystyrene--HIPS, or polyester resin-based
materials--CPET, foamed polypropylene, polyethylene), blends of
polyolefin's polystyrene--HIPS, or polyester resin-based
materials--CPET, paper and paper laminations with polypropylene,
polyester, etc. In an alternative embodiment, container 10 may be
fabricated using known injection molding or compression molding
techniques. Sidewall 14 extends upwardly from bottom 12, defining
an interior 20 for containing a food item (not shown). Flange 16
extends radially outwardly and downwardly relative to a top of
sidewall 14.
[0032] Handles 18 extend from the corners of flange 16. Sidewall 14
and flange 16 are uniquely configured to provide torsional support
when container 10 is lifted. Container 10 can incorporate different
wall thicknesses. In one embodiment, container 10 has a wall
thickness from about 0.02 to about 0.05 inches.
[0033] Throughout this specification, directional terminology, such
as "top," "bottom," "upwardly," "downwardly," "above," "below,"
etc. is used with reference to the preferred upright orientation of
container 10 in FIG. 1. However, container 10 can be positioned in
a wide variety of different orientations, such that the directional
terminology does not limit the invention.
[0034] With reference to FIG. 2, bottom 12 in this embodiment is
generally rectangular in shape, defining four rounded corners 22.
Alternatively, a variety of other shapes are acceptable, including
circular, oval, square, etc. In one embodiment, bottom 12 is
rectangular. In alternative embodiments, bottom 12 can be oval or
circular. A rectangular flange 16 configuration is useful for
maximizing the cubic capacity of the container, shipping crate,
warehouse space and retail space.
[0035] Bottom 12 defines opposing longitudinal sides 24 and
opposing lateral sides 26, as best shown in the top plan view of
FIG. 2. The longitudinal sides 24 and lateral sides 26 may be flat
or curved relative to a central axis of container 10.
[0036] As shown in FIGS. 3 and 4, bottom 12 is generally flat. A
flat bottom 12 promotes stable placement of the container 10 on a
table top, in a microwave oven or on another flat surface.
[0037] In an alternative embodiment, bottom 12 may be concaved
upwardly or inwardly relative to interior 20 to enhance microwave
interaction with food items contained within container 10. In yet
another embodiment, bottom 12 may include a load bearing surface
around the perimeter of bottom 12. This configuration promotes the
overall stability of the container.
[0038] Sidewall 14 is continuous, extending from bottom 12. In this
regard, sidewall 14 is defined by a base section 40, an
intermediate section 42 and an upper section 44. Base section 40
extends from bottom 12. Intermediate section 42 extends between
base section 40 and upper section 44. Finally, upper section 44
terminates in flange 16.
[0039] Base section 40 extends radially outwardly and upwardly from
bottom 12. In particular, base section 40 is curved in transverse
cross-section (or "transversely curved"). With respect to the
central axis of container 10, base section 40 forms a convex curve.
Moreover, base section 40 defines a transverse, cross-sectional
radius in the range of from about 0.25 to about 1.0 inch. However,
a radius in the range of from about 0.4 to about 0.6 inch promotes
the overall stability and torsional resistance of container 10.
[0040] Intermediate section 42 extends generally upwardly from base
section 40, and is linear in transverse cross-section. As shown in
FIGS. 3 and 4, however, intermediate section 42 forms a slight
radial projection outward from bottom to top. Accordingly,
intermediate section 42 tapers inwardly relative to the central
axis in transverse cross-section. Thus, a transverse
cross-sectional length and width of container 10 along intermediate
section 42 is greater at a top portion thereof as compared to
adjacent base section 40. The radial projection of intermediate
section 42 defines an angle relative to a horizontal plane in the
range of from about 70 to about 89 degrees.
[0041] Finally, upper section 44 extends from intermediate section
42, and defines a collar 48 and a stacking wall 50. Collar 48
extends radially outwardly from intermediate section 42. Stacking
wall 50, in turn, extends generally upwardly from collar 48 and
terminates at flange 16. In one embodiment, stacking wall 50
defines, in transverse cross-section, a slight inward taper from
bottom to top, relative to the central axis. With this
configuration, upper section 44 promotes stacking of another,
similarly formed container (not shown) within container 10, but
prevents the second container from entirely nesting within
container 10, with collar 48 of the second container resting on
flange 16. If the second container were allowed to fully nest
within container 10, frictional forces would prevent easy
disassembly of the second container from container 10.
[0042] An additional feature of sidewall 14 is best illustrated by
the longitudinal or top plan cross-sectional view of FIG. 2, where
the flange 16 is illustrated as preferably defining opposing
longitudinal sides 52 and opposing lateral sides 54. Sides 52, 54
correspond with sides 24, 26 of bottom 12 as previously
described.
[0043] With reference to FIG. 1, flange 16 extends from sidewall
14, and is generally defined by a rim section 60 and a recessed
section 62. As best shown by FIG. 3, the rim section 60 extends
radially outwardly from upper section 44 of sidewall 14 terminating
at edge 66, providing an outer surface 64. Rim section 60 of the
invention forms a relatively flat outer surface 64, which is useful
for receiving a sealing film (not shown) that is otherwise utilized
to seal a food item (not shown) within container 10.
[0044] Recessed section 62 extends from edge 66 of rim section 60
opposite sidewall 14. As depicted in FIGS. 3 and 4, recessed
section 62 extends around the exterior of container 10, generally
downwardly relative to rim section 60, and radially outward
relative to sidewall 14. The location of recessed section 62 where
longitudinal sides 52 meet lateral sides 54 defines multiple
corners 22 of container 10. Each corner 22 includes a handle 18.
Handles 18 extend radially outward from sidewall 14 and include
grips 66. Grips 66 are generally located in a plane that is
parallel to but lower than the outer surface 64 of flange 16. This
aspect of the invention has been found to enhance the overall
stability of the container.
[0045] Recessed section 62 preferably extends an appreciable
distance downwardly relative to outer surface 64 of rim section 60.
In one embodiment, recessed section 62 of the invention has a
downward extension (relative to the outer surface 64) in the range
of from about 0.1 to about 0.2 inch. It is believed that this
relatively small downward extension, within the critical range,
contributes to overall stability of container 10 while reducing the
amount of space required to store nested empty containers 10 and
full packaged containers 10.
[0046] Flange 16 provides a relatively large spacing between
recessed section 62 and sidewall 14, thereby dissipating the amount
of heat transferred from sidewall 14 to recessed section 62 that
might otherwise be touched by a user, while not noticeably
increasing manufacturing costs. For example, when container 10
containing a food substrate was heated for 2 minutes using a 1000
watt microwave oven, the temperature of sidewall 14 was found to be
about 140.degree. F. (60.degree. C.). The temperature of flange 16
was about 100.degree. F. (38.degree. C.). However, the temperature
of the grips 66 was less than 100.degree. F. (38.degree. C.),
enabling a person to remove container 10 safely from the microwave
oven.
[0047] An additional feature of flange 16 is best illustrated by
the longitudinal or top plan view of FIG. 2. Flange 16 is shown as
preferably defining opposing longitudinal edges 70 and opposing
lateral edges 72. Edges 70, 72 correspond with sides 52, 54 of
sidewall 14 previously described. Longitudinal edges 70 are located
between corners 22 forming a generally linear edge of container 10.
In contrast, lateral edges 72 include catch members 80 between
corners 22 that extend radially outwardly past corners 22 to create
a non-linear lateral edge 72.
[0048] With reference back to FIG. 1, and with additional reference
to FIG. 2, handles 18 are formed as integral extensions of flange
16. In one preferred embodiment, handles 18 each define a radial
extension from flange 16 of from about 0.3 to about 0.5 inch.
[0049] Both of flange 16 and collar 48 define compound curves as
previously described. This characteristic has been found to provide
container 10 with an elevated level of torque resistance when a
lifting force is applied at a single point along corners 22.
Following heating, container 10 is preferably lifted by a user (not
shown) via handles 18. In the event the user inadvertently lifts
container 10 with a single hand, grasping a handle 18 at one of
corners 22, the compound curvature nature of flange 16 and collar
48 resist deflection or bending of the container 10 due to a weight
of the contained food item (not shown).
[0050] With reference to FIG. 5, sleeve 100 and the shape of
packaging sleeve 100 will now be discussed. Sleeve 100 is a
box-shaped container made of paperboard or a similar paper product.
Sleeve 100 includes a sleeve base 102, two depending sleeve sides
104, 106, a sleeve top 108, and a second sleeve top 212. Apertures
110 and 112 are disposed in base 102 of sleeve 100, although it
will be appreciated that any number of apertures may be disposed in
base 102 while remaining within the scope of the invention.
Perforation 213 is shown along a central axis of sleeve 100.
[0051] Sleeve 100 is designed to hold one or more containers 10
firmly in place within sleeve 100 to form a sleeve assembly 200 as
shown in FIG. 5. In one embodiment, sleeve 100 is designed to hold
four separate containers 10, 220, 240, and 260. Containers 220,
240, and 260 are substantially similar to container 10 in size and
configuration. Container 240 is shown on top of container 220,
while container 260 is shown on top of container 10. Containers 240
and 260 are shown upside-down on top of containers 220 and 10,
respectively, so that flanges 16 of the containers rest against one
another. However, containers 240 and 260 may be located in an
upright configuration while remaining within the scope of the
invention.
[0052] With reference to FIGS. 5 and 6, apertures 110 and 112 are
primarily disposed through base 102. However apertures 110 and 112
also extend onto side 104 and side 106. The portion of apertures
110 or 112 that extends onto side 104 is a first port 120. The
portion of apertures 110 or 112 that extends onto side 106 is a
second port 122. Ports 120 contain surface 124 on side 104. Surface
124 is disposed of a convex curvature. This convex curvature
facilitates the locking of container 10 in sleeve 100 as surface
124 interferes with the underside of catch members 80. However
surface 124 may be disposed of a concave curvature or linear
profile while remaining within the scope of the invention.
[0053] FIG. 7 shows a single-tray assembly 700. Assembly 700
includes container 10 and sleeve 710. Sleeve 710 includes a first
side 720, a second side 730, a bottom, 740, and a top 750. Top 750
includes an easy open and re-close partition 760. Partition 760
separates top 750 into a first side 770 and a second side 780
during removal of container 10 from sleeve 710. In a preferred
embodiment, first side 770 overlaps second side 780 at partition
760. The die cut tab profile of partition 760 enables first side
720 to become interlocked with second side 730. Catch member 80 is
shown extending through port 790 in side 730. Partition 760 may be
included on a variety of sleeve configurations while remaining
within the scope of the invention.
[0054] FIG. 8 shows a tray assembly 800 utilizing a full wrap
around sleeve 810. Sleeve 810 contains 4 trays, including container
10 and container 260. Sleeve 810 is shown in greater detail in FIG.
9. Sleeve 810 is a box-shaped container made of paperboard or a
similar paper product. Sleeve 810 includes a sleeve base 812, two
depending sleeve sides 814, 816, and a sleeve top 818. Apertures
820 and 822 are disposed in side 814. Apertures 824 and 826 are
disposed in side 816.
[0055] FIG. 12 shows an alternative embodiment of the tray assembly
400 utilizing an alternative embodiment of the full wrap around
sleeve 410. Sleeve 410 contains 4 trays, including container 10 and
container 260. Sleeve 410 is shown in greater detail in FIG. 13.
Sleeve 410 is a box-shaped container made of paperboard or a
similar paper product. Sleeve 410 includes a sleeve base 412, two
depending sleeve sides 414, 416, and a sleeve top 418. Apertures
420 and 422 are disposed in side 414. Apertures 424 and 426 are
disposed in side 416.
[0056] Apertures 420, 422, 424, and 426 generally comprise
identical configurations. Therefore, the only the configuration of
aperture 426 will be discussed in detail. Aperture 420 is
particularly suitable for applying pressure to catch members 80 to
create a frictional force that assists in holding containers 10 and
260 into sleeve 410. Aperture 426 includes a generally hourglass
shape with narrow portion 480 between wide portions 482 and 484.
The center of aperture 426 includes a diamond-shaped center portion
486. Slits 488 and 490 are formed in sleeve 410 on opposing sides
of center portion 486. Sleeve 410 also includes crease 492 that
extends from the end of slit 488 to wide portion 484, crease 494
that extends from the end of slit 490 to wide portion 484, crease
496 that extends from the end of slit 490 to wide portion 482, and
crease 498 that extends from the end of slit 488 to wide portion
482. Creases 492, 494, 496, and 498 generally comprise an arc
configuration facilitate deformation of sleeve 410 around aperture
426. However, creases 492, 494, 496, 498 may form a variety of
patterns including straight, wavy or zigzagged while remaining
within the scope of the invention.
[0057] As shown in FIG. 12, the portion of sleeve 410 between
aperture 426 and crease 492 comprises flap 502. The portion of
sleeve 410 between aperture 426 and crease 498 comprises flap 504.
The portion of sleeve 410 between aperture 426 and crease 496
comprises flap 506. Moreover, the portion of sleeve 410 between
aperture 426 and crease 494 comprises flap 508.
[0058] In a preferred embodiment, the portion of flaps 502, 504,
506, and 508 adjacent to aperture 426 push outwardly as catch
members 80 of trays 10 and 260 move through aperture. Once catch
members 80 are in a desired position relative to sleeve 410, catch
members 502, 504, 506, 508 move back to a position that is planar
with side 416.
[0059] FIG. 10 shows tray assembly 900. Sleeve 910 contains 9
trays, including containers 10, 260, 902, 220, and 904. Containers
260 and 902 are shown stacked atop container 10. Container 10 is
disposed in a right-side-up configuration. Container 260 is stacked
upside-down atop container 10. Container 902 is stacked
right-side-up atop the bottom of container 902. Two containers are
stacked above each of containers 220 and 904 in a similar
fashion.
[0060] Sleeve 940 is shown in FIG. 11. Sleeve 910 is a box-shaped
container made of paperboard or a similar paper product. Sleeve 910
includes a sleeve base 912, two depending sleeve sides 914, 916,
and a sleeve top 918. Apertures 920 and 922 are disposed in base
912. Apertures 924 and 926 are disposed in side 916. Similarly,
apertures 928 and 930 are disposed in side 914. Flap 933 is
attached to side 914 of sleeve 910. Flap 933 may be secured to top
918 with adhesive to seal the containers in sleeve 940.
[0061] Assemblies 200 and 800 in FIGS. 6 and 8 are shown in a
2.times.2 tray configuration, meaning that two trays are each
stacked two trays high. Assembly 900 in FIG. 10 shows a 3.times.3
tray configuration, meaning that three trays are each stacked three
trays high. There are many variants on these configurations while
remaining within the scope of the invention. For examples, tray
assemblies may also include, but are not limited to, the following
configurations: 1.times.2, 1.times.4, 1.times.6, 2.times.1,
2.times.3, 3.times.1, ,3.times.2 and 3.times.3.
[0062] Assemblies 200, 700, 800, and 900 are used to package foods
for preparation by a consumer in a microwave oven, but are not
necessarily limited to foods to be microwaved. During packaging,
the food distributor places food products in the various containers
10, 220, 240, and 260. A heat seal (not shown) is placed over each
of the containers and is hermetically sealed to outer surface 64 to
provide an air tight compartment in interior 20. Next, sealed tray
10 is placed in sleeve 100 by sliding the bottom of container 10
through opening 110 so that the lower portion of flange 16 of
container 10 catch members on base 102 of the sleeve. Another
container 220 is inserted into opening 112 in similar fashion.
Next, container 260 is placed on top of container 10 such that
flange 16 of container 10 touches flange 16 of container 260.
Moreover, container 240 is placed on top of container 10 such that
flange 16 of container 10 touches flange 16 of container 240. After
the trays are in place, as described, panels 104 and 108 are folded
together over trays 240 and 260. In this configuration, catch
members 80 of containers 10 extend at least partially through ports
120 or 122 to lock the trays 10, 220, 240, and 260 in sleeve 100.
Once the top panel 108 is secure against panel 212, assembly 200 is
ready for distribution in the marketplace. This configuration of
assembly 200 provides sufficient interference to prevent any one of
containers 10, 220, 240, and 260 from inadvertently sliding out of
the assembly 200 during distribution, storage, while on a store
shelf, or in a consumer's home.
[0063] After assembly 200 is packed, sleeve 100 protects containers
10, 220, 240, and 260 and insures that the heat seal remains sealed
to flange 16. It also helps provide a tamper-evident package that
displays nutritional information, ingredients, heating directions,
and other information. Sleeve 100 also safeguards the containers by
acting as a protective layer during shipping and also when the tray
is displayed on the shelf, freezer, refrigerator, or other display
area. For this reason, sleeve top 108 is typically a continuous
piece that is free of any apertures.
[0064] Once a customer purchases assembly 200, there is no need to
remove the container from sleeve 100 until container 10 and its
contents are ready to be cooked. After assembly 200 is purchased,
the consumer places the assembly in a home pantry, freezer or
refrigerator until the consumer wishes to cook the food in
container 10.
[0065] When the consumer desires to prepare the food in container
10 for consumption, the consumer takes the assembly and separates
it along perforation 270. Perforation 270 may include a zip strip,
or other apparatus to separate assembly along line 270. Next, one
container is removed from the assembly by tearing sleeve 100 or
bending the sleeve to a shape in which catch members 80 can slide
out of ports 120.
[0066] The container 10 and sleeve 100 of the invention provides a
marked improvement over previous designs. More particularly, the
container 10 is well suited for pre-made food packaging and heating
applications, in that a thermoformed plastic is utilized such that
overall costs are minimized. To this end, a wide variety of food
items can be contained and heated within the container, including
meat products, pasta products, vegetable products, combinations of
meat/pasta/vegetable, desserts, grain based products and cereals,
etc. Further, container 10 provides improved heat deflection at
handles 18 and is essentially reinforced against torsional forces
generated when the container is lifted by a single hand following
heating within an oven.
[0067] Although the invention has been described with reference to
preferred embodiments, workers of ordinary skill will recognize
that changes can be made in form and detail without departing from
the spirit and scope of the invention.
* * * * *