U.S. patent application number 12/943769 was filed with the patent office on 2012-05-10 for packaging for food product.
This patent application is currently assigned to Sara Lee Corporation. Invention is credited to Benjamin M. Cichowski, Jeffrey Anthony Czarny.
Application Number | 20120114808 12/943769 |
Document ID | / |
Family ID | 46019864 |
Filed Date | 2012-05-10 |
United States Patent
Application |
20120114808 |
Kind Code |
A1 |
Cichowski; Benjamin M. ; et
al. |
May 10, 2012 |
PACKAGING FOR FOOD PRODUCT
Abstract
A packaged food product includes a food product; a packaging
having an interior containing the food product, the packaging
including a first film defining a recess to receive the food
product, the first film having an anti-fog treatment applied to at
least a portion of the recess, the first film configured to define
a space between the food product and the first film and receive
heated water vapor released from the food product during heating of
the food product; and a second film releasably sealed to the first
film, the second film comprising an absorbent layer configured to
absorb moisture released from the food product; and at least one
vent portion configured to relieve steam pressure from the interior
during heating of the food product.
Inventors: |
Cichowski; Benjamin M.;
(Naperville, IL) ; Czarny; Jeffrey Anthony;
(Schaumburg, IL) |
Assignee: |
Sara Lee Corporation
|
Family ID: |
46019864 |
Appl. No.: |
12/943769 |
Filed: |
November 10, 2010 |
Current U.S.
Class: |
426/113 |
Current CPC
Class: |
B65D 75/366 20130101;
H05B 6/80 20130101; B65D 81/267 20130101; H05B 6/6479 20130101;
B65D 81/264 20130101; B65D 81/3446 20130101 |
Class at
Publication: |
426/113 |
International
Class: |
B65D 81/34 20060101
B65D081/34 |
Claims
1. A packaged food product comprising: a food product; a packaging
having an interior containing the food product, the packaging
comprising: a first film defining a recess to receive the food
product, the first film having an anti-fog treatment applied to at
least a portion of the recess, the first film configured to define
a space between the food product and the first film and receive
heated water vapor released from the food product during heating of
the food product; and a second film releasably sealed to the first
film, the second film comprising an absorbent layer configured to
absorb moisture released from the food product; and at least one
vent portion configured to release steam from the interior during
heating of the food product.
2. The packaged food product of claim 1, wherein the at least one
vent portion comprises an interface between the first film and the
second film, the interface configured to permit steam to escape
from the interior during heating of the food product.
3. The packaged food product of claim 1, wherein the interface
comprises at least one weakened area configured to direct moisture
through the absorbent layer.
4. The packaged food product of claim 1, wherein the at least one
vent portion comprises a plurality of vents provided on the first
film.
5. The packaged food product of claim 1, wherein the second film
comprises a laminated film, the laminated film comprising the
absorbent layer facing the food product and an outer layer provided
on an opposite side of the absorbent layer from the food
product.
6. The packaged food product of claim 5, wherein the absorbent
layer is in direct contact with the food product.
7. The packaged food product of claim 5, wherein the second film
further comprises a middle adhesive layer.
8. The packaged food product of claim 7, wherein the outer layer of
the second film comprises a polymer material and the absorbent
layer comprises a paper material.
9. The packaged food product of claim 1, wherein the packaging is
configured to maintain the interior at or below a predetermined
level of humidity during heating of the food product.
10. The packaged food product of claim 1, further comprising a
scent material provided in at least one of the first film and the
second film, the scent material configured to release a scent based
on increased levels of heat and/or moisture.
11. A package for food products, the packaging comprising: a
packaging having an interior configured to receive a food product,
the packaging comprising: a first film defining a recess configured
to receive the food product and having an anti-fog treatment
applied to at least a portion of the recess, the first film
configured to permit steam to travel in a space between the food
product and the first film during heating of the food product; and
a second film configured to be releasably sealed to the first film,
the second film comprising an absorbent layer configured to face
the food product to absorb moisture released from the food product
during heating of the food product; and at least one vent portion
configured to release steam from the interior during heating of the
food product.
12. The package of claim 11, wherein the absorbent layer is in
direct contact with the food product.
13. The package of claim 11, wherein the second film comprises an
outer layer provided to an opposite side of the absorbent layer
from the food product.
14. The package of claim 13, wherein the outer layer comprises a
polymer material and the absorbent layer comprises a paper
material; and Wherein the first film is sealed to the second film
through the paper material.
15. The package of claim 11, wherein the space between the food
product and the first film is configured to provide even
distribution of steam about the food product during heating of the
food product.
16. The package of claim 11, wherein the first film is configured
to support the food product after removal of the second film from
the first film and during consumption of the food product by a
consumer.
17. A packaged food product comprising: a multi-component food
product; a packaging, the packaging having an interior containing
the food product, the packaging comprising: a first film, the first
film comprising an anti-fog layer provided as part of the first
film; and a second film releasably sealed to the first film, the
second film comprising: an absorbent layer facing the food product
and configured to absorb moisture released from the food product; a
middle layer at least partially adhered to the absorbent layer; and
an outer layer provided adjacent the middle layer; wherein the
packaging is configured to provide a space between the first film
and the food product through which steam released from the food
product may travel during heating of the food product.
18. The packaged food product of claim 17, wherein the at least one
vent portion comprises a seal between the first and second
film.
19. The packaged food product of claim 17, wherein the first film
comprises a recess that receives the food product, and wherein the
anti-fog layer is provided on the recess.
20. The packaged food product of claim 17, wherein the
multi-component food product comprises at least one bread-based
component and at least one protein-based component.
Description
BACKGROUND
[0001] The present disclosure relates generally to the field of
packagings for food products, and more specifically, to packagings
for food products that provide a more convenient means for
preparing (e.g., microwave cooking, etc.) frozen or refrigerated
food products for consumption by consumers.
[0002] There are many challenges associated with providing
consumers with an easy and effective means for preparing food
products using microwave ovens. Some of the long unresolved
problems associated with microwave cooking include inconveniences
to consumers, dryness/sogginess of food products, and uneven
cooking of food products, among others.
[0003] For example, many packaged food products require users to
open a packaging, remove a food product, wrap the food product in a
separate covering such as paper towel, etc., and then place the
wrapped food product into the microwave. Such additional steps take
considerable time and are inconvenient for consumers. Further, food
products often release moisture during microwave cooking. Without
proper control of the released moisture, the resulting food product
may be soggy, or alternatively, overly dry, and undesirable for
consumption. Further yet, many food products are unevenly heated
when prepared in a microwave oven, due to improper control of
moisture and/or other factors.
[0004] It would be advantageous to provide an improved packaged
food product that addresses and/or overcomes one or more of these
challenges by providing a user-friendly, easy-to-use, one-step
packaged food product that is also aesthetically pleasing in
appearance. As such, various embodiments disclosed herein provide a
packaged food product that may be microwaveably cooked in a
"one-step" fashion, and that includes, among other features,
venting and moisture absorption features to control the humidity
within the packaging and provide for an optimal moisture content of
multi-component food products.
SUMMARY
[0005] One embodiment relates to a packaged food product comprising
a food product; a packaging having an interior containing the food
product, the packaging comprising a first film defining a recess to
receive the food product, the first film having an anti-fog
treatment applied to at least a portion of the recess, the first
film configured to define a space between the food product and the
first film and receive heated water vapor released from the food
product during heating of the food product; and a second film
releasably sealed to the first film, the second film comprising an
absorbent layer configured to absorb moisture released from the
food product; and at least one vent portion configured to relieve
steam pressure from the interior during heating of the food
product.
[0006] Another embodiment relates to a package for food products,
the packaging comprising a packaging having an interior configured
to receive the food product, the packaging comprising a first film
defining a recess configured to receive the food product and having
an anti-fog treatment applied to at least a portion of the recess,
the first film configured to permit steam to travel in a space
between the food product and the first film during heating of the
food product; and a second film configured to be releasably sealed
to the first film, the second film comprising an absorbent layer
configured to face the food product to absorb moisture released
from the food product during heating of the food product; and at
least one vent portion configured to release steam from the
interior during heating of the food product.
[0007] Another embodiment relates to a packaged food product
comprising a multi-component food product; a packaging, the
packaging having an interior containing the food product, the
packaging comprising: a first film, the first film comprising an
anti-fog layer provided as part of the first film; and a second
film releasably sealed to the first film, the second film
comprising an absorbent layer facing the food product and
configured to absorb moisture released from the food product; a
middle layer at least partially adhered to the absorbent layer; and
an outer layer provided adjacent the middle layer; wherein the
packaging is configured to provide a space between the first film
and the food product through which steam released from the food
product may travel during heating of the food product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a packaged food product
according to an exemplary embodiment.
[0009] FIG. 2 is an exploded perspective view of the packaged food
product of FIG. 1 according to an exemplary embodiment.
[0010] FIG. 3 is an exploded view of a film used in the packaged
food product of FIG. 1 according to an exemplary embodiment.
[0011] FIG. 4 is a cross-section side view of the packaged food
product of FIG. 1 according to an exemplary embodiment.
[0012] FIG. 5 is a perspective view of a packaged food product
according to an alternative exemplary embodiment.
[0013] FIG. 6 is an exploded perspective view of the packaged food
product of FIG. 5 according to an exemplary embodiment.
[0014] FIG. 7 is an exploded view of a film used in the packaged
food product of FIG. 5 according to an exemplary embodiment.
[0015] FIG. 8 is a cross-section side view of the packaged food
product of FIG. 5 according to an exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0016] Referring to FIG. 1, a packaged food product 10 (e.g., a
breakfast product, a snack product, etc.) is shown according to an
exemplary embodiment. Packaged food product 10 may be any of a
variety of packaged food products, including, but not limited to,
breakfast items such as breakfast sandwiches, etc., lunch items
such as lunch sandwiches, etc., dinner items, snack portions, and
the like. As shown in FIG. 1, packaged food product 10 includes a
food product 12 provided within the interior of packaging 14. Food
product 12 may naturally contain moisture that is released when
food product 12 is heated as a result of undergoing a cooking
process (e.g., microwave cooking, etc.).
[0017] Referring to FIGS. 1 and 2, according to an exemplary
embodiment, food product 12 is a multi-component food product and
includes a plurality of physically separate food components shown
as components 16, 18, and 20. For example, in some embodiments,
food product 12 may be a breakfast sandwich, such that component 16
may be one or more pieces of biscuit, bun, or similar bread item,
component 18 may be a sausage, bacon, or other meat item, and
component 20 may be a cheese, sauce, or other topping item.
According to various other embodiments, food product 12 may be any
of a wide variety of other products, including a lunch sandwich, a
snack item, etc. As such, components 16, 18, and 20 may be any of a
variety of different components. According to yet other
embodiments, food product 12 may include fewer or more components
than those shown in FIG. 2 (e.g., a single food component, two food
components, four or more food components, etc.)
[0018] Further, while in some embodiments food product 12 may be
intended to be sold to consumers in a frozen state, in other
embodiments food product 12 may be intended to be sold to consumers
in a refrigerated or other state. Thus, the embodiments herein may
extend to preparing packaged food products having food products in
either a frozen or refrigerated state.
[0019] According to one embodiment, packaging 14 includes a first
film 22 (e.g., a top film or portion, a formed portion, a forming
film, etc.) and a second film 24 (e.g., a second film or portion, a
flat portion, a non-forming film, etc.). First and/or second films
22, 24 may be formed using any suitable process, including a
vacuum-forming process, a flow-wrapping process, etc. First film 22
includes a recess 28 (e.g., a pocket, receptacle, formed portion,
etc.) and a generally flat portion 30 extending about recess 28. As
discussed in greater detail below, in one embodiment, recess 28 is
sized to provide a space, or gap 42 (e.g., "a steam dome") about
food product 12 when food product 12 is heated in a microwave oven.
First film 22 may be made from a semi-rigid film material, such as
polyesters (e.g., amorphous polyethylene terephthalate (APET),
polyethylene terephthalate (PETG), etc.), polyvinyl chloride (PVC),
polypropylene (PP) or reduced density PP, high impact polystyrene,
and the like. As such, first film 22 may have sufficient rigidity
to support food product 12 after heating and during consumption of
food product 12 (e.g., after removal of second film 24 from first
film 22). In other embodiments, first film 22 may be made from a
variety of other materials, including various polymer or other
materials.
[0020] Referring now to FIGS. 2-4, second film 24 is a generally
flat film. According to an exemplary embodiment, second film 24
includes an absorbent layer configured to absorb at least a portion
of the moisture released from food product 12 during heating of
food product 12 (e.g., such that liquids, etc. may travel along a
path such as that indicated by arrows 48, 49 shown in FIG. 4). For
example, as shown in FIG. 3, second film 24 may include an
absorbent layer 36 (e.g., a paper material, etc.). In one
embodiment, second film 24 may be a substantially rigid film. In
other embodiments, part or all of second film 24 may be a
semi-rigid or flexible film.
[0021] Referring to FIG. 3, according to an exemplary embodiment,
second film 24 is a laminated film having different layers of
material laminated together. For example, as shown in FIG. 3,
second film 24 may include absorbent layer 36 (e.g., a first layer,
an absorbent layer, a paper-based layer, etc.), a middle layer 35
(e.g., an adhesive layer, a second layer, etc.) and an outer layer
38 (e.g., a third layer, a plastic layer, an outer barrier, etc.).
Layers 35, 36, 38 may be laminated (e.g., bonded, sealed, adhered,
coupled, etc.) together using any suitable methods. According to an
exemplary embodiment, absorbent layer 36 includes an inner-facing
cellulose side 37 (e.g., a paper-based side) and an outer-facing
polypropylene side 39 (e.g., a polymer-based side). Middle layer 35
may be a polyethylene adhesive or similar material. Outer layer 38
may be a thermoplastic polymer such as oriented polyethylene
terephthalate (e.g., a 48 gauge OPET material, etc.) or similar
material.
[0022] According to one embodiment, first film 22 and second film
24 are sealed by way of melting a portion of absorbent layer 36,
for example, during a heat sealing process. For example, absorbent
layer 36 may include an inner-facing paper-based layer that also
includes polypropylene fibers. As such, first and second films 22,
24 may be heat sealed together (e.g., at seal portion 26) such that
the polypropylene fibers present in absorbent layer 36 at least
partially melt during the heat sealing process, thereby bonding
first and second films 22, 24 together. In sealing films 22 and 24,
the seal is formed through the paper-based layer of absorbent layer
36 and with the polypropylene material. The strength of the seal
may in some embodiments be varied by changing the paper content of
the absorbent layer, as paper fibers tend to degrade the strength
of the seal.
[0023] According to one embodiment, absorbent layer 36 may be
positioned such that absorbent layer 36 faces food product 12.
According to other embodiments, one or both of layers 35, 38 may be
omitted from second film 24, such that absorbent layer 36 may act
as both an inner and/or outer layer for second film 24. Absorbent
layer 36 is configured to absorb moisture (e.g., heated water
vapor, steam, liquids such as water, oils, grease, etc.) released
from food product 12 during heating (e.g., exposure to microwave
energy) of food product 12. As such, absorbent layer 36 acts to
control the moisture content of food product 12 and prevent food
product 12 from becoming too soggy (due to excessive moisture) or
too dry (due to lack of moisture). In one embodiment, absorbent
layer 36 may be or include an absorbent paper material, such as
cellulose. In other embodiments, absorbent layer 36 may be or
include a variety of other materials.
[0024] According to one embodiment, outer layer 38 is provided to
an opposite side of absorbent layer 36 from food product 12. Outer
layer 38 acts as an outer barrier for packaging 14 and prevents
unwanted moisture, gases, and other products from entering/exiting
packaging 14. In one embodiment, outer layer 38 is or includes a
plastic material, such as 48 gauge OPET. In other embodiments,
outer layer 38 may be or include a variety of other materials.
[0025] Referring further to FIGS. 1-4, according to an exemplary
embodiment, first film 22 is sealed (e.g., releasably sealed and/or
resealably sealed, coupled, etc.) to second film 24 along a seal
portion 26 (see FIGS. 2 and 4) such that after heating of packaged
food product 10, second film 24 may be removed from first film 22,
providing consumers access to food product 12. Food product 12 is
contained with the interior of packaging 14 formed by first and
second films 22, 24. Seal portion 26 may include any of a number of
seal types, including heat sealing, adhesives, ultrasonic welding,
and the like. In one embodiment, some or all of seal 26 is a
non-hermetic heat seal that permits passage of fluids (e.g., steam,
moisture, etc.) through seal 26. In some embodiments, seal portion
26 may extend around the entire periphery of recess 28 of first
film 22. As discussed below, certain portions of seal portion 26
may provide a self-venting feature for packaged food product 10 to
provide for the release of steam during heating of food product
12.
[0026] Referring now to FIG. 4, according to an exemplary
embodiment, packaging 14 is configured to provide a "steam dome"
around portions of food product 12 during heating of food product
12. For example, as shown in FIG. 4, a steam dome shown as gap or
space 42 is provided between food product 12 and recess 28 of first
film 22. As food product 12 is heated, steam is generated and
"inflates" first film 22. Space 42 provides an area through which
this steam is able to travel and continue to provide heat to food
product 12 (e.g., acting as an insulator to keep the food product
heated longer by conducting heat) and to provide for
"steam-assisted cooking," or "steam-conductive heating." This may
serve to equilibrate the moisture within packaging 14 and ensure
faster and more even cooking of food product 12 relative to more
traditional means of microwave cooking, where steam is simply
released into the interior of the microwave oven. Further,
providing space 42 also permits moisture to uniformly re-enter food
product 12 to avoid over-drying of food product 12, resulting in an
optimal moisture content food product 12.
[0027] According to some embodiments, an anti-fog layer feature or
layer 50 (e.g., an anti-fog treatment or feature, etc.) may be
provided as part of or on the inner surface of first film 22.
Anti-fog layer 50 may be a separate layer of material, or may be
provided as an integral part of first film 22. For example, in some
embodiments, anti-fog material may be added to a resin (e.g., as
resin chips or the like) used to make one or more films of
packaging 14. Providing an anti-fog surface on first film 22
eliminates and/or prevents the formation of water beads or droplets
that may otherwise form on first film 22 during heating of food
product 12.
[0028] Furthermore, anti-fog layer 50 resists fogging (clouding,
discoloring, etc.) of the films due to extreme or sudden
temperature changes. An anti-fog surface also maintains an
aesthetically appealing visual appearance to packaged food product
10 prior to, during, and after heating of packaged food product 10,
as the packaging does not "fog up" (e.g., the packaging remains
substantially transparent if a transparent packaging material is
used). According to various alternative embodiments, an anti-fog
treatment may be provided on or as a part of one or both of first
film 22 and second film 24. In one embodiment, as water condenses
on the films, the anti-fog treatment causes the water to run (e.g.,
drain, flow, wick, etc.) toward absorbent layer 36, where it may
remain and/or be regenerated back into steam. As a result of the
anti-fog treatment, rather than water beads or droplets forming,
the anti-fog treatment reduces the surfaces tension of the film
(i.e., "wetting" the film) such that only a fine layer of water
forms (e.g., a "non-scattering" film of water) and runs down the
sides of the film.
[0029] As indicated earlier, one or more vent portions may be
provided as part of packaging 14. For example, seal portion 26 may
provide a self-venting feature for packaging 14, such that one or
more portions of seal portion 26 (e.g., the interface between first
and second films 22, 24) may be configured to permit a desired
amount of steam or moisture to escape from the interior of
packaging 14 during heating of food product 12 (e.g., along a path
indicated by arrow 46 shown in FIG. 4). In some embodiments, one or
more portions of seal portion 26 may be "weakened" to provide
venting of steam and/or moisture. Furthermore, first film 22 may be
shaped or sized to direct moisture to weakened portions of seal
portion 26. For example, first film 22 may include one or more
flutes (e.g., corrugations, etc.) or other features to direct
moisture to specific portions of seal portion 26.
[0030] In yet other embodiments, packaging 14 may be configured
such that a user may "peel back" a portion of first film 22 from
second film 24 (e.g., using an "easy peel" feature) to provide an
opening through which steam may escape from the interior of
packaging 14 during heating of food product 12. For example, due to
the presence of paper fibers (e.g., non-woven, porous paper) in the
films, seal portion 26 may be weakened as the moisture (e.g.,
steam) escaping from the package reduces the tensile strength of
the paper fibers. According to yet further embodiments, one or more
vent portions may be configured to provide venting only upon
heating of packaged food product 10 (e.g., such that the vent
portions are otherwise substantially impermeable to liquids and/or
gases).
[0031] In some embodiments, excess moisture may be directed through
specific portions of seal portion 26 to areas of packaging 14
outside of seal portion 26. For example, weakened portions or
channels may be used to direct moisture to areas 21 of packaging 14
to take advantage of the absorbency of those areas that may
otherwise not by utilized. Weakened portions of seal 26 may be
provided in a variety of ways, including narrowing the "width" of
the seal and/or reducing the "thickness" of the seal. Other ways of
providing weakened areas of seal 26 may be utilized according to
various other embodiments. For example, various parameters of
packaging machinery (e.g., pressure, temperature, dwell time, etc.)
may be varied in order to provide a seal of a desired strength
(e.g., a "controllable seal" formed through "fiber intervention,"
where the presence of papers fibers in the seal area can be
increased or decreased to control the strength of the seal).
[0032] As shown in FIG. 1, areas 21 may be provided in one or more
of the "corners" of packaging 14. According to various alternative
embodiments, the location and number of areas 21 may be varied to
suit a particular packaging configuration (e.g., variations in
size, shape, etc.). In some embodiments, a scented material may be
provided in areas 21, and the scented material may be activated by
heat and/or moisture, such that as the food product is prepared and
moisture and/or heat travels to areas 21, a scent (e.g., a fresh
bread scent, a sage sausage scent, etc.) may be activated and/or
released. In one embodiment, the scented material is provided in
one or more absorbent layers of the packaging, although the scented
material may be provided using different methods according various
other embodiments. As indicated above, the scented material may
release a scent (e.g., a fresh bread scent) that is normally
associated by consumers with the food product (e.g., a bread food
product) being prepared, to enhance the consumer experience. The
scent may be activated by the contact with the moisture, the heat,
air, or the like or combinations thereof.
[0033] In combination with the absorbent features of second film
24, the venting features of packaging 14 are intended to control
the humidity and/or temperature and equilibrate the moisture
content (e.g., maintain a consistent, even, or desired level of
moisture) within the interior of packaging 14 during heating of
food product 12 such that, for example, the humidity level within
the interior of packaging 14 remains at or below a predetermined
level during the dynamic heating cycle of food product 12. The
absorbent layer acts as a "buffer" or "moisture sink" to control
the amount of steam/moisture within the packaging. For example, one
or more venting features of packaging 14 may be configured to
"delay" any venting of steam or moisture until a predetermined
temperature, pressure, or moisture content is reached within the
interior of packaging 14. This may help to provide for faster
cooking cycles and ensure a proper moisture content for food
product 12 and avoid an over-dry or soggy food product.
[0034] In order to prepare the packaged food product of the present
disclosure, a consumer may first simply place the packaged food
product in a microwave oven, with the "flat" portion (e.g., second
film 24) facing downward (to permit formation of the "stream
dome"). The consumer may then heat the packaged food product in the
microwave oven for an appropriate amount of time (e.g., 1 minute, 2
minutes, etc.). During heating, steam may be released from the food
product and form a "steam dome" around the exterior of the food
product (e.g., inflating first film 22 to define space 42). A
portion of the moisture from the steam may be reabsorbed by the
food product, a portion may be vented to the outside environment,
and a portion may be absorbed by the absorbent layer of the
packaging. Additional moisture (e.g., liquids such as oils, grease,
etc.) released by the food product may further be absorbed by the
absorbent layer of the packaging. The food product construction;
the moisture content of the food product; the size of space 42; the
type, amount of, and performance of the absorbent layer; and the
size, location, and performance of the vent portions are balanced
to provide the proper level of moisture within packaging 14 during
preparation of food product 12. Upon completion of the heating
cycle, the consumer may simply remove the packaged food product
from the microwave oven, remove the flat film (e.g. second film 24)
and consume the food product directly from the remaining packaging.
If desired, a portion of the packaging may be used to hold the food
product during consumption.
[0035] Referring now to FIGS. 5-8, a packaged food product 110
(e.g., a breakfast product, a snack product, etc.) is shown
according to an alternative exemplary embodiment. Packaged food
product 110 may be similar to packaged food product 10 and include
any of a variety of packaged food products, including, but not
limited to, breakfast items such as breakfast sandwiches, etc.,
lunch items such as lunch sandwiches, etc., dinner items, snack
portions, and the like. As shown in FIG. 5, packaged food product
110 includes a food product 112 provided within the interior of
packaging 114.
[0036] Referring to FIGS. 5 and 6, according to an exemplary
embodiment, food product 112 is a multi-component food product and
includes a plurality of physically separate food components shown
as components 116, 118, and 120. For example, in some embodiments,
food product 112 may be a breakfast sandwich, such that component
116 may be one or more pieces of biscuit, bun, or similar bread
item, component 118 may be a sausage, bacon, or other meat item,
and component 120 may be a cheese, sauce, or other topping item.
According to various other embodiments, food product 112 may be any
of a wide variety of other products, including a lunch sandwich, a
snack item, etc. As such, components 116, 118, and 120 may be any
of a variety of different components. According to yet other
embodiments, food product 112 may include fewer or more components
than those shown in FIG. 6 (e.g., a single food component, two food
components, four or more food components, etc.)
[0037] Further, while in some embodiments food product 112 may be
intended to be sold to consumers in a frozen state, in other
embodiments food product 112 may be intended to be sold to
consumers in a refrigerated or other state. Thus, the embodiments
herein may extend to preparing packaged food products having food
products in either a frozen or refrigerated state.
[0038] According to one embodiment, packaging 140 includes a first
film 122 (e.g., a top film or portion, a formed portion, etc.) and
a second film 124 (e.g., a second film or portion, a flat portion,
etc.). First and second films 122, 124 may be formed using any
suitable process, including a vacuum-forming process, a
flow-wrapping process, etc. First film 122 includes a recess 128
(e.g., a pocket, receptacle, formed portion, etc.) and a generally
flat portion 130 extending about recess 128. As discussed in
greater detail below, in one embodiment, recess 128 is sized to
provide a space, or gap 142 (e.g., "a steam dome") about food
product 112 when food product 112 is heated in a microwave oven.
First film 122 may be made from a semi-rigid film material, such as
polyesters (e.g., amorphous polyethylene terephthalate (APET),
polyethylene terephthalate (PETG), etc.), polyvinyl chloride (PVC),
polypropylene (PP) or reduced density PP, high impact polystyrene,
and the like. As such, first film 122 may have sufficient rigidity
to support food product 112 after heating and during consumption of
food product 112 (e.g., after removal of second film 124 from first
film 122). In other embodiments, first film 122 may be made from a
variety of other materials, including various polymer or other
materials.
[0039] Referring now to FIGS. 6-8, second film 124 is a generally
flat film. According to an exemplary embodiment, second film 124
includes an absorbent layer configured to absorb at least a portion
of the moisture released from food product 112 during heating of
food product 112 (e.g., such that liquids, etc. may travel along a
path such as that indicated by arrow 148 shown in FIG. 8). For
example, as shown in FIG. 7, second film 124 may include an
absorbent layer 136 (e.g., a paper material, etc.). In one
embodiment, second film 124 may be a substantially rigid film. In
other embodiments, part or all of second film 124 may be a
semi-rigid or flexible film.
[0040] Referring to FIG. 7, according to an exemplary embodiment,
second film 124 is a laminated film having different layers of
material laminated together. For example, as shown in FIG. 7,
second film 124 may include an inner layer 134 (e.g., a first
layer, a plastic layer, a perforated layer, etc.), absorbent layer
136 (e.g., a second layer, an absorbent layer, a paper-based layer,
etc.), and an outer layer 138 (e.g., a third layer, a plastic
layer, an outer barrier, etc.). Layers 134, 136, 138 may be
laminated (e.g., bonded, sealed, adhered, coupled, etc.) together
using any suitable methods.
[0041] According to one embodiment, inner layer 134 is positioned
such that inner layer 134 faces food product 112. In some
embodiments, inner layer 134 may include one or more perforations
140 (e.g., slits, slots, apertures, micro-perforations, etc.) that
are configured to permit moisture released from food product 112
during heating of food product 112 to travel through inner layer
134 to be absorbed by absorbent layer 136. Perforations 140 may be
provided in any desired configuration, with any of a variety of
sizes, shapes, etc., and the configuration of perforations 140 may
be based on the food product to be contained within packaging 140.
In one embodiment, inner layer 134 may be made from a food-grade
plastic material, such as polyethylene (PE). In other embodiments,
inner layer 134 may be or include a variety of other materials.
[0042] According to one embodiment, absorbent layer 136 may be
provided between inner layer 134 and outer layer 138. According to
other embodiments, one or both of layers 134, 138 may be omitted
from second film 124, such that absorbent layer 136 may also act as
an inner and/or outer layer for second film 124. Absorbent layer
136 is configured to absorb moisture (e.g., liquids such as water,
oils, grease, etc.) released from food product 112 during heating
of food product 112. As such, absorbent layer 136 acts to control
the moisture content of food product 112 and prevent food product
112 from becoming too soggy (due to excessive moisture) or too dry
(due to a lack of moisture). In one embodiment, absorbent layer 136
may be or include an absorbent paper material, such as cellulose.
In other embodiments, absorbent layer 136 may be or include a
variety of other materials. The amount of moisture absorbed by
absorbent layer 136 may be controlled at least in part by
controlling the configuration (number, size, spacing, etc.) of
perforations 140 in inner layer 134.
[0043] According to one embodiment, outer layer 138 is provided to
an opposite side of absorbent layer 136 from inner layer 134. Outer
layer 138 acts as an outer barrier for packaging 114 and prevents
unwanted moisture, gases, and other products from entering/exiting
packaging 114. In one embodiment, outer layer 138 is or includes a
plastic material, such as 48 gauge OPET. In other embodiments,
outer layer 138 may be or include a variety of other materials.
[0044] Referring further to FIGS. 5-8, according to an exemplary
embodiment, first film 122 is sealed (e.g., releasably sealed
and/or resealably sealed, coupled, etc.) to second film 124 along a
seal portion 126 (see FIGS. 6 and 8) such that after heating of
packaged food product 110, second film 124 may be removed from
first film 122, providing consumers access to food product 112.
Food product 112 is contained with the interior of packaging 114
formed by first and second films 122, 124. Seal portion 126 may
include any of a number of seal types, including heat sealing,
adhesives, ultrasonic welding, and the like. In some embodiments,
seal portion 126 may extend around the entire periphery of recess
128 of first film 122. As discussed below, certain portions of seal
portion 126 may provide a self-venting feature for packaged food
product 110 to provide for the release of steam during heating of
food product 112.
[0045] Referring now to FIG. 8, according to an exemplary
embodiment, packaging 114 is configured to provide a "steam dome"
around portions of food product 112 during heating of food product
112. For example, as shown in FIG. 8, a steam dome shown as gap or
space 142 is provided between food product 112 and recess 128 of
first film 122. As food product 112 is heated, steam is generated.
Space 142 provides an area through which this steam is able to
travel and continue to provide heat to food product 112. This may
serve to equilibrate the moisture within packaging 114 and ensure
faster and more even cooking of food product 112 relative to more
traditional means of microwave cooking, where steam is simply
released into the interior of the microwave oven. Further,
providing space 142 also permits moisture to uniformly re-enter
food product 112 to avoid over-drying of food product 112,
resulting in an optimal moisture content food product 112.
[0046] According to some embodiments, an anti-fog layer 150 (e.g.,
an anti-fog treatment or feature, etc.) may be provided as part of
the inner surface of first film 122. Anti-fog layer 150 may be a
separate layer of material, or may be provided as an integral part
of first film 122. Providing an anti-fog surface on first film 122
prevents the formation of water beads or droplets that may
otherwise form on first film 122 during heating of food product
112. An anti-fog surface also maintains an aesthetically appealing
visual appearance to packaged food product 110 prior to, during,
and after heating of packaged food product 110. According to
various alternative embodiments, an anti-fog treatment may be
provided on one or both of first film 122 and second film 124.
[0047] As indicated earlier, one or more vent portions may be
provided as part of packaging 114. For example, first film 122 may
be provided with perforations 132 to permit a desired amount of
steam to escape from the interior of packaging 114 during heating
of food product 112 (e.g., along a path indicated by arrow 144 in
FIG. 8). Perforations 132 may be provided in any of a variety of
shapes, sizes, locations, number and so on to suit a particular
food product. Alternatively or in addition, seal portion 126 may
provide a self-venting feature for packaging 114, such that one or
more portions of seal portion 126 (e.g., the interface between
first and second films 122, 124) may be configured to permit a
desired amount of steam to escape from the interior of packaging
114 during heating of food product 112 (e.g., along a path
indicated by arrow 146 shown in FIG. 8).
[0048] In yet other embodiments, packaging 114 may be configured
such that a user may "peel back" a portion of first film 122 from
second film 124 (e.g., using an "easy peel" feature) to provide an
opening through which steam may escape from the interior of
packaging 114 during heating of food product 112. For example, due
to the presence of paper fibers in the films, the seal may be
weakened as the moisture (e.g., steam) escaping from the package
reduces the tensile strength of the paper fibers. According to yet
further embodiments, one or more vent portions may be configured to
provide venting only upon heating of packaged food product 110
(e.g., such that the vent portions are otherwise substantially
impermeable to liquids and/or gases).
[0049] It should be noted that any of the features shown in the
embodiments illustrated in FIGS. 5-8 may be used alone or in any
number of combinations with the features shown in the embodiments
illustrated in FIGS. 1-4. All such features and combinations of
features are to be understood to be within the scope of the present
disclosure.
[0050] In some embodiments, one or both of the top and bottom films
may have a structure different than that disclosed herein. For
example, one or more portions of the laminated films may be heat
sealed, for example, to provide "channels" or "pathways" that
direct moisture along portions of the films and/or to "trap"
moisture in desired portions of the films. Other variations in the
structure of the films disclosed herein may be made according to
various other embodiments.
[0051] The various embodiments of the packaged food product
disclosed herein provide many benefits to consumers. For example,
the packaged food product provides an "on-the-go" food product
having user-friendly packaging requiring only a "single step"
heating in a microwave oven. Control of steam and moisture content
within the packaging during heating decreases preparation time,
provides for optimal moisture content of the food product, and
ensures an evenly heated food product. Further, the anti-fog
treatment of the packaging reduces water droplet formation and
maintains an aesthetically pleasing appearance for consumers.
Further yet, because the food product may be heated without needing
to open the packaging, no additional materials are required (e.g.,
a napkin, paper towel, etc.), no messes are made within the
microwave (e.g., due to spills, splattering, melting, etc.
resulting from unpackaged food products or open packagings), and
the food product may be eaten right out of the packaging after
heating. The creation of a "steam dome" assists in both faster
cooking and providing an easy peel feature by weaning the seal
through the escape of steam.
[0052] It is important to note that the construction and
arrangement of the elements of the products and methods as shown in
the exemplary embodiments are illustrative only. Although only a
few embodiments have been described in detail in this disclosure,
those skilled in the art who review this disclosure will readily
appreciate that many modifications are possible (e.g., variations
in sizes, dimensions, structures, shapes and proportions of the
various elements, values of parameters, mounting arrangements,
materials, colors, orientations, etc.) without materially departing
from the novel teachings and advantages of the subject matter
recited in the various embodiments. Accordingly, all such
modifications are intended to be included within the scope of the
present disclosure as defined in the appended claims. The order or
sequence of any process or method steps may be varied or
re-sequenced according to alternative embodiments. Other
substitutions, modifications, changes, and/or omissions may be made
in the design, operating conditions, and arrangement of the
exemplary embodiments without departing from the spirit of the
present disclosure.
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