U.S. patent number RE34,683 [Application Number 07/673,405] was granted by the patent office on 1994-08-02 for control of microwave interactive heating by patterned deactivation.
This patent grant is currently assigned to James River Corporation of Virginia. Invention is credited to David H. Hollenberg, Leon Katz, Patrick L. Maynard, Thomas D. Pawlowski, Michael A. Schmelzer, Gerald J. VanHandel.
United States Patent |
RE34,683 |
Maynard , et al. |
* August 2, 1994 |
**Please see images for:
( Certificate of Correction ) ** |
Control of microwave interactive heating by patterned
deactivation
Abstract
A patterned microwave interactive element and laminate including
a patterned microwave interactive element for use in forming food
packaging materials that may be employed to store and subsequently
cook the food stored therein are provided. The pattern of the
microwave interactive element is selected to focus the heat
generated to predetermined areas of the food contained in the
packaging. Areas where the microwave interactive element has been
deactivated may be formed by a variety of methods, such as by
demetallization, by the application of an inactivating chemical, by
mechanical means and the like, to create a preselected pattern of
inactive areas relative to the active areas, thereby controlling
the temperatures produced in different sections of the packaging
material. Optimum browning and/or crisping of the microwave heated
food product may be achieved by selecting a pattern of microwave
interactive and inactive areas tailored to specific food
products.
Inventors: |
Maynard; Patrick L. (Combined
Locks, WI), Schmelzer; Michael A. (Appleton, WI),
Pawlowski; Thomas D. (Neenah, WI), Hollenberg; David H.
(Neenah, WI), Katz; Leon (Stamford, CT), VanHandel;
Gerald J. (Neenah, WI) |
Assignee: |
James River Corporation of
Virginia (Richmond, VA)
|
[*] Notice: |
The portion of the term of this patent
subsequent to September 12, 2006 has been disclaimed. |
Family
ID: |
27362253 |
Appl.
No.: |
07/673,405 |
Filed: |
February 28, 1991 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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206961 |
Jun 10, 1988 |
4865921 |
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24063 |
Mar 10, 1987 |
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Reissue of: |
239264 |
Sep 1, 1988 |
04883936 |
Nov 28, 1989 |
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Current U.S.
Class: |
219/730; 219/759;
426/107 |
Current CPC
Class: |
B65D
81/3446 (20130101); B65D 2581/344 (20130101); B65D
2581/3447 (20130101); B65D 2581/3464 (20130101); B65D
2581/3467 (20130101); B65D 2581/3472 (20130101); B65D
2581/3474 (20130101); B65D 2581/3477 (20130101); B65D
2581/3478 (20130101); B65D 2581/3479 (20130101); B65D
2581/3483 (20130101); B65D 2581/3487 (20130101); B65D
2581/3494 (20130101) |
Current International
Class: |
B65D
81/34 (20060101); H05B 006/80 () |
Field of
Search: |
;219/1.55E,1.55F,1.55M,1.55R ;426/107,234,243 ;99/DIG.14
;428/34.6,461 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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0205304 |
|
Dec 1986 |
|
EP |
|
0317203 |
|
May 1989 |
|
EP |
|
8805249 |
|
Jul 1988 |
|
WO |
|
Primary Examiner: Leung; Philip H.
Attorney, Agent or Firm: Sixbey, Friedman, Leedom &
Ferguson
Parent Case Text
.Iadd.This is a continuation-in-part of U.S. Pat. No. 4,865,921,
issued on Ser. No. 206,961, filed on Jun. 10, 1988 which is a
continuation of Ser. No. 024,063, filed on Mar. 10, 1987,
abandoned. .Iaddend.
Claims
We claim:
1. A microwave interactive heating element capable of converting
microwave radiation to heat energy to heat a food product proximate
to said heating element, wherein said element is formed of a layer
of microwave interactive material supported on a substrate and said
element includes a plurality of first areas having a reduced
capability to generate heat in response to microwave radiation and
a plurality of second areas having an unaltered capability to
generate heater in response to microwave radiation arranged in a
predetermined pattern relative to said first areas, wherein said
pattern is formed by selectively deactivating without removing
selected areas of said microwave interactive material from said
substrate in the predetermined pattern to form said first areas and
by leaving the remainder of said predetermined pattern untreated to
form said second areas, thereby producing preselected temperature
differences in said food product corresponding to said pattern when
said heating element is subjected to microwave radiation.
2. The microwave interactive heating element of claim 1, wherein
said first areas are arranged alternately with said second areas in
concentric rings.
3. The microwave interactive heating element of claim 1, wherein
said first areas are arranged to form a grid around said second
areas.
4. The microwave interactive heating element of claim 1, wherein
said first areas are formed in the shaped of discrete squares
separated by a grid formed of said second areas.
5. The microwave interactive heating element of claim 1, wherein
said first areas are arranged alternately with said second areas in
parallel lines.
6. The microwave interactive heating element of claim 1, wherein
the reduced capability of said first area to generate heat in
response to microwave radiation is produced by the application of
an inactivating chemical to said first area. .function.7. The
microwave interactive heating element of claim 1, wherein the
reduced capability of said first area to generate heat in response
to microwave radiation is produced by mechanically reducing the
amount of microwave interactive material in said
first area. .]. 8. A microwave interactive heater for insertion
into a container intended for the storage and cooking by microwave
energy of a food product contained therein, said heater
comprising:
a. a supporting film;
b. a microwave interactive material deposited on the entire surface
of one side of said film, and
c. a substrate supporting said film and said microwave interactive
material, wherein first, deactivated areas have been formed in said
microwave interactive material by the application of an
inactivating chemical to reduce the capability of the first areas
to generate heat in response to microwave radiation to create a
predetermined pattern of said first areas relative to second areas
untreated by said inactivating chemical so that the capability of
said microwave interactive material in said second areas to
generate heat in response to microwave radiation is
not affected by said inactivating chemical. 9. The microwave
interactive heater of claim 8, wherein said first areas are
arranged alternately with
said second areas in concentric rings. 10. The microwave
interactive heater of claim 8, wherein said first areas are
arranged to form a grid
around said second areas. 11. The microwave interactive heater of
claim 8, wherein said first areas are formed in the shapes of
discrete squares
separated by a grid formed of said second areas. 12. The microwave
interactive heater of claim 8, wherein said first areas are
arranged
alternately with said second areas in parallel lines. 13. The
microwave interactive heater in claim 8, wherein said first areas
are formed by inactivating said microwave interactive material in
incremental steps to produce a temperature gradient when said
laminate is subjected to
microwave radiation. 14. The microwave interactive heater of claim
8, wherein the sections of the food product in contact with said
first areas are heated to a lower temperature than the sections of
the food product in
contact with said second area. 15. A container for packaging
several different foods, storing said foods and cooking said foods
by microwave energy, said container including a plurality of
heaters formed according to claim 8, wherein each heater is
positioned in said container in contact with one of said foods and
the pattern of first and second areas on said heater is selected to
produce the optimum temperature required to brown or
crisp the food. 16. A method of producing patterns on the surface
of a food product in contact with a heater element heated by
microwave energy comprising the steps of:
a. forming a beater element including a microwave interactive
material that has been selectively inactivated to produce a
preselected pattern of microwave active and microwave inactive
areas wherein said microwave active areas are capable of browning
the surface of said food product to a significantly greater degree
than said microwave inactive areas;
b. placing said food product in contact with said heater element in
a microwave oven;
c. subjecting said food product and said heater element to
microwave energy for a time sufficient to differentially brown the
surface of the food product in a pattern corresponding to said
preselected pattern, wherein the surface of the food product in
contact with the microwave active areas of said heater is browned
to a substantially greater degree than the surface of the food
product in contact with the microwave inactive areas
of said heater. 17. A method according to claim 16, wherein said
food product is a hot dog and said preselected pattern comprise a
plurality of parallel lines of alternating active and inactive
areas, and in step (b) said hot dog is placed across the parallel
lines of the pattern to contact said heater element so that
following step (c) the surface of said hot dog is selectively
browned in a pattern of parallel lines resembling grill
marks. 18. A method according to claim 16, wherein said food
product is a pancake and said preselected pattern is a grid of
active areas separating islands of inactive areas, and in step (b)
said pancake is placed in contact with the grid pattern on the
heater element so that following step (c) the surface of said
pancake is selectively browned in a waffle-like
grid pattern. 19. A method of forming a heating element selectively
responsive to microwave radiation for use in the microwave cooking
of food products having portions that require browning or heating
to different degrees, said method including the steps of:
a forming a layer of microwave interactive material on a substrate
to completely cover said substrate;
b. selecting a pattern of microwave interactive and microwave
inactive areas that will produce the different amounts of heat
required to optimally brown or heat the food product; and
c. applying a chemical capable of inactivating said microwave
interactive material only to the areas said layer of microwave
interactive material corresponding to said microwave inactive areas
of said pattern to produce said microwave inactive areas, thereby
forming said selectively responsive
heating element. 20. The method of forming a heating element
described in claim 19, wherein said pattern comprises concentric
rings of alternating
microwave interactive and microwave inactive areas. 21. The method
of forming a heating element described in claim 19, wherein said
pattern comprises parallel lines of alternating microwave
interactive and
microwave inactive areas. 22. The method of forming a heating
element described in claim 19, wherein said pattern comprises a
grid with said microwave interactive areas forming discrete islands
separated by lines of
microwave inactive areas. 23. The method of forming a heating
element described in claim 19, wherein said pattern comprises a
grid with said microwave inactive areas forming discrete islands
separated by lines of
microwave interactive areas. .Iadd.24. A microwave interactive
heating element of claim 1, wherein said plurality of first areas
are contiguous. .Iaddend. .Iadd.25. A microwave interactive heating
element of claim 1, wherein said plurality of first areas are
noncontiguous. .Iaddend. .Iadd.26. A microwave interactive heating
element as defined in claim 1, wherein said second areas are
contiguous. .Iaddend. .Iadd.27. A microwave interactive heating
element as defined in claim 1, wherein said second areas are
noncontiguous. .Iaddend. .Iadd.28. A microwave interactive heating
element capable of converting microwave radiation to heat energy to
heat a food product proximate to said heating element, wherein said
element is formed of a layer of microwave interactive material
supported on a substrate and said element includes a first area
having a reduced capability to generate heat in response to
microwave radiation and a second area having an unaltered
capability to generate heat in response to microwave radiation
arranged in a predetermined pattern, wherein said pattern is formed
by selectively deactivating without removing a selected area of
said microwave interactive material from said substrate in the
predetermined pattern to form said first area and by leaving the
remainder of said predetermined pattern untreated to form said
second area. .Iaddend.
Description
TECHNICAL FIELD
The present invention relates generally to the production of
microwave interactive elements for food packaging and specifically
to the production of a microwave interactive element wherein
deactivated patterns are formed to control microwave heating at
various levels within the same package.
BACKGROUND ART
The increasing popularity of microwave ovens for cooking all or a
part of a meal has led to the development of a large variety of
food products capable of being cooked in a microwave oven directly
in the food packaging in which they are stored. The convenience of
being able to cook food without removing it from the package
appeals to a great many consumers. Unfortunately, however,
currently available packaging for microwavable food products
suffers from some significant disadvantages. A major disadvantage
is the inability of this packaging to control the amount of
microwave energy received by different areas of the food contained
within the packaging. Microwave interactive material may be used in
the packaging to promote surface browning and crisping of the food.
However, because substantially the same amount of microwave energy
reaches the entire food item through the packaging, the thinner
areas may be dried out and overcooked while the thicker areas may
be barely cooked at all. Frozen food products, such as sandwiches,
pastries and the like, which have a thick center section and
thinner edges are particularly likely to cook unevenly in available
freezer-to-microwave oven packaging.
This type of microwavable food package is described by Turpin et al
in U.S. Pat. No. 4,190,757, which includes a microwave interactive
layer supported on or adjacent to one of the inside container walls
for browning the food in the container. The microwave interactive
layer described in this patent, however, suffers from the
disadvantages discussed above. Moreover, the heat transferred to
the food cooked in packaging containing such a layer may vary over
the surface area of the food due to surface or dimensional
irregularities and variations in size of the food.
A package assembly for storing and then heating food in a microwave
oven is disclosed in U.S. Pat. Nos. 4,555,605; 4,612,431 and
4,742,203 to Brown et al and assigned to the same assignee as the
present invention. The packaging assembly described in these
patents includes a microwave interactive layer on the bottom of a
food tray which is used to form a stand enclosing an air space. The
air space is described to promote the even distribution of heat to
the underside of the food product. This arrangement functions
effectively to brown or crisp food items that have a substantially
uniform thickness, such as pizza. However, the application of
evenly distributed heat energy to a food that varies in thickness
is not likely to brown or crisp all areas of the food to the degree
required.
U.S. Pat. No. 4,230,924 to Brastad et al. discloses a food
packaging material for microwave cooking that converts some of the
microwave energy to heat energy to brown the outside of the food
and allows the remainder to dielectrically heat the interior of the
food. This packaging material is in the form of a transparent
flexible dielectric substrate that has been metallized through a
mask so that the coating is subdivided into metallic islands
separated by dielectric gaps. This flexible material is intended to
be wrapped around and conform to the shape of the food product and
is disclosed to affect the degree to which the outer surface of the
food product browns during microwave cooking. However, the
microwave interactive food wrap described in this patent does not
provide the desired control over the degree of browning and
crispness of microwave cooked food products, and its use, moreover,
is limited to those foods like fish sticks that can be wrapped
during microwave cooking.
U.S. Pat. No. 4,258,086 Beall discloses the production of a
flexible metallized film useful for wrapping food to be browned in
a microwave oven. A patterned metal foil master is employed in
conjunction with microwave energy to remove portions of the
metallic film coating and create an arrangement of metallic islands
separated by dielectric gaps substantially identical to that
disclosed in the Brastad et al U.S. Pat. No. 4,230,924.
Consequently, the Beall microwave wrap suffers from similar
disadvantages. Moreover, neither of these patents suggests that the
amount of microwave interactive material left on the metallized
food wrap affects or has any relationship whatever to the degree of
browning or crisping produced in the food cooked in such wrap.
The prior art, therefore, has failed to provide a food packaging
material useful for the microwave heating of a wide variety of
foods and food products which employs a microwave interactive
material that has been selectively deactivated according to a
predetermined pattern to focus the heat generated by the microwave
interactive material, thus producing varied temperatures on
different surfaces of the food as required to brown or crisp the
food properly.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention to
provide a food packaging material useful for microwave heating that
overcomes the aforementioned disadvantages of the prior art.
It is another object of the present invention to provide a food
packaging material useful for the microwave heating of foods that
achieves the optimum browning or crisping of a wide variety of food
that differ from each other in shape, texture and consistency.
It is yet another object of the present invention to provide a food
packaging material useful for the microwave heating of food
products including a microwave interactive element deactivated
according to a predetermined pattern that directs and focuses the
heat energy on selected surfaces of the food product during cooking
to produce a properly browned or crisped product.
It is still another object of the present invention to provide a
food packaging material useful for the microwave heating of food
products that produces different temperatures on different surface
areas of the food product.
It is still a further object of the present invention to provide a
food packaging material useful for the microwave heating of food
products including a microwave interactive element treated to
produce surface temperature gradients when the microwave
interactive element is subjected to microwave energy.
It is yet a further object of the present invention to provide a
food packaging material suitable for the storage and subsequent
microwave heating of different foods within the same package.
It is a additional object of the present invention to provide a
food packaging material suitable for the storage and subsequent
microwave heating of food products that applies individually
selected temperatures or heating levels to food products contained
therein.
The aforesaid objects are achieved by providing a food packaging
material suitable for the storage and subsequent microwave heating
of a wide variety of food products. The food packaging material
described herein includes a microwave interactive element which
allows different levels and amounts of microwave energy to
differentially pass through and interact with different areas of
the element to produce correspondingly varied temperatures on
different surface areas of the food product to achieve the desired
degree of browning and crispness. A microwave interactive element
which will achieve these results is formed from a microwave
interactive material that is selectively deactivated in accordance
with a predetermined pattern that will produce a corresponding
focused pattern of heat energy onto the food product in contact
with the patterned microwave interactive element. The heating
activity of the microwave interactive layer is selectively reduced
by inactivating a selected area of the interactive material in the
microwave interactive material in patterns that may be shaped to
correspond to a specific food product, to avoid overlaps or other
undesirable heating areas in the package or to produce a gradual
temperature gradient across one or more areas of the microwave
interactive layer.
Further objects and advantages will be apparent from the following
description, claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of a food product is
subjected to microwave energy in a contained includes a prior art
microwave interactive element;
FIG. 2 is a diagrammatic representation of a laminate including
microwave interactive element formed according to the present
invention;
FIG. 3 represents a tray blank including one embodiment of a
microwave interactive layer deactivated according to the
invention;
FIG. 4 is a diagrammatic representation of a food product in a tray
formed from the blank shown in FIG. 3;
FIG. 5 represents a second embodiment of a microwave interactive
layer deactivated according to the present invention;
FIG. 6 represents a variation of the FIG. 3 embodiment of microwave
interactive layer deactivated according to the present invention,
and
FIG. 7 represents a third embodiment of a microwave interactive
layer deactivated according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Most commercially available packaging for food products intended to
be cooked by microwave energy has the overall configuration of a
three dimensional rectangular solid, the food product being encased
within the walls. This configuration is easily formed from flat two
dimensional blanks made of paperboard and the like, which can then
be folded to produce a three dimensional container of the desired
size. These containers typically include a microwave interactive
material that is laminated to the material forming the carton
blank. If the microwave interactive material is laminated to the
container blank prior to folding, heat-generating areas of the
interactive material can overlap each other when the package is
assembled. This results in the excessive generation of heat at the
areas of overlap and may lead to scorching of the food or the
container.
Alternatively, the microwave interactive material may be laminated
to a substrate and cut into an appropriate shape and and size prior
to insertion into an assembled container. While the microwave
interactive laminate may be cut into a shape that approximates that
of the food product, the easiest and most economical shape to
produce is a rectangle. However, when the food to be packaged in
the container with a rectangular microwave interactive laminate is
not rectangular but circular, triangular or irregular in shape,
heat generating areas of the laminate will not be covered by the
food product. The result is that the exposed areas of the microwave
interactive laminate can produce excessive heat, which may scorch
the food or the container. Moreover, the efficiency of the
microwave interactive material is diminished when heat generating
areas of the material are not covered by a food product to be
heated.
FIG. 1 illustrates these problems. The container 10 shown in FIG. 1
includes a microwave interactive element 12 formed by laminating a
microwave interactive material (not shown) to a substrate (not
shown). The microwave interactive element 12 is made to conform
substantially to the shape and size of the bottom wall 14 of the
container 10. Enclosed within the container 10 is a sandwich 16
which has a different shape and size than both the container 10 and
the microwave interactive element 12. Consequently, when the
container 10 i placed in a microwave oven (not shown) to cook the
sandwich 16, only the heat generated in the area of arrows 18 will
be used to brown or crisp the food. Heat will still be generated in
the areas of arrows 20; however, there is no food to absorb the
heat energy in these areas. The likely result is that the edges 22
of the sandwich 16 will be overcooked or even toughened, while the
center 24 may not be browned or crisped adequately, particularly if
the food product shown in FIG. 1 was stored in a frozen state
before being cooked in a microwave oven.
The present invention overcomes these problems by providing a
microwave interactive material wherein predetermined selected
portions of the microwave interactive material are deactivated to
render them non-microwave interactive, which results in the
focusing of heat energy at the surfaces of the food product
corresponding to the non-deactivated portions of the microwave
interactive material. These microwave interactive patterns may be
easily and conveniently shaped to the size and shape of a food
product so that undesirable heating areas in the food packaging are
avoided. Moreover, the heating activity may be selectively reduced
in different portions of the microwave interactive patterns to heat
various surface areas of a food product at different temperatures
or to different degrees.
The production of microwave interactive material with deactivated
areas may be accomplished in any manner known to those skilled in
the art, but is preferably accomplished according to the process
disclosed by U.S. patent application Ser. No. 024,063, filed on
Mar. 10, 1987 and assigned to the assignee of the present
invention, the disclosure of which is herein incorporated by
reference. FIG. 2 illustrates a microwave interactive laminate 25
having active and deactivated areas produced according to the
process described in Ser. No. 024,063. The relative sizes of the
layers shown are exaggerated for purposes of illustration.
The laminate 25 includes a substrate 26, which may also function as
one of the walls of the container comprising the food packaging,
that supports a microwave interactive layer 28 formed on a film 30.
The microwave interactive layer 28 is preferably positioned between
the substrate and the film as shown. The film 30 should be a heat
tolerant and stable material capable of supporting microwave
interactive material deposited thereon. The microwave interactive
layer 28 is a thin layer of material which generates heat in
response to microwave energy unless treated to reduce or eliminate
this capability. Treatment of the microwave interactive material to
reduce or eliminate its microwave interactive capability may be
according to the chemical deactivation method described in the
aforementioned U.S. patent application Ser. No. 024,063 or
mechanically according to the abrasion process described in U.S.
patent application Ser. No. 148,483, also assigned to the same
assignee as the present invention. The disclosure of Ser. No.
148,483 is herein incorporated by reference. Additionally, other
methods of producing a selectively microwave interactive material
wherein the heat generating capability is produced according to a
preselected pattern are contemplated to fall within the scope of
the present invention. For example, selected heat generating
capability may be produced according to a desired pattern by
printing the microwave interactive material in that specific
pattern directly on the film 30 or n the substrate 26.
Sections 32 of layer 28 represent areas of the microwave
interactive material that have been chemically deactivated in
accordance with the process of Ser. No. 024,063. Section 34 of
layer 28 has not been chemically deactivated. Therefore, section 34
remains microwave interactive and capable of generating heat. The
substrate layer 26 could be a structure separate from the food
packaging container as well as one of the container walls. It is
preferred to form the substrate of a material having a relatively
high insulating capacity and a heat stability sufficient to
withstand cooking temperatures in a microwave oven, such as
paperboard, plastics, ceramics and composite materials including,
for example, fiber/polymer composites. The film supporting the
microwave interactive layer is bonded to the substrate with a
suitable adhesive to complete the laminate 25.
The film layer 30 functions both as a base on which the microwave
interactive layer 28 is deposited and as a barrier to separate a
food product resting on top of the laminate 25 from the microwave
interactive layer 28. The film layer 30 must be sufficiently stable
at high temperatures when laminated to the substrate 26 so that it
is suitable for contact with food at the temperatures reached while
the food is being cooked in a microwave oven. Film layer 30 may be
formed from a wide variety of stable plastic films, including those
made from polyesters, polyolefins, nylon, cellophane and
polysulfones. Biaxially oriented polyester is the film material
preferred for food containers because of its heat stability and
surface smoothness.
The microwave interactive layer 28 may be applied to or deposited
on the film 30 by any one of a number of methods known in the art,
including vacuum vapor deposition, sputtering, printing and the
like. Vacuum vapor deposition techniques, however, are preferred.
The microwave interactive layer 28 may be any suitable lossy
material that will generate heat in response to microwave
radiation. Preferred microwave interactive materials useful in
forming layer 28 include compositions containing metals or other
materials such as aluminum, iron, nickel, copper, silver, stainless
steel, nichrome, magnetite, zinc, tin, iron, tungsten and titanium.
Some carbon-containing compositions are also suitable for this
purpose. These compositions can be used alone or in combination,
and the composition selected may be in the form of a powder, flakes
or fine particles. Aluminum metal is the microwave interactive
material that is most preferred for many of the applications of the
present invention.
The reduction or elimination of the heatgenerating capability of
the microwave interactive material 28 may be accomplished by a wide
variety of methods, such as, for example, demetallization and
deactivation. One type of suitable demetallization method is
described in U.S. Pat. No. 4,398,994 to Beckett. However, any
demetallization method that results in the removal of the microwave
interactive material to produce the desired the desired patterns
may be employed. Likewise, deactivation of the microwave
interactive material may also be accomplished by any one of a
number of deactivation methods capable of producing the desired
patterns. Chemical agents suitable for this purpose and the
specific techniques for achieving the chemical deactivation of
otherwise microwave interactive materials are described in detail
in the aforementioned U.S. patent application Ser. No. 024,063.
However, any other method and/or material which will deactivate a
selected portion of a microwave interactive material without
completely removing the deactivated portion could also be used in
the present invention. The mechanical deactivation method described
in detail in the aforementioned Ser. No. 148,483 is also a suitable
way to selectively reduce the capability of the microwave
interactive material to generate heat. The goal desired to be
achieved by whatever materials and/or method chosen is the
production of a layer, like layer 28 in FIG. 2, including some
areas (34) that will convert microwave radiation to heat energy and
some areas (32) that are no longer capable of converting microwave
radiation to heat energy. In this manner the heating capacity or
activity of various portions of a microwave interactive material
can be selectively reduced. Further, selected areas of reduced
heating activity can be positioned as required in a food package so
that different areas of a food product can be heated at different
temperatures and to different degrees.
The representation of one embodiment of such a patterned microwave
interactive layer is shown in the tray blank 38 of FIG. 3. The
configuration of activated areas (40, 42) and deactivated (44, 46)
areas in the blank 38 has been found to be effective for browning a
food that is substantilly round in shape and is relatively thick in
the center portion, such as, for example, the round pastry cup
containing a filling shown in FIG. 4. The active areas on what will
form the bottom 39 when the blank 38 is assembled to form a tray
include a central circular area 40 and spaced rings 42 concentric
to the circle 40. Side panels 41 and 43 also have active areas 45
selectively positioned to produce only a single layer of microwave
interactive material when the tray is assembled. The selective
positioning of the active areas 45 thus avoids the excessive heat
that is generated when multiple layers of microwave interactive
material overlap. The deactivated areas include concentric rings 44
interposed between the active concentric rings 42 and corner areas
46. Side panels 41 and 43 also include deactivated areas 47.
Although the tray blank bottom section 39 will most often form the
bottom of the tray, for some food products placing the patterned
bottom 39 above the food would produce a more desirable degree of
browning or crisping. When a tray formed from blank 38 is subjected
to microwave radiation in a microwave oven, the greatest amount of
surface heat will be generated in the central circular area 40.
This area corresponds to the center of the food load, which is the
thickest and requires the most surface heat. A lesser amount of
surface heat is generated in the area of concentric rings 42
because these rings are separated by deactivated, non-heat
generating rings 44. The edges of the food, which generally require
less energy to brown than the center, will be adjacent to these
deactivated areas. Corner sections 46 of the boom 39 are also
deactivated since there is no food adjacent to those sections to be
browned and, therefore, no heat is required in sections 467.
In contrast, the prior art microwave interactive layer 12 in FIG. 1
is fully capable of converting microwave radiation to heat across
its entire surface and generates heat in areas where there is no
food and it is not required for browning or crisping. By employing
a pattern of deactivated and active microwave interactive material,
such as that shown in FIG. 3, the microwave energy can be focused,
and heat generated only where it is required for browning or
crisping the food product adjacent to the microwave interactive
layer.
FIG. 4 illustrates diagramatically a food container formed from the
tray blank 38 of FIG. 3, which includes a microwave interactive
heater 82 with the pattern of microwave interactive and deactivated
areas of FIG. 3 in the bottom 84 of the container. The container
sidewalls 86 correspond to side panels 41 and 43 in FIG. 3 and form
a single substantially continuous microwave interactive layer
around the food located in the container. This container is
particularly suitable for achieving the optimum browning of a food
product, such as the filled pastry cup including a pastry shell 88
and a filling 90 shown in FIG. 4. The central part 40' of the
heater 82 corresponds to the fully metallized circular area 40 in
FIG. 3, and the spaced metallized sections 42' correspond to
concentric metallized rings 42 in FIG. 3. The deactivated sections
44' and 46' in FIG. 4 correspond to deactivated areas 44 and 46 in
FIG. 3. The bottom of the pastry directly contacts the heater 82
and thus can be properly browned. There is little or no contact,
however, between the pastry and the sidewalls 86. As a result, the
heating produced by the sidewalls is primarily by radiation and,
therefore, is less efficient. Consequently, the use of a
substantially continuous microwave interactive sidewall does not
scorch the pastry.
In most instances, the food heated with the patterned microwave
interactive material of the present invention will be in direct
contact with this material. However, in some applications, such as,
for example, the tray blank side panels 41 and 43 of FIG. 3 used to
heat the filled pastry cup in FIG. 4, it may be desirable to
provide either an unpatterned or a patterned microwave interactive
layer that is no in direct contact with the food but, rather, is
spaced some distance from it. Radiant heat will be transferred to a
food product in close proximity to such a microwave interactive
area in an amount that is inversely proportional to the square of
the distance between the microwave interactive material and the
food product.
The types of patterns that may be employed for this purpose are
essentially unlimited and may be varied as desired according to the
browning or crisping requirements of a particular food product.
FIGS. 5-7 illustrate several embodiments of patterns that have been
found to focus microwave radiation to generate heat effectively in
the heating of a variety of food products. Ideally, to insure
optimum browning and crisping, each type of food product should be
packaged in a container having a pattern of microwave active and
deactivate areas specifically designed for that type of food
product. The present invention achieves this objective and
facilitates the production of microwave interactive material
specifically designed to produce the desired degree of browning and
crisping in a particular food product when that food product is
heated in a microwave oven. The patterns of FIGS. 5-7 represent
patterns of microwave active and deactivated areas that may be
employed to optimally brown and crisp a wide variety of different
types of food products in a microwave oven.
The patterns shown in FIG. 5-7, which were produced by the chemical
deactivation method of Ser. No. 024,063, have been tested to
determine the amount of heat actually generated in an area by these
patterns. The test data demonstrate that the amount of heating in
an area is not highly dependent on the specific pattern, but,
instead, depends primarily on and is roughly proportional to the
percentage of active area in the pattern. This is not the case,
however, if the metal comprising the microwave interactive material
is broken into discrete areas smaller than approximately 1/8
inch.times.1/8 inch. The formation of discrete interactive areas
smaller than this size substantially interferes with the heating
capability of the microwave interactive material.
FIG. 5 illustrates a grid pattern in which the squares 50, only two
of which are designated by the reference numeral, are areas of
microwave interactive material. The parallel horizontal strips 52
and the parallel vertical strips 54 separating the squares form a
grid and are areas where the microwave interactive material has
been deactivated. Other grid-like patterns in which the "islands"
are not squares but circles, ellipses, ovals or the like could also
be used. This pattern and two patterns that are essentially the
reverse of the FIG. 5 pattern, wherein the squares 50 were
deactivated while the strips 52 and 54 remained microwave
interactive, were tested to determine the relative percentages of
power transmitted, power reflected and power absorbed by samples
with these patterns. The percentage of active area remaining in the
pattern after the chemical deactivation process described in Ser.
No. 024,063 varied from 25% to 75% as indicated in Table I below.
The relative peak temperatures were measured in the absence of a
competing load in a 700 watt microwave oven using an infrared video
system. The power transmission, reflection and absorbance of each
sample was measured with a network analyzer and a slotted waveguide
applicator.
TABLE I ______________________________________ Pattern Peak (Screen
count: % % % Temp. lines/inch) Transmitted Reflected Absorbed Deg.
F. ______________________________________ Squares-4 line: 20%
active 92.3 0.3 7.4 172.5 45% active 77.2 0.6 22.2 307.5 69% active
50.6 0.7 48.8 345.0 Grid-4 line: 21% active 5.9 0.6 93.6 265.0 46%
active 0.2 2.3 97.5 305.0 73% active 0.0 4.1 96.0 345.0 Grid-20
line: 3% active 98.4 0.1 1.5 165.0 28% active 17.7 0.6 81.7 265.0
59% active 0.0 3.1 96.9 325.0
______________________________________
For each of the samples tested above, the results demonstrate that
the greater the percentage of active area, the higher the peak
temperature reached. Consequently, reduction of the peak surface
cooking temperature produced by the pattern can be achieved by
removing a greater amount of active area from the microwave
interactive material during the deactivation process.
FIG. 6 illustrates a concentric ring pattern different from the on
shown in FIG. 3 in that the pattern of microwave interactive areas
extends substantially uniformly through the pattern and does not
include the large deactivated sections of the FIG. 3 pattern. The
dark concentric rings 60 represent areas capable of converting
microwave radiation to heat energy, and the light concentric rings
62 represent the chemically deactivated areas. The ring pattern of
FIG. 6 was tested on samples as described above in connection with
FIG. 5. The results of these tests are presented in Table II
below:
TABLE II ______________________________________ Peak Pattern % % %
Temp. Rings Transmitted Reflected Absorbed Deg. F.
______________________________________ 1/16" active 17.8 1.3 80.9
305.0 1/8" inactive 1/16" active 7.8 1.7 90.5 325.0 1/16" inactive
1/8" active 4.9 1.6 93.6 325.0 1/8" inactive 1/8" metal 3.4 1.6
94.9 345.0 1/16" space ______________________________________
FIG. 7 illustrates a parallel line pattern wherein the dark lines
70 represent microwave interactive areas and the light lines 72
represent areas of microwave interactive material that has been
chemically deactivated according to Ser. No. 024,063. This pattern
was tested as discussed in connection with FIG. 5 in two
orientations: with the lines perpendicular to the microwave
electric field and with the lines parallel to the microwave
electric field. The results of the tests are set forth in Table
III.
TABLE III ______________________________________ % Trans- % % Peak
Pattern mitted Reflected Absorbed Temp. Lines par per par per par
per Deg. F. ______________________________________ 1/16" active 0.0
96.2 2.8 0.2 97.2 3.7 285.0 1/8" inactive 1/16" active 0.0 93.8 4.0
0.3 96.0 6.0 325.0 1/16" inactive 1/8" active 0.0 90.6 4.0 0.4 96.0
9.1 325.0 1/8" inactive 1/8" active 0.0 83.1 5.1 0.6 94.9 16.4
345.0 1/16" inactive ______________________________________ Note:
"par" and "per" indicate lines parallel or perpendicular to electri
field in the waveguide.
As in the other tests, the greater the area of active material,
which in this case and in the case of the concentric ring pattern,
represents the microwave interactive area, the higher the peak
temperature reached by the sample. The orientation of the
microwaves has been found to have an effect on the performance of
some of the proposed patterns, for example, the FIG. 7 pattern.
However, this is not a matter of concern to the user of a typical
household microwave oven, since the microwaves produced by these
ovens are random and unoriented.
Using the concepts of the present invention, different patterns can
be employed to produce interesting touches on food products. The
following examples illustrate two possible applications.
EXAMPLE I
A microwave heater was formed by laminating the patterned microwave
interactive material of FIG. 7 to a rectangular substrate
approximately 2 inches by 6 inches in size. The alternating strips
of the active and deactivated pattern were approximately 1/8 inch
wide. An open-ended sleeve sized to fit a hot dog was formed from
the rectangle. A cold jumbo size, low-salt Armour brand hot dog was
placed in the sleeve and heated in a 700 watt microwave oven for
about 60 seconds. When removed from the oven the surface of the
heated hot dog had dark parallel "burn" marks about 1/8 inch wide
from one end to the other and appeared as if it had been grilled or
broiled. The pattern of FIG. 7 effectively heated the portions of
the surface of the hot dog in contact with the microwave active
strips to a sufficiently high temperature to produce these very
dark grill marks, thus giving the hot dog the appearance of having
been grilled.
EXAMPLE II
A microwave heater was formed with a pattern that was the reverse
of the pattern of FIG. 5, wherein the active areas formed line of
the grid and the deactivated areas formed the squares. The lines of
active material were approximately 1/16 inch wide, and the inactive
"islands" were about 3/16 inch on a side. Pancake batter was poured
on the patterned heater. A second identically patterned heater was
placed on top of the batter, and the two heaters with the batter in
between them were placed in a 700 watt microwave oven and heated
for about 2 minutes. After heating, both sides of the "waffle"
displayed a waffle-like grid pattern of alternating golden brown
squares separated by a grid of dark brown lines. In another test,
pancake batter was poured on a heater formed as described above and
heated in a 700 watt microwave oven for about 2 minutes without the
top heater. The resulting product had a waffle-like-grid only on
the side in contact with the patterned heater.
Other possibilities for creating distinctive patterns by the
differential browning of food also exist. For example, a pattern
including the brand name of the food product or a message of some
sort could be created with the microwave interactive areas forming
the name or message. When the food product is placed on the film or
substrate supporting the microwave interactive layer containing
such a pattern, the higher heat produced by the patterned area
relative to the surrounding deactivated area will "brand" the
surface of the food with the name or message. Other patterns could
similarly be used to create desired effects. The variety of
patterns that may be created on foods is limited only by the
imagination.
Additional, in accordance with the concepts of the present
invention, a container for the microwave cooking of food may be
provided including a microwave interactive layer which, rather than
containing discrete areas capable of producing different
temperatures, is characterized by temperature gradients. These may
range from fully metallized, microwave active to fully deactivated.
Incremental increases in the deactivated area can create such a
gradient. When the gradient is subjected to microwave radiation, a
corresponding temperature gradient is produced on the surface of
the food contacting the microwave interactive material containing
the gradient. Deactivation of the microwave interactive material to
produce such a gradient can be accomplished the same way a vignette
is produced according to the printing arts. The mechanical
deactivation method described in Ser. No. 148,483 could also be
used to produce such a gradient.
The production of deactivated areas of a microwave interactive
material to produce patterns characterized by temperature
differences can also be applied to pattern microwave interactive
heaters produced by other methods, for example by printed metal or
by applying a patterned coating containing microwave interactive
material.
It will be apparent to those skilled in the art that various
modifications and variations can be made in the present invention
without departing from its scope and spirit. Such modifications and
variations are intended to fall within the scope of the present
invention.
Industrial Applicability
The patterned microwave interactive materials of the present
invention will find their primary application in the production of
packaging for the storing and subsequent heating of food by
microwave energy where it is desired to provide a food product
which will be optimally browned and/or crisped. The patterned
microwave interactive materials of the present invention can also
be employed whenever the differential surface heating of a
substance or substances by microwave energy is desired.
* * * * *