TECHNICAL FIELD
[0001] The present invention relates to a tray for heating, browning, and/or crisping a
food item in a microwave oven as defined in the preamble of claim 1. In more general
terms, the present invention deals with heating or cooking a food item in a microwave
oven, in particular heating or cooking a food item in a microwave oven, where the
food item has an irregular surface.
BACKGROUND
[0002] Microwave ovens provide a convenient means for heating a variety of food items, including
numerous dough-based and potato-based frozen convenience food items. There are known
constructs and systems specifically adapted to heating or cooking food items in microwave
ovens. e.g.,
US 5519195 A discloses a tray of the generic type as defined in the preamble of claim 1.
[0003] Unfortunately, in many instances, such food items mentioned above tend to bow, dome,
or otherwise warp during the freezing process instead of remaining in their original
shape. As a result, many presently available microwave energy interactive packages
are unable to provide sufficient contact with the surface of the food item to provide
the desired balance of thorough heating with a browned, crisp outer surface. Thus,
there is a need for improved materials and packages that provide the desired degree
of heating, browning, and/or crisping of a food item having a contoured or irregular
surface.
SUMMARY
[0004] The above object is achieved by a tray for heating, browning, and/or crisping a food
item in a microwave oven according to the present invention, as defined in claim 1.
Thus the present invention is directed to various microwave energy interactive trays
particularly suited for heating, browning, and/or crisping a food item having a contoured
or irregular surface in a microwave oven.
[0005] The various constructs may include one or more features that enhance microwave heating,
browning, and/or crisping of a food item. The various constructs also may include
one or more features that accommodate the contours of a food item having an irregular
surface, for example, a domed or bowed surface. For example, the various constructs
may include one or more elevated or raised portions that bring the microwave enhancing
features into closer proximity to the surface of the food item. In some instances,
such raised portions may be shaped, sized, and/or configured to create the visual
appearance of grill marks. Furthermore, the various constructs may include one or
more features that allow moisture generated during the heating process to be vented
away from the food item, thereby further enhancing browning and/or crisping. For example,
in some examples, the construct may include one or more venting channels extending
across at least a portion of the elevated portions.
[0006] The elevation patterns, the spacing between elevated portions, the height of the
elevations, and the width and depth of the spaces therebetween may be selected based
on the type of food item to be heated and the desired cooking effect. For example,
greater or fewer elevated portions may be provided, depending on, for example, the
degree of irregularity of the surface of the food item to be browned and/or crisped,
the moisture content of the food item, the thickness of the food item, characteristics
of the food item (e.g., fat content), and the surface area occupied by the food item.
[0007] Further, the construct may include one or more depressed portions (as viewed from
one side of the construct) corresponding to the elevated portion in the other side
of the construct. Where such depressed portions are in the bottom of a construct that,
in use, lie adjacent the bottom of a microwave oven, such depressions may provide
an insulating air gap that reduces heat loss from the microwave energy interactive
element to the microwave oven floor and further enhances heating, browning, and/or
crisping of the food item.
[0008] The elevated portions may be formed using any suitable method, process, or technique.
In one aspect, the contours may be formed using a mechanical and/or thermal pressing
process. In such a process, a blank typically is cut to the desired size and shape
and placed into a forming mold or die with male and female sides. The male and female
sides of the die are brought together, thereby applying pressure to the blank and
deforming the blank to create the desired pattern of contours.
[0009] Additional aspects, features, and advantages of the present invention will become
apparent from the following description and accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The description refers to the accompanying drawings in which like reference characters
refer to like parts throughout the several views, and in which:
FIG. 1A is a schematic perspective view of an exemplary tray according to various aspects
of the invention, having a generally circular shape;
FIG. 1B is a schematic top plan view of the tray of FIG. 1A;
FIG. 1C is a schematic cross-sectional view of the tray of FIG. 1B taken along a line 1C-1C;
FIG. 1D is a schematic cross-sectional view of the tray of FIG. 1B taken along a line 1D-1D;
FIG. 1E is a schematic top plan view of the tray of FIGS. 1A-1D including a microwave energy interactive element, according to various aspects of
the invention;
FIG. 2 is a schematic top plan view of another exemplary tray according to various aspects
of the invention, similar to the tray of FIGS. 1A-1D, including a microwave energy interactive element having a patterned configuration;
FIG. 3 is a schematic top plan view of yet another exemplary tray according to various aspects
of the invention, similar to the tray of FIGS. 1A-1D, including a microwave energy interactive element having a patterned configuration;
FIG. 4 is a schematic top plan view of still another exemplary tray according to various
aspects of the invention, similar to the tray of FIGS. 1A-1D, including a microwave energy interactive element having a patterned configuration;
FIG. 5 is a schematic top plan view of still another exemplary tray according to various
aspects of the invention, similar to the tray of FIGS. 1A-1E, including a plurality of elongate apertures;
FIG. 6A is a schematic perspective view of another exemplary tray according to various aspects
of the invention, including a plurality of channels;
FIG. 6B is a schematic top plan view of the tray of FIG. 6A;
FIG. 6C is a schematic cross-sectional view of the tray of FIG. 6B taken along a line 6C-6C;
FIG. 6D is a schematic cross-sectional view of the tray of FIG. 6B taken along a line 6D-6D;
FIG. 7A is a schematic perspective view of an exemplary variation of the tray of FIGS. 6A-6D according to various aspects of the invention, including a plurality of side walls;
FIG. 7B is a schematic top plan view of the tray of FIG. 7A;
FIG. 7C is a schematic cross-sectional view of the tray of FIG. 7B taken along a line 7C-7C;
FIG. 7D is a schematic cross-sectional view of the tray of FIG. 7B taken along a line 7D-7D;
FIG. 8A is a schematic perspective view of an exemplary variation of the tray of FIGS. 6A-6D according to various aspects of the invention, including additional channels;
FIG. 8B is a schematic top plan view of the tray of FIG. 8A;
FIG. 8C is a schematic cross-sectional view of the tray of FIG. 8B taken along a line 8C-8C;
FIG. 8D is a schematic cross-sectional view of the tray of FIG. 8B taken along a line 8D-8D;
FIG. 9A is a schematic perspective view of an exemplary variation of the tray of FIGS. 8A-8D according to various aspects of the invention, including obliquely oriented channels;
FIG. 9B is a schematic top plan view of the tray of FIG. 9A;
FIG. 9C is a schematic cross-sectional view of the tray of FIG. 9B taken along a line 9C-9C;
FIG. 9D is a schematic cross-sectional view of the tray of FIG. 9B taken along a line 9D-9D;
FIG. 9E is a schematic cross-sectional view of the tray of FIG. 9B taken along a line 9E-9E;
FIG. 10A is a schematic perspective view of an exemplary variation of the tray of FIGS. 8A-8D according to various aspects of the invention, including a substantially planar heating
surface;
FIG. 10B is a schematic top plan view of the tray of FIG. 10A;
FIG. 10C is a schematic cross-sectional view of the tray of FIG. 10B taken along a line 10C-10C;
FIG. 10D is a schematic cross-sectional view of the tray of FIG. 10B taken along a line 10D-10D;
FIG. 11A is a schematic perspective view of another exemplary tray according to various aspects
of the invention, having a generally square shape;
FIG. 11B is a schematic top plan view of the tray of FIG. 11A;
FIG. 11C is a schematic cross-sectional view of the tray of FIG. 11B taken along a line 11C-11C;
FIG. 11D is a schematic cross-sectional view of the tray of FIG. 11B taken along a line 11D-11D;
FIG. 11E is a schematic cross-sectional view of the tray of FIG. 11B taken along a line 11E-11E;
FIG. 12A is a schematic perspective view of a variation of the tray of FIGS. 11A-11E according to various aspects of the invention, including a plurality of channels;
FIG. 12B is a schematic top plan view of the tray of FIG. 12A;
FIG. 12C is a schematic cross-sectional view of the tray of FIG. 12B taken along a line 12C-12C;
FIG. 12D is a schematic cross-sectional view of the tray of FIG. 12B taken along a line 12D-12D;
FIG. 13A is a schematic perspective view of a reference example not covered by the present
invention but representing background that is useful for understanding the invention,
said reference example resulting from a variation of the tray of FIGS. 11A-11E, including a plurality of raised portions that collectively act as a platform;
FIG. 13B is a schematic top plan view of the tray of FIG. 13A;
FIG. 14A is a schematic perspective view of another reference example not covered by the present
invention, having a generally triangular shape;
FIG. 14B is a schematic top plan view of the tray of FIG. 14A;
FIG. 14C is a schematic cross-sectional view of the tray of FIG. 14B taken along a line 14C-14C;
FIG. 14D is a schematic cross-sectional view of the tray of FIG. 14B taken along a line 14D-14D;
FIG. 14E is a schematic cross-sectional view of the tray of FIG. 14B taken along a line 14E-14E;
FIG. 15A is a schematic perspective view of a reference example not covered by the present
invention resulting from a variation of the tray of FIGS. 14A-14D, including a plurality of channels;
FIG. 15B is a schematic top plan view of the tray of FIG. 15A;
FIG. 15C is a schematic cross-sectional view of the tray of FIG. 15B taken along a line 15C-15C;
FIG. 15D is a schematic cross-sectional view of the tray of FIG. 15B taken along a line 15D-15D;
FIG. 15E is a schematic cross-sectional view of the tray of FIG. 15B taken along a line 15E-15E;
FIG. 15F is a schematic cross-sectional view of the tray of FIG. 15B taken along a line 15F-15F;
FIG. 16A is a schematic perspective view of another reference example not covered by the present
invention resulting from a variation of the tray of FIGS. 14A-14D , including a plurality of channels;
FIG. 16B is a schematic top plan view of the tray of FIG. 16A;
FIG. 16C is a schematic cross-sectional view of the tray of FIG. 16B taken along a line 16C-16C;
FIG. 16D is a schematic cross-sectional view of the tray of FIG. 16B taken along a line 16D-16D;
FIG. 16E is a schematic cross-sectional view of the tray of FIG. 16B taken along a line 16E-16E;
FIG. 16F is a schematic cross-sectional view of the tray of FIG. 16B taken along a line 16F-16F;
FIG. 17A is a schematic perspective view of still another reference example not covered by
the present invention, having a somewhat circular sector shape;
FIG. 17B is a schematic top plan view of the tray of FIG. 17A;
FIG. 17C is a schematic cross-sectional view of the tray of FIG. 17B taken along a line 17C-17C;
FIG. 17D is a schematic cross-sectional view of the tray of FIG. 17B taken along a line 17D-17D;
FIG. 17E is a schematic end view of the tray of FIG. 17B, viewed along a line 17E-17E;
FIG. 18A is a schematic perspective view of a reference example not covered by the present
invention, resulting from a variation of the tray of FIGS. 17A-17E, including additional channels;
FIG. 18B is a schematic top plan view of the tray of FIG. 18A;
FIG. 18C is a schematic cross-sectional view of the tray of FIG. 18B taken along a line 18C-18C;
FIG. 18D is a schematic cross-sectional view of the tray of FIG. 18B taken along a line 18D-18D;
FIG. 18E is a schematic end view of the tray of FIG. 18B, viewed along a line 18E-18E;
FIG. 19A is a schematic perspective view of a reference example not covered by the present
invention resulting from a variation of the tray of FIGS. 17A-17E, including additional channels;
FIG. 19B is a schematic top plan view of the tray of FIG. 19A;
FIG. 19C is a schematic cross-sectional view of the tray of FIG. 19B taken along a line 19C-19C;
FIG. 19D is a schematic cross-sectional view of the tray of FIG. 19B taken along a line 19D-19D;
FIG. 19E is a schematic cross-sectional view of the tray of FIG. 19B taken along a line 19E-19E; and
FIG. 20 schematically illustrates various points on a slice of bread where the degree of
browning was measured for bread pieces heated using a commercially available susceptor
disk and for bread pieces heated using a tray according to the invention.
DESCRIPTION
[0011] Various aspects of the invention may be illustrated by referring to the figures.
For purposes of simplicity, like numerals may be used to describe like features. It
will be understood that where a plurality of similar features are depicted, not all
of such features necessarily are labeled on each figure. Additionally, it will be
understood that where a particular reference character is used to denote a dimension
on more than one figure or exemplary embodiment, the reference character may represent
any numerical value, and the value may differ for each exemplary embodiment. For example,
"
L1" may be used to denote a particular length on multiple figures, but each may have
a different numerical value in a given embodiment.
[0012] FIGS. 1A-1D depict an exemplary construct, in this example, a disk or tray
100, according to various aspects of the invention. The tray 100 is substantially circular
in shape, and is substantially symmetrical along a longitudinal centerline
CL and a transverse centerline
CT. However, numerous other shapes and configurations are contemplated hereby. For example,
the tray may have a triangular, rectangular, square, hexagonal, or any other regular
and irregular shape. Likewise, the tray may include no lines of symmetry, a single
line of symmetry, or multiple lines of symmetry.
[0013] The tray
100 includes a somewhat planar peripheral rim or base
102, and a pair of opposed raised portions or platforms
104 that serve as surfaces for receiving one or more food items (not shown) thereon.
The raised portions
104 are separated by a recess
106 that lies substantially within the same plane as the rim
102. In this example, the recess
106 lies along the transverse centerline
CT. However, the recess
106 may have any other suitable shape or position, as needed or desired for a particular
application.
[0014] Still viewing
FIGS. 1A-1D, each platform
104 is substantially semicircular in shape, suitable for receiving, for example, a half
panini or other sandwich thereon. As best seen in
FIGS. 1A and
1B, each platform
104 includes a top surface or face
108 (also referred to as "uppermost surface" and "heating surface"), a somewhat upstanding
interior face
110, a somewhat upstanding exterior face
112, and a pair of opposed corner faces
114. It will be understood that, in this and other aspects of the invention, the various
faces
108, 110, 112, and
114 are described as being individual faces or surfaces merely for purposes of simplicity
and ease of description, and that such faces or surfaces may be substantially continuous
and without having a defined boundary between them. Furthermore, it will be understood
that the platform may have any desired shape, and that numerous other regular and
irregular shapes are contemplated hereby.
[0015] In this example, the interior face
110 and the exterior face
112 of each platform
104 extends obliquely, sloping outwardly and downwardly, and tapers in height from the
top face
108 towards the recess
106 or rim
102, respectively. Likewise, corner faces
114 slope outwardly and downwardly from the top face
108 towards the recess
106 and/or rim
102, such that the corner face
114 has a generally rounded or convex shape. However, in this and other aspects, it is
contemplated that the various faces that define the platform in accordance with the
invention may be substantially upright, or may taper inwardly and downwardly from
the platform, if needed or desired for a particular application.
[0016] If desired, one or both platforms
104 may be contoured to conform generally to the shape of a food item. In this example,
each platform
104 is uniform in height
H1 when viewed along the longitudinal centerline
CL of the tray
100, as shown in
FIG. 1C, and is bowed or crowned when viewed along the interior face
110 of the platform
104, as shown in
FIG. 1D, such that the platform
104 and therefore, the top surface
108, decreases in height, from the longitudinal centerline
CL towards each of the corner faces
114. Such a tray
100 may be particularly well-suited for use with food items that have a somewhat bowed
shape, such as frozen dough based food items (e.g., sandwiches, pizzas, etc.).
[0017] The tray
100 may be characterized as having various heights, for example,
H1, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, and
L8, and radii of curvature, for example,
R1, R2, and
R3, each of which may vary for a particular application. The dimensions of each platform
104 may be substantially identical, such that the tray
100 is substantially symmetrical across each side of the longitudinal centerline
CL, or may differ, such that the tray
100 is not symmetrical across each side of the longitudinal centerline
CL. Likewise, the dimensions of each platform
104 may be substantially identical, such that the tray
100 is substantially symmetrical across each side of the transverse centerline
CT, or may differ, such that the tray
100 is not symmetrical across each side of the transverse centerline
CT.
[0018] If desired, any of the various trays of the invention may include features that alter
the effect of microwave energy during the heating or cooking of the food item. For
example, any of the trays may be formed at least partially from one or more microwave
energy interactive elements (sometimes referred to as "microwave interactive elements")
that promote browning and/or crisping of a particular area of the food item, shield
a particular area of the food item from microwave energy to prevent overcooking thereof,
or transmit microwave energy towards or away from a particular area of the food item.
Each microwave interactive element comprises one or more microwave energy interactive
materials or segments arranged in a particular configuration to absorb microwave energy,
transmit microwave energy, reflect microwave energy, or direct microwave energy, as
needed or desired for a particular microwave heating construct and food item.
[0019] The microwave interactive element may be supported on a microwave inactive or transparent
substrate for ease of handling and/or to prevent contact between the microwave interactive
material and the food item, as will be discussed in greater detail below. As a matter
of convenience and not limitation, and although it is understood that a microwave
interactive element supported on a microwave transparent substrate includes both microwave
interactive and microwave inactive elements or components, such structures may be
referred to herein as "microwave interactive webs".
[0020] In one example, the microwave interactive element may comprise a thin layer of microwave
interactive material that tends to absorb microwave energy, thereby generating heat
at the interface with a food item. Such elements often are used to promote browning
and/or crisping of the surface of a food item. When supported on a film or other substrate,
such an element may be referred to collectively with the substrate as a "susceptor
film" or sometimes, simply, "susceptor".
[0021] For example, as schematically shown in
FIG. 1E by stippling, a microwave energy interactive element
116, for example, a susceptor, may overlie all or a portion of each platform
104, including all or a portion of the top surface
108, recess
106, interior face
110, and/or corner faces
114 of one or both platforms
104. A susceptor or other microwave energy interactive element also may overlie all or
a portion of exterior face
112.
[0022] Where the susceptor is supported on a polymer film, it will be understood that the
polymer film substrate may overlie additional portions or substantially the entire
tray, with the microwave energy interactive element (i.e., the susceptor) positioned
between the substrate and the particular tray component in the desired location to
heat, brown, and/or crisp the food item. In this manner, a tray according to the invention
can be pressed or otherwise formed from a multilayer structure comprising the susceptor
film joined to the material used to form the tray.
[0023] To use the tray, one or more food items
F (shown schematically with dashed lines in
FIG. 1E) typically are placed on each platform and placed into a microwave oven (not shown).
In one particular example, the food item is a sandwich that has been separated into
two sections, each including a piece of bread and one or more toppings in an "open
face" configuration. In another particular example, the food item is a pizza, which
has been separated into, or provided as, two separate pieces, slices, or portions.
In yet another example, the food item is a single item, for example, a pizza, that
has not been divided into separate pieces, slices, or portions. In such an example,
the pizza may overlie both platforms and the recess therebetween. Alternatively, it
is contemplated that the tray may include a single platform having a generally circular
shape to accommodate the doming of circular pizza. In this instance, the platform
may have an overall domed configuration, such that the height of the platform decreases
in any direction from the center of the platform outwardly towards the base of the
tray. Alternatively still, it is contemplated that the tray may include a plurality
of platforms, each intended to receive one or more of a plurality of items, or one
or more portions of a plurality of items, to be heated.
[0024] In any case, the food items are positioned on the heating surface
108 of each platform
104 with the surface to be browned and/or crisped, for example, the bread or pizza crust,
adjacent to the tray
100. The contoured heating surface
108 of the platform
104 generally accommodates the contoured surface of the food item, which often is prone
to bowing during the freezing process, and brings the susceptor into closer proximity
to the surface of the food item to be browned and/or crisped.
[0025] It is noted that, with any of the numerous trays contemplated hereby, the food item
or items may be slightly larger than the respective platform, in this example, platform
104, and therefore, the food may extend slightly beyond the "boundaries" of the heating
surface, in this example, top face
108. As the food item thaws, any such portion of the food item extending beyond the heating
surface may flex downwardly and be brought into proximate and/or intimate contact
with the various upstanding faces of the platform, for example, faces
110, 112, and/or
114. Where a microwave energy interactive element, for example, a susceptor, overlies
such faces, the faces may serve as heating surfaces to enhance browning and/or crisping
of the corresponding portions of the food item.
[0026] As the microwave heating cycle progresses, the susceptor converts microwave energy
to thermal energy, which then is transferred to the adjacent surface of the food item.
In this manner, the browning and/or crisping of the surface of the food item can be
enhanced. Furthermore, platforms
104 maintain the food item in a position elevated from the floor or turntable of the
microwave oven, which reduces the amount of sensible heat transferred from the susceptor
to the ambient environment of the microwave oven and further enhances browning and/or
crisping.
[0027] Any of the numerous microwave interactive elements described herein or contemplated
hereby may be substantially continuous, that is, without substantial breaks or interruptions,
or may be discontinuous, for example, by including one or more breaks or apertures
that transmit microwave energy therethrough. The breaks or apertures may be sized
and positioned to heat particular areas of the food item selectively. The number,
shape, size, and positioning of such breaks or apertures may vary for a particular
application depending on type of tray or other construct being formed, the food item
to be heated therein or thereon, the desired degree of shielding, browning, and/or
crisping, whether direct exposure to microwave energy is needed or desired to attain
uniform heating of the food item, the need for regulating the change in temperature
of the food item through direct heating, and whether and to what extent there is a
need for venting.
[0028] It will be understood that the aperture may be a physical aperture or void in the
material used to form the construct, or may be a non-physical "aperture". A non-physical
aperture may be a portion of the tray that is microwave energy inactive by deactivation
or otherwise, or one that is otherwise transparent to microwave energy. Thus, for
example, the aperture may be a portion of the tray formed without a microwave energy
active material or, alternatively, may be a portion of the tray formed with a microwave
energy active material that has been deactivated. While both physical and non-physical
apertures allow the food item to be heated directly by the microwave energy, a physical
aperture also provides a venting function to allow steam or other vapors to be released
from the food item.
[0029] FIGS. 2-5 illustrate numerous examples of microwave energy interactive trays according to the
invention that include one or more discontinuities in the microwave energy interactive
element. The various trays
200, 300, 400, and
500 include features that are similar to tray
100 shown in
FIGS. 1A-1E, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"2" (FIG. 2), "3" (FIG. 3), "4" (FIG. 4), or "5"
(FIG. 5) instead of a "
1".
[0030] In the example shown in
FIG. 2, the microwave energy interactive element
216 comprises a plurality of spaced susceptor bands or stripes (shown by stippling) extending
obliquely across the transverse centerline
CL of the tray
200, with microwave inactive or transparent areas
218 therebetween. The bands may have any width, orientation, and configuration as desired.
When used to heat a food item, the microwave energy interactive bands may form a corresponding
plurality of darkened areas on the outer surface of the food item. Such marks may
resemble grill marks, such as with a panini grill.
[0031] In this and other aspects of the invention, it will be understood that the arrangement
of microwave energy interactive and microwave energy transparent areas may be selected
to provide various levels of heating, as needed or desired for a particular application.
For example, where greater heating is desired, the total inactive area may be increased.
In doing so, more microwave energy is transmitted to the food item. Alternatively,
by decreasing the total inactive area, more microwave energy is absorbed by the microwave
energy interactive areas, converted into thermal energy, and transmitted to the surface
of the food item to enhance browning and/or crisping.
[0032] In the example shown in
FIG. 3, the microwave energy interactive element
316 comprises a plurality of substantially uniformly spaced susceptor squares (shown
by stippling) with a grid-like arrangement of microwave energy transparent areas
318 therebetween. It will be understood that the dimensions of the susceptor squares
and the spaces therebetween may vary for a particular application. Furthermore, it
will be understood that the susceptor elements need not be in the shape of a square.
Other shapes are contemplated hereby. In this example, the pattern of browning on
the exterior surface of a food item may resemble a plurality of substantially uniformly
spaced squares.
[0033] In the example shown in
FIG. 4, the microwave energy interactive element
416 comprises a plurality of concentric susceptor rings (shown by stippling) with microwave
energy transparent areas or rings
418 therebetween. In this example, the pattern of browning on the exterior surface of
a food item (not shown) may resemble a plurality of substantially uniformly spaced
half circles, for example, where each food item overlies only one platform
404, or a plurality of partial concentric circles, for example, where the food item overlies
both platforms
404 and extends across recess
406.
[0034] In the example shown in
FIG. 5, a plurality of physical apertures
520 extend through the thickness of the tray
500 and interrupt the microwave energy interactive element
516. In this example, the apertures
520 are in the form of elongate slots that extend obliquely across the platforms
504. However, it will be understood that the apertures may have any suitable shape, for
example, circular, square, triangular, oval, oblong, or any other regular or irregular
shape, may have any suitable configuration, for example, random, tiled, staggered,
concentric rings, and may have any suitable placement, for example, central, peripheral,
or throughout all or a portion of the tray. In this example, the pattern of browning
may include plurality of obliquely oriented, darkened areas on the outer surface of
the food item. Such darkened areas may resemble grill marks.
[0035] It will be understood that any of the various trays of the invention may include
a microwave energy interactive element, for example, a susceptor, that renders the
tray microwave energy interactive. In each embodiment, the microwave energy interactive
element may be substantially continuous, may have one or more interruptions or discontinuities.
Such interruptions or discontinuities may include non-physical apertures and/or physical
(venting) apertures, for example, as shown in
FIGS. 2-5, or may have any other pattern, arrangement, or configuration. It will be understood
that the precise combination of features may be selected as needed or desired to enhance
the heating, browning, and/or crisping of a particular food item. While such elements
may be discussed below in connection with some of the various trays of the invention,
such elements are not shown in the remaining figures.
[0036] Alternatively or additionally, any of the various trays of the invention may include
one or more venting channels that allow moisture to escape from the food item, thereby
further enhancing the heating, browning, and/or crisping of the food item.
[0037] For example,
FIGS. 6A-6D schematically illustrate still another exemplary disk or tray
600 according to various aspects of the invention. The tray 600 includes features that
are similar to tray
100 shown in
FIGS. 1A-1D, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"6" instead of a "
1".
[0038] In this example, a pair of substantially parallel channels
616 (or "grooves" or "indentations") extends across the top face 608 of each platform
604 between, and optionally through one or both of, the interior face
608 and the exterior face
612. In this example, the channels
616 are substantially parallel to and substantially evenly spaced about the longitudinal
centerline
CL, and substantially perpendicular to the transverse centerline
CT. However, the channels may have any orientation needed or desired for a particular
application. In this and other examples described herein or contemplated hereby, the
channels may have any suitable depth as needed to provide the desired degree of ventilation
for the particular heating application. In one aspect, the channels have a depth that
is less than the height of the top face, such that the bottom of at least one channel
lies above the plane of the rim and/or recess of the tray.
[0039] If desired, one or both platforms
604 may be contoured to conform generally to the shape of a food item. In this example,
the height
H1 of each platform
604 is substantially uniform when viewed along the longitudinal centerline
CL of the tray
600, as shown in
FIG. 6C, and varies in height when viewed along the interior face
610 of the platform
604, as shown in
FIG. 6D. In this example, the height of the platform
604, and therefore the height of the top face
608, tapers or decreases when viewed from the longitudinal centerline
CL toward the each of the corner faces
610. However, other shapes and contours are contemplated.
[0040] The tray
600 may be characterized as having various heights, for example,
H1 and
H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, and
L9, and radii of curvature, for example,
R1, R2, R3, and
R4, each of which may vary for a particular application. The dimensions of each platform
604 may be substantially identical or may differ, with various degrees of symmetry being
contemplated hereby.
[0041] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
600. For example, a susceptor (not shown) may overlie all or a portion of one or both
platforms
604, including all or a portion of each top face
608, interior face
610, exterior face
612, and/or corner face
614, all or a portion of recess
606, and/or all or a portion of one or more of channels
616.
[0042] To use the tray
600, one or more food items (not shown) typically are placed on each platform and placed
into a microwave oven (not shown). The contoured heating surface
608 of the platform
604 generally accommodates the contoured surface of the food item, which may vary as
a result of the freezing process, and brings the susceptor into closer proximity to
the surface of the food item to be browned and/or crisped.
[0043] As the microwave heating cycle proceeds, the susceptor converts microwave energy
to thermal energy, which then is transferred to the adjacent surface of the food item.
In this manner, the browning and/or crisping of the surface of the food item may be
enhanced. At least some of any steam released from the food item may be carried away
from the food item along channels
616, thereby further enhancing browning and/or crisping. Additionally, platforms
604 maintain the food item in an elevated position, which reduces the amount of sensible
heat transferred from the susceptor to the ambient environment of the microwave oven,
still further enhancing the browning and/or crisping of the food item. The pattern
of browning and/or crisping may include an overall darkened appearance with somewhat
lighter areas corresponding to the areas overlying channels
616.
[0044] FIGS. 7A-7D schema tically de pict still another exemplary tray
700 according to various aspects of the invention. The tray
700 includes features that are similar to tray
100 shown in
FIGS. 1A-1D and tray
600 shown in
FIGS. 6A-6D, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a "7" instead of a "
1" or
"6", respectively.
[0045] In this example, the tray
700 includes a plurality of walls
718 extending substantially upwardly from the rim or flange
702, which serves as a base or lowermost portion of the tray
700. If desired, the walls
718 may be terminated with a lip
720. If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
700. For example, a susceptor (not shown) may overlie all or a portion of one or both
platforms
704, including all or a portion of each top face
708, interior face
710, exterior face
712, and/or corner face
714, all or a portion of recess
706, and/or all or a portion of one or more of channels
716. Such a tray
700 may be suitable for use, for example, where the food item to be heated, browned,
and/or crisped includes components that may otherwise fall from a tray without walls,
or where it is desired that the tray serve as a container from which the food item
is consumed.
[0046] The tray
700 may be characterized as having various heights, for example,
H1 and
H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, L9, L10, and
L11, radii of curvature, for example,
R1, R2,
R3,
R4, R5, R6, and
R7, and angles, for example,
A1, each of which may vary for a particular application. The specifications of each platform
704 may be substantially identical or may differ, with various degrees of symmetry being
contemplated hereby.
[0047] FIGS. 8A-8D schematically illustrate another exemplary disk or tray
800 according to various aspects of the invention. The tray
800 includes features that are similar to tray
100 shown in
FIGS. 1A-1D and tray
600 shown in
FIGS. 6A-6D, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with an
"8" instead of a "
1" or
"6", respectively.
[0048] In this example, the tray
800 includes four substantially parallel channels
816 or indentations extending across the top face
808 of each platform
804, and optionally through one or both of, the interior face
810 and the exterior face
812. Such additional channels
816 may be desirable where additional venting is needed to attain the desired degree
of browning and/or crisping of a food item prepared thereon. The channels
816 may have any suitable depth as needed to provide the desired degree of ventilation
for the particular heating application.
[0049] The tray
800 may be characterized as having various heights, for example,
H1 and
H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, L9, and
L10, and radii of curvature, for example,
R1, R2, R3, and
R4 each of which may vary for a particular application. The dimensions of each platform
804 may be substantially identical or may differ, with various degrees of symmetry being
contemplated hereby.
[0050] As with the various other exemplary trays of the invention, a microwave energy interactive
element (not shown) may overlie and may be joined to at least a portion of the tray
800. For example, a susceptor (not shown) may overlie all or a portion of one or both
platforms
804, including all or a portion of each top face
808, interior face
810, exterior face
812, and/or corner face
814, all or a portion of recess
806, and/or all or a portion of one or more of channels
816. The resulting pattern of browning and/or crisping may include an overall darkened
appearance with somewhat lighter areas corresponding to the areas overlying channels
816, generally resembling grill marks.
[0051] FIGS. 9A-9E schematically depict another exemplary tray
900 according to various aspects of the invention. The tray
900 includes features that are similar to tray
100 (FIGS. 1A-1D), tray
600 (FIGS. 6A-6D), and tray
800 (FIGS. 8A-8D), except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"9" instead of a "
1",
"6", or
"8", respectively.
[0052] In this example, the tray
900 includes four substantially parallel channels
916 or indentations extending obliquely across the top face
908 of each platform
904, and optionally through one or both of, the interior face
910 and the exterior face
912. Such additional channels
916 may be desirable where additional venting is needed to attain the desired degree
of browning and/or crisping of a food item prepared thereon.
[0053] The tray 900 may be characterized as having various heights, for example,
H1 and
H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, and
L8, and radii of curvature, for example,
R1, R2, R3, and
R4 each of which may vary for a particular application. The dimensions of each platform
904 may be substantially identical or may differ, with various degrees of symmetry being
contemplated hereby.
[0054] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
900. For example, a susceptor (not shown) may overlie all or a portion of one or both
platforms
904, including all or a portion of each top face
908, interior face
910, exterior face
912, and/or corner face
914, all or a portion of recess
906, and/or all or a portion of one or more of channels
916. The resulting pattern of browning and/or crisping may include an overall darkened
appearance with somewhat lighter, obliquely oriented areas corresponding to the areas
overlying channels
916, generally resembling grill marks.
[0055] FIGS. 10A-10D schematically illustrate another exemplary tray
1000 according to various aspects of the invention. The tray
1000 includes features that are similar to tray
100 (FIGS. 1A-1D), tray
600 (FIGS. 6A-6D), and tray
800 (FIGS. 8A-8D), except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"10" instead of a "
1",
"6", or
"8", respectively.
[0056] In this example, the platforms
1004 have a substantially planar top face
1008, as best seen in
FIGS. 10C and
10D. Such a tray
1000 may be particularly well-suited for use with food items that have a substantially
planar surface.
[0057] The tray
1000 may be characterized as having various heights, for example,
H1 and
H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, L9, and
L10, and radii of curvature, for example,
R1, R2, R3, and
R4, each of which may vary for a particular application.
[0058] FIGS. 11A-11E schematically illustrate yet another exemplary tray
1100 according to various aspects of the invention. The tray
1100 is substantially symmetrical along a longitudinal centerline
CL and a transverse centerline
CT. However, the tray may include no lines of symmetry, a single line of symmetry, or
multiple lines of symmetry, as needed or desired for a particular application.
[0059] In this example, the tray
1100 is substantially square in shape with somewhat rounded corners
1102. The tray
1100 includes a somewhat planar peripheral rim or base
1104, which serves as a base or lowermost portion of the tray
1100, and a plurality of walls
1106 extending substantially upwardly from the rim
1104. If desired, the walls
1106 may be terminated with a lip
1108. Such a tray
1100 may be suitable for use, for example, where the food item to be heated, browned,
and/or crisped includes components that may otherwise fall from a tray without walls,
or where it is desired that the tray serve as a container from which the food item
is consumed.
[0060] The tray
1100 includes a pair of opposed raised portions or platforms
1110 that serve as surfaces for receiving one or more food items (not shown) thereon.
The platforms
1110 are separated by a recess
1112 that lies substantially within the same plane as the rim
1104. In this example, the recess
1112 lies along the transverse centerline
CT. However, the recess
1112 may have any other suitable position, as needed or desired for a particular application.
The platforms
1110 optionally may be separated further by a divider
1114 extending upwardly along at least a portion of the length of the recess
1112. The divider
1114 may assist the user with proper placement of the food items on the tray
1100 to achieve the desired level heating, browning, and/or crisping, and may assist with
maintaining the food items in the proper location on the tray
1100 during the heating cycle.
[0061] Still viewing
FIGS. 11A-11D, the platforms
1110 are somewhat elongate and rectangular in shape with rounded corners
1116. Each platform
1110 includes a top surface or face
1118 (also referred to as "uppermost surface" and "heating surface"), a somewhat upstanding
interior face
1120, a somewhat upstanding exterior face
1122, and a pair of opposed corner faces
1124. It will be understood that, in this and other aspects of the invention, the various
faces
1118, 1120, 1122, and 1124 are described as being individual faces or surfaces merely for purposes of simplicity
and ease of description, and that such faces or surfaces may be substantially continuous
and without having a defined boundary between them.
[0062] As shown in
FIG. 11B, the shape of the exterior surface
1122 in top plan view generally corresponds to or "tracks" the shape of the upstanding
walls
1106. The interior face
1120 and exterior face
1122 of each platform,
1110 extend obliquely or slope, outwardly and downwardly, from the respective platform
1110 towards the recess
1112 or rim
1104, respectively, as best seen in
FIG. 11C. However, in this and other aspects, it is contemplated that the various faces that
form the platform in accordance with the invention may be substantially upright, or
may taper inwardly and downwardly from the platform, if needed or desired for a particular
application.
[0063] If desired, one or both platforms
1110 may be contoured to conform generally to the shape of a food item. In this example,
the thickness of each platform
1110, and therefore the height
H1 of each top face
1118, is substantially uniform when viewed along the longitudinal centerline
CL of the tray
1100, as shown in
FIG. 11C, and varies in height when viewed along the interior face
1120 of the platform
1110, as shown in
FIG. 11D. In this example, the thickness of the platform
1114, and therefore the height of the top face
1118, decreases or tapers from the longitudinal centerline
CL toward the each of the corner faces
1124.
[0064] The tray
1100 may be characterized as having various heights, for example,
H1,
H2, H3, and
H4, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, and
L9, radii of curvature, for example,
R1, R2, R3, R4, R5, R6, R7, R8, and
R9, and angles, for example,
A1, A2, and
A3, each of which may vary for a particular application. The dimensions of each platform
1110 may be substantially identical, such that the tray
1100 is substantially symmetrical across each side of the longitudinal centerline
CL and/or the transverse centerline
CT, or may differ, such that the tray
1100 is not symmetrical across each side of the longitudinal centerline
CL and/or the transverse centerline
CL.
[0065] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1100. For example, a susceptor (not shown) may overlie all or a portion of one or both
platforms
1110, including all or a portion of each top face
1118, interior face
1120, exterior face
1122, and/or corner face
1124, and/or all or a portion of recess
1112.
[0066] FIGS. 12A-12D schematically depict still another exemplary tray
1200 according to various aspects of the invention. The tray
1200 includes some features that are similar to tray
1100 shown in
FIGS. 11A-11D, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a "12" instead of an "
11".
[0067] In this example, a pair of substantially parallel venting channels
1226 extends across the top face
1218 of each platform
1210, and optionally through one or both of, the interior face
1220 and the exterior face
1222. The channels
1226 may have any suitable depth as needed to provide the desired degree of ventilation
for the particular heating application. In this example, the channels
1226 are substantially parallel to and substantially evenly spaced about the longitudinal
centerline
CL, and substantially perpendicular to the transverse centerline
CT. However, the channels
1226 may have any orientation needed or desired for a particular application. Additionally,
it is noted that the tray
1200 does not include a transverse dividing wall
1114 (FIGS. 11A-11E).
[0068] The tray
1200 may be characterized as having various heights, for example,
H1 and
H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, L9, and
L10, radii of curvature, for example,
R1, R2, R3, R4, R5, R6, R7, R8, R9, and
R10, and angles, for example,
A1, each of which may vary for a particular application. The dimensions of each platform
1210 may be substantially identical or may differ, and varying degrees of symmetry are
contemplated hereby.
[0069] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1200. For example, a susceptor (not shown) may overlie all or a portion of one or both
platforms
1210, including all or a portion of each top face
1218, interior face
1220, exterior face
1222, and/or corner face
1224, all or a portion of recess
1212, and/or all or a portion of one or more of channels
1226.
[0070] FIGS. 13A and
13B schematically depict, as a reference example, a tray
1300 not covered by the present invention. The tray
1300 includes some features that are similar to tray
1100 shown in
FIGS. 11A-11D, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"13" instead of an
"11".
[0071] In this example, platforms
1110 of FIGS. 11A-11D are replaced with a plurality of substantially rectangular raised portions
1328 arranged as a pair of opposed groups
1330 separated by transverse divider
1314. Each group includes three raised portions
1328 arranged in a substantially parallel configuration oblique to transverse wall
1314. However, other numbers, shapes, and arrangements of raised portions are contemplated.
The raised portions
1328 within each group
1330 collectively serve as a platform for receiving a food item (not shown) thereon, with
the spaces
1332 between adjacent raised portions
1328 providing ventilation of the food item (not shown) during the heating cycle.
[0072] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1300. For example, a susceptor (not shown) may overlie all or a portion of one or more
raised portions
1328 to enhance the heating, browning, and/or crisping of a food item heated thereon.
[0073] FIGS. 14A-14E schematically depict, as another reference example, a tray
1400 not covered by the present invention, either. The tray
1400 is substantially triangular in shape with rounded corners
1402 and is substantially symmetrical along a longitudinal centerline
CL. However, numerous other shapes and configurations are contemplated hereby. The tray
1400 also includes a transverse centerline
CT, as indicated in
FIG. 14B.
[0074] The tray
1400 includes a rim or base
1404 and a plurality of walls
1406 extending upwardly from the base
1404. The walls
1406 optionally terminate with a flange or lip
1408. The tray
1400 further includes a substantially triangular shaped raised portion or platform
1410 including a top surface or face
1412 intended to receive a food item thereon, and a plurality of somewhat upstanding side
faces
1414 joined by somewhat arcuate corner faces
1416. In this example, the top surface
1412 is substantially planar. However, it will be understood that contoured surfaces are
contemplated hereby. The side faces
1414 and corner faces
1416 extend obliquely and outwardly from the top surface
1412 to the base
1404, as best seen in
FIGS. 14C-14E.
[0075] It will be understood that, in this and other aspects of the invention, the various
faces
1412, 1414, and
1416 are described as being individual faces or surfaces merely for purposes of simplicity
and ease of description, and that such faces or surfaces may be substantially continuous
and without having a defined boundary between them. Furthermore, it will be understood
that the platform may have any desired shape, and that numerous other regular and
irregular shapes are contemplated hereby.
[0076] The various elements and aspects of the tray
1400 may be characterized as having various heights, for example,
H1 and H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8,
L9, L10, L11, L12, L13, and
L14, radii of curvature, for example,
R1, R2, R3, R4, R5, R6, R7, and
R8, and angles, for example,
A1, each of which may vary for a particular application.
[0077] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1400. For example, a susceptor (not shown) may overlie all or a portion of the platform
1410, including all or a portion of top face
1412, side faces
1414, and/or corner faces
1416. Additionally, as with the various other examples of constructs provided herein or
contemplated hereby, the tray may include one or more physical apertures (not shown)
to allow for venting through the sidewalls and/or bottom of the tray. The tray
1400 may be used as described above in connection with the various other exemplary trays.
[0078] FIGS. 15A-15F schematically illustrate, as still another reference example, a tray
1500 not covered by the present invention. The tray
1500 includes features that are similar to tray
1400 shown in
FIGS. 14A-14E, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"15" instead of a
"14".
[0079] In this example, the tray 1500 includes a plurality of channels
1518 in the platform
1510 ext ending in a direction that is substantially parallel to transverse centerline
CT and substantially perpendicular to longitudinal centerline
CL. Other configurations are contemplated. In this example, the tray
1500 includes six channels
1518 of varying length, with shorter channels
1518 proximate a first, narrower end
1520 of the tray
1500, and longer channels
1518 proximate a second, wider end
1522 of the tray
1500. The channels
1518 may have any suitable depth as needed to provide the desired degree of ventilation
for the particular heating application.
[0080] The tray
1500 may be characterized as having various heights, for example,
H1,
H2, and
H3, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, L9, L10, L11, L12, L13, L14, and
L15, radii of curvature, for example,
R1,
R2, R3, R4, R5, R6, R7, and
R8, and angles, for example,
A1, each of which may vary for a particular application.
[0081] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1500. For example, a susceptor (not shown) may overlie all or a portion of the platform
1510, including all or a portion of top face
1512, side faces
1514, and/or corner faces
1516, and/or all or a portion of one or more of channels
1518. The tray
1500 may be used as described above.
[0082] FIGS. 16A-16F schematically depict, as still another reference example, a tray
1600 not covered by the present invention. The tray
1600 includes features that are similar to tray
1400 shown in
FIGS. 14A-14E and tray
1500 shown in
FIGS. 15A-15F, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"16" instead of a
"14" or
"15", respectively.
[0083] In this example, the tray
1600 includes a plurality of channels
1618 in the platform
1610 extending in a transverse direction substantially parallel to transverse centerline
CT and substantially perpendicular to longitudinal centerline
CL, and a plurality of grooves or channels
1624 extending in a longitudinal direction substantially parallel to longitudinal centerline
CL and substantially perpendicular to transverse centerline
CT. Such additional channels may be desirable where additional venting is needed.
[0084] In this example, the tray
1600 includes six transverse channels
1618 of varying length, with shorter channels
1618 proximate a first, narrower end
1620 of the tray
1600, and longer channels
1618 proximate a second, wider end
1622 of the tray
1600. The tray
1600 also includes three longitudinal channels
1624a, 1624b of varying length, with the longest channel
1624a proximate the longitudinal centerline
CL and the shorter channels
1624b proximate walls
1606. However, other configurations may be used if desired. The channels
1618, 1624a, 1624b may have any suitable depth as needed to provide the desired degree of ventilation
for the particular heating application.
[0085] The tray
1600 may be characterized as having various heights, for example,
H1,
H2, and
H3, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, L9, L10, L11, L12, L13, L14, and
L15, radii of curvature, for example,
R1, R2, R3, R4, R5, R6, R7, and
R8, and angles, for example,
A1, each of which may vary for a particular application.
[0086] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1600. For example, a susceptor (not shown) may overlie all or a portion of the platform
1610, including all or a portion of top face
1612, side faces
1614, and/or corner faces
1616, and/or all or a portion of one or more of channels
1618, 1624a, and/or
1624b. The tray
1600 may be used substantially as described above.
[0087] FIGS. 17A-
17E schematically illustrate, as still another reference example, a tray
1700 not covered by the present invention. The tray
1700 generally has the shape of a sector of a circle, with a pair of radial sides
1702, an arcuate side
1704, and rounded corners
1706 joining the radial sides
1702 and arcuate side
1704. The tray
1700 is substantially symmetrical along a longitudinal centerline
CL. The tray
1700 also includes a transverse centerline
CL.
[0088] The tray
1700 includes a peripheral rim
1708 and a platform
1710 extending upwardly from the rim
1708. The platform
1710 includes a substantially planar top surface or face
1712 for receiving a food item (not shown) and a plurality of adjoined side faces
1714 and corner faces
1716 that extend obliquely and outwardly between the top face
1712 to the rim
1708. The platform
1710 includes a plurality of channels
1718 extending in a generally transverse direction. In this example, the platform
1710 includes six channels of varying length, with shorter channels
1718 proximate a first, narrower end
1720 of the tray
1700, and longer channels proximate a second, wider end
1722 of the tray
1700 (i.e., proximate the arcuate side
1704 of the tray
1700). The channels
1718 may have any suitable depth as needed to provide the desired degree of ventilation
for the particular heating application. Each channel
1718 may have a radius of curvature similar to that of the arcuate side
1704, in this example,
R4. However, numerous other configurations are contemplated hereby.
[0089] The tray
1700 may be characterized as having various heights, for example,
H1, lengths, for example,
L1,
L2, L3, and
L4, radii of curvature, for example,
R1, R2, R3, R4, R5, R6, and
R7, and angles, for example,
A1, each of which may vary for a particular application.
[0090] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray 1700. For example, a susceptor (not shown)
may overlie all or a portion of the platform
1710, including all or a portion of top face
1712, side faces
1714, and/or corner faces
1716, and/or all or a portion of one or more of channels 1718.
[0091] FIGS. 18A-18E schematically illustrate, as still another reference example, a tray
1800 not covered by the present invention. The tray
1800 includes features that are similar to tray
1700 shown in
FIGS. 17A-17E, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with an
"18" instead of a "17".
[0092] In this example, in addition to channels
1818 extending in a generally transverse direction, the platform
1810 includes a plurality of channels
1824a, 1824b extending in a generally longitudinal direction. In this example, the tray
1800 includes three generally longitudinal channels
1824a, 1824b of varying length, with the longest channel
1824a proximate to the longitudinal centerline
CL and the shorter channels
1824b proximate radial sides
1802. Channels
1824b are aligned obliquely with respect to channel
1824a and longitudinal centerline
CL, such that each channel
1824b is substantially equidistant from faces
1814 and channel
1824a, which is substantially aligned with the longitudinal centerline
CL. However, numerous other arrangements are contemplated by the invention. The various
channels
1818, 1824a, 1824b may have any suitable depth as needed to provide the desired degree of ventilation
for the particular heating application.
[0093] The tray
1800 may be characterized as having various heights, for example,
H1, lengths, for example,
L1,
L2, L3, and
L4, radii of curvature, for example,
R1,
R2, R3, R4, R5,
R6, and
R7, and angles, for example,
A1 and
A2, each of which may vary for a particular application.
[0094] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1800. For example, a susceptor (not shown) may overlie all or a portion of the platform
1810, including all or a portion of top face
1812, side faces
1814, and/or corner faces
1816, and/or all or a portion of one or more of channels
1818, 1824a, and/or
1824b.
[0095] FIGS.
19A-19E schematically illustrate, as still another reference example, a tray
1900 not covered by the present invention. The tray
1900 includes features that are similar to tray
1700 shown in
FIGS. 17A-17E, except for variations noted and variations that will be understood by those of skill
in the art. For simplicity, the reference numerals of similar features are preceded
in the figures with a
"19" instead of a
"17".
[0096] In this example, the tray
1900 includes a plurality of adjoined side walls
1926 and corner walls
1928 extending upwardly from the rim
1908. Such a tray might be suitable, for example, where the food item heated in the tray
includes components that may fall from the food item, or where it is desired that
the tray be used as a container for transporting the food item before or during consumption.
As with the numerous other examples herein, the walls may include one or more apertures
extending therethrough to provide additional ventilation during the heating cycle.
[0097] If desired, a microwave energy interactive element (not shown) may overlie and may
be joined to at least a portion of the tray
1900. For example, a susceptor (not shown) may overlie all or a portion of the platform
1910, including all or a portion of top face
1912, side faces
1914, and/or corner faces
1916, and/or all or a portion of one or more of channels
1918. The tray 1900 may be characterized as having various heights, for example,
H1 and
H2, lengths, for example,
L1,
L2, L3, L4, L5, L6, L7, L8, L9, L10, L11, L12, L13, and
L14, radii of curvature, for example,
R1, R2, R3, R4, R5, R6, R7, R8, R9, and
R10, and angles, for example,
A1, each of which may vary for a particular application.
[0098] Numerous materials may be suitable for use in forming the various constructs of the
invention, provided that the materials are resistant to softening, scorching, combusting,
or degrading at typical microwave oven heating temperatures, for example, at from
about 121.1°C to about 218.33°C (about 250°F to about 425°F). The particular materials
used may include microwave energy interactive materials and microwave energy transparent
or inactive materials.
[0099] For example, all or a portion of each tray may be formed at least partially from
a paperboard material, which may be cut into a blank prior to use in the tray. For
example, a tray may be formed at least partially from paperboard having a basis weight
of from about 97.65 to about 537.08 g/m
2 (about 60 to about 330 lbs/ream (lbs/3000 sq. ft.)), for example, from about 130.2
to about 227.85 g/m
2 (about 80 to about 140 lbs/ream). The paperboard generally may have a thickness of
from about 0.1524 to about 0.762 mm (about 6 to about 30 mils), for example, from
about 0.3048 to about 0.7112 mm (about 12 to about 28 mils). In one particular example,
the paperboard has a thickness of about 0.3048 mm (12 mils). Any suitable paperboard
may be used, for example, a solid bleached or solid unbleached sulfate board, such
as SUS® board, commercially available from Graphic Packaging International. Alternatively,
all or a portion of the tray may be formed at least partially from a polymer or polymeric
material, for example, coextruded polyethylene terephthalate or polypropylene. Other
materials are contemplated hereby.
[0100] The microwave energy interactive material may be an electroconductive or semiconductive
material, for example, a metal or a metal alloy provided as a metal foil; a vacuum
deposited metal or metal alloy; or a metallic ink, an organic ink, an inorganic ink,
a metallic paste, an organic paste, an inorganic paste, or any combination thereof.
Examples of metals and metal alloys that may be suitable for use with the present
invention include, but are not limited to, aluminum, chromium, copper, inconel alloys
(nickel-chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless
steel, tin, titanium, tungsten, and any combination or alloy thereof.
[0101] Alternatively, the microwave energy interactive material may comprise a metal oxide.
Examples of metal oxides that may be suitable for use with the present invention include,
but are not limited to, oxides of aluminum, iron, and tin, used in conjunction with
an electrically conductive material where needed. Another example of a metal oxide
that may be suitable for use with the present invention is indium tin oxide (ITO).
ITO can be used as a microwave energy interactive material to provide a heating effect,
a shielding effect, a browning and/or crisping effect, or a combination thereof. For
example, to form a susceptor, ITO may be sputtered onto a clear polymer film. The
sputtering process typically occurs at a lower temperature than the evaporative deposition
process used for metal deposition. ITO has a more uniform crystal structure and, therefore,
is clear at most coating thicknesses. Additionally, ITO can be used for either heating
or field management effects. ITO also may have fewer defects than metals, thereby
making thick coatings of ITO more suitable for field management than thick coatings
of metals, such as aluminum.
[0102] Alternatively still, the microwave energy interactive material may comprise a suitable
electroconductive, semiconductive, or non-conductive artificial dielectric or ferroelectric.
Artificial dielectrics comprise conductive, subdivided material in a polymer or other
suitable matrix or binder, and may include flakes of an electroconductive metal, for
example, aluminum.
[0103] The substrate typically comprises an electrical insulator, for example, a polymer
film or other polymeric material. As used herein the terms "polymer", "polymer film",
and "polymeric material" include, but are not limited to, homopolymers, copolymers,
such as for example, block, graft, random, and alternating copolymers, terpolymers,
etc. and blends and modifications thereof. Furthermore, unless otherwise specifically
limited, the term "polymer" shall include all possible geometrical configurations
of the molecule. These configurations include, but are not limited to isotactic, syndiotactic,
and random symmetries.
[0104] The thickness of the film typically may be from about 8.89 µm to about 0.254 mm (about
35 gauge to about 10 mil). In one aspect, the thickness of the film is from about
10.16 µm to about 20.32 µm (about 40 to about 80 gauge). In another aspect, the thickness
of the film is from about 11.43 to about 12.7 µm (about 45 to about 50 gauge). In
still another aspect, the thickness of the film is about 12.192 µm (48 gauge). Examples
of polymer films that may be suitable include, but are not limited to, polyolefins,
polyesters, polyamides, polyimides, polysulfones, polyether ketones, cellophanes,
or any combination thereof. Other non-conducting substrate materials such as paper
and paper laminates, metal oxides, silicates, cellulosics, or any combination thereof,
also may be used.
[0105] In one example, the polymer film comprises polyethylene terephthalate (PET). Polyethylene
terephthalate films are used in commercially available susceptors, for example, the
QWIKWAVE® Focus susceptor and the MICRORITE® susceptor, both available from Graphic
Packaging International (Marietta, Georgia). Examples of polyethylene terephthalate
films that may be suitable for use as the substrate include, but are not limited to,
MELINEX®, commercially available from DuPont Teijan Films (Hopewell, Virginia), SKYROL,
commercially available from SKC, Inc. (Covington, Georgia), and BARRIALOX PET, available
from Toray Films (Front Royal, VA), and QU50 High Barrier Coated PET, available from
Toray Films (Front Royal, VA).
[0106] The polymer film may be selected to impart various properties to the microwave interactive
structure, for example, printability, heat resistance, or any other property. As one
particular example, the polymer film may be selected to provide a water barrier, oxygen
barrier, or a combination thereof. Such barrier film layers may be formed from a polymer
film having barrier properties or from any other barrier layer or coating as desired.
Suitable polymer films may include, but are not limited to, ethylene vinyl alcohol,
barrier nylon, polyvinylidene chloride, barrier fluoropolymer, nylon 6, nylon 6,6,
coextruded nylon 6/EVOH/nylon 6, silicon oxide coated film, barrier polyethylene terephthalate,
or any combination thereof.
[0107] One example of a barrier film that may be suitable for use with the present invention
is CAPRAN® EMBLEM 1200M nylon 6, commercially available from Honeywell International
(Pottsville, Pennsylvania). Another example of a barrier film that may be suitable
is CAPRAN® OXYSHIELD OBS monoaxially oriented coextruded nylon 6/ethylene vinyl alcohol
(EVOH)/nylon 6, also commercially available from Honeywell International. Yet another
example of a barrier film that may be suitable for use with the present invention
is DARTEK® N-201 nylon 6,6, commercially available from Enhance Packaging Technologies
(Webster, New York). Additional examples include BARRIALOX PET, available from Toray
Films (Front Royal, VA) and QU50 High Barrier Coated PET, available from Toray Films
(Front Royal, VA), referred to above.
[0108] Still other barrier films include silicon oxide coated films, such as those available
from Sheldahl Films (Northfield, Minnesota). Thus, in one example, a susceptor may
have a structure including a film, for example, polyethylene terephthalate, with a
layer of silicon oxide coated onto the film, and ITO or other material deposited over
the silicon oxide. If needed or desired, additional layers or coatings may be provided
to shield the individual layers from damage during processing.
[0109] The barrier film may have an oxygen transmission rate (OTR) as measured using ASTM
D3985 of less than about 20 cm
3/m
2/day (cc/m
2/day). In one aspect, the barrier film has an OTR of less than about 10 cm
3/m
2/day (cc/m
2/day). In another aspect, the barrier film has an OTR of less than about 1 cm
3/m
2/day (cc/m
2/day). In still another aspect, the barrier film has an OTR of less than about 0.5
cm
3/m
2/day (cc/m
2/day). In yet another aspect, the barrier film has an OTR of less than about 0.1 cm
3/m
2/day (cc/m
2/day),
[0110] The barrier film may have a water vapor transmission rate (WVTR) of less than about
100 g/m
2/day as measured using ASTM F1249. In one aspect, the barrier film has a WVTR of less
than about 50 g/m
2/day. In another aspect, the barrier film has a WVTR of less than about 15 g/m
2/day. In yet another aspect, the barrier film has a WVTR of less than about 1 g/m
2/day. In still another aspect, the barrier film has a WVTR of less than about 0.1
g/m
2/day. In a still further aspect, the barrier film has a WVTR of less than about 0.05
g/m
2/day.
[0111] Other non-conducting substrate materials such as metal oxides, silicates, cellulosics,
or any combination thereof, also may be used in accordance with the present invention.
[0112] The microwave energy interactive material may be applied to the substrate in any
suitable manner, and in some instances, the microwave energy interactive material
is printed on, extruded onto, sputtered onto, evaporated on, or laminated to the substrate.
The microwave energy interactive material may be applied to the substrate in any pattern,
and using any technique, to achieve the desired heating effect of the food item. For
example, the microwave energy interactive material may be provided as a continuous
or discontinuous layer or coating including circles, loops, hexagons, islands, squares,
rectangles, octagons, and so forth. Examples of various patterns and methods that
may be suitable for use with the present invention are provided in
U.S. Patent Nos. 6,765,182;
6,717,121;
6,677,563;
6,552,315;
6,455,827;
6,433,322;
6,410,290;
6,251,451;
6,204,492;
6,150,646;
6,114,679;
5,800,724;
5,759,418;
5,672,407;
5,628,921;
5,519,195;
5,420,517;
5,410,135;
5,354,973;
5,340,436;
5,266,386;
5,260,537;
5221,419;
5,213,902;
5,117,078;
5,039,364;
4,963,420;
4,936,935;
4,890,439;
4,775,771;
4,865,921; and
Re. 34,683. Although particular examples of patterns of microwave energy interactive material
are shown and described herein, it should be understood that other patterns of microwave
energy interactive material are contemplated by the present invention.
[0113] It will be understood that while susceptor elements are discussed in detail herein,
numerous other microwave energy interactive elements and combinations thereof are
contemplated hereby. For example, the microwave interactive element may comprise a
foil (not shown) having a thickness sufficient to shield one or more selected portions
of the food item from microwave energy (sometimes referred to as a "shielding element").
Such shielding elements may be used where the food item is prone to scorching or drying
out during heating.
[0114] The shielding element may be formed from various materials and may have various configurations,
depending on the particular application for which the shielding element is used. Typically,
the shielding element is formed from a conductive, reflective metal or metal alloy,
for example, aluminum, copper, or stainless steel. The shielding element generally
may have a thickness of from about 0.0007239 to about 0.127 cm (about 0.000285 inches
to about 0.05 inches). In one aspect, the shielding element has a thickness of from
about 0.000762 to about 0.0762 cm (about 0.0003 inches to about 0.03 inches). In another
aspect, the shielding element has a thickness of from about 0.000889 to about 0.0508
cm (about 0.00035 inches to about 0.020 inches), for example, 0.04064 cm (0.016 inches).
[0115] As still another example, the microwave interactive element may comprise a segmented
foil, such as, but not limited to, those described in
U.S. Patent Nos. 6,204,492,
6,433,322,
6,552,315, and
6,677,563. Although segmented foils are not continuous, appropriately spaced groupings of such
segments often act as a transmitting element to direct microwave energy to specific
areas of the food item. Such foils also may be used in combination with other elements,
for example, susceptors.
[0116] It will be understood that with some combinations of elements and materials, the
microwave interactive material or element may have a grey or silver color this is
visually distinguishable from the substrate or the other components in the structure.
However, in some instances, it may be desirable to provide a structure having a uniform
color and/or appearance. Such a structure may be more aesthetically pleasing to a
consumer, particularly when the consumer is accustomed to packages, containers, trays,
or other constructs having certain visual attributes, for example, a solid color,
a particular pattern, and so on. Thus, for example, the present invention contemplates
using a silver or grey toned adhesive to join the microwave interactive elements to
the substrate, using a silver or grey toned substrate to mask the presence of the
silver or grey toned microwave interactive element, using a dark toned substrate,
for example, a black toned substrate, to conceal the presence of the silver or grey
toned microwave interactive element, overprinting the metallized side of the web with
a silver or grey toned ink to obscure the color variation, printing the non-metallized
side of the structure with a silver or grey ink or other concealing color in a suitable
pattern or as a solid color layer to mask or conceal the presence of the microwave
interactive element, or any other suitable technique or combination thereof.
[0117] The present invention may be understood further by way of the following examples,
which are not to be construed as limiting in any manner.
EXAMPLE 1
[0118] A construct according to
FIGS. 1A-1D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
L1 was about 15.24 cm (6.0 in.),
L2 was about 13.97 cm (5.5 in.),
L3 was about 0.71 cm (0.28 in.),
L4 was about 2.39 cm (0.94 in.),
L5 was about 4.83 cm (1.9 in.),
L6 was about 15.75 cm (6.2 in.),
L7 was about 13.72 cm (5.4 in.),
L8 was about 1.07 cm (0.42 in.),
R1 was about 0.635 cm (0.25 in.),
R2 was about 0.635 cm (0.25 in.), and
R3 was about 0.635 cm (0.25 in.). However, other suitable dimensions are contemplated
hereby. A 48 gauge metallized polyethylene terephthalate film (i.e., a susceptor film)
was joined to the construct, substantially as illustrated in
FIG. 1E.
EXAMPLE 2
[0119] A construct according to
FIGS. 1A-1D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
L1 was about 15.24 cm (6.0 in.),
L2 was about 13.97 cm (5.5 in.), L3 was about 0.71 cm (0.28 in.), L4 was about 2.39
cm (0.94 in.), L5 was about 4.83 cm (1.9 in.), L6 was about 15.75 cm (6.2 in.), L7
was about 13.72 cm (5.4 in.),
L8 was about 1.07 cm (0.42 in.),
R1 was about 0.635 cm (0.25 in.),
R2 was about 0.635 cm (0.25 in.), and R3 was about 0.635 cm (0.25 in.). However, other
suitable dimensions are contemplated hereby. A 12.192 µm (48 gauge) metallized polyethylene
terephthalate film (i.e., a susceptor film) was joined to the construct, substantially
as illustrated in FIG. 2.
EXAMPLE 3
[0120] A construct according to
FIGS. 1A-1D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
L1 was about 15.24 cm (6.0 in.), L2 was about 13.97 cm (5.5 in.),
L3 was about 0.71 cm (0.28 in.), L4 was about 2.39 cm (0.94 in.), L5 was about 4.83
cm (1.9 in.),
L6 was about 15.75 cm (6.2 in.), L7 was about 13.72 cm (5.4 in.),
L8 was about 1.07 cm (0.42 in.),
R1 was about 0.635 cm (0.25 in.),
R2 was about 0.635 cm (0.25 in.), and
R3 was about 0.635 cm (0.25 in.). However, other suitable dimensions are contemplated
hereby. A 12.192 µm (48 gauge) metallized polyethylene terephthalate film (i.e., a
susceptor film) was joined to the construct, substantially as illustrated in
FIG. 3.
EXAMPLE 4
[0121] A construct according to FIGS.
1A-1D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
L1 was about 15.24 cm (6.0 in.), L2 was about 13.97 cm (5.5 in.),
L3 was about 0.71 cm (0.28 in.), L4 was about 2.39 cm (0.94 in.),
L5 was about 4.83 cm (1.9 in.), L6 was about 15.75 cm (6.2 in.), L7 was about 13.72
cm (5.4 in.), L8 was about 1.07 cm (0.42 in.),
R1 was about 0.635 cm (0.25 in.),
R2 was about 0.635 cm (0.25 in.), and
R3 was about 0.635 cm (0.25 in.). However, other suitable dimensions are contemplated
hereby. A 12.192 µm (48 gauge) metallized polyethylene terephthalate film (i.e., a
susceptor film) was joined to the construct, substantially as illustrated in FIG.
4.
EXAMPLE 5
[0122] A construct according to FIGS.
1A-1D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
L1 was about 15.24 cm (6.0 in.), L2 was about 13.97 cm (5.5 in.), L3 was about 0.71
cm (0.28 in.), L4 was about 2.39 cm (0.94 in.),
L5 was about 4.83 cm (1.9 in.), L6 was about 15.75 cm (6.2 in.), L7 was about 13.72
cm (5.4 in.), L8 was about 1.07 cm (0.42 in.),
R1 was about 0.635 cm (0.25 in.), R2 was about 0.635 cm (0.25 in.), and
R3 was about 0.635 cm (0.25 in.). However, other suitable dimensions are contemplated
hereby. A 12.192 µm (48 gauge) metallized polyethylene terephthalate film (i.e., a
susceptor film) was joined to the construct, as substantially as illustrated in FIG.
5.
EXAMPLE 6
[0123] A construct according to
FIGS. 6A-6D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.), H2 was about 0.152 cm (0.060) in.,
L1 was about 15.24 cm (6.0 in.), L2 was about 13.97 cm (5.5 in.), L3 was about 0.71
cm (0.28 in.), L4 was about 2.39 cm (0.94 in.), L5 was about 4.83 cm (1.9 in.), L6
was about 15.75 cm (6.2 in.), L7 was about 13.72 cm (5.4 in.), L8 was about 2.54 cm
(1.0 in.), L9 was about 1.07 cm (0.42 in.),
R1 was about 0.635 cm (0.25 in.), R2 was about 0.635 cm (0.25 in.), R3 was about 0.635
cm (0.25 in.), and R4 was about 0.635 cm (0.25 in.). However, other suitable dimensions
are contemplated hereby. A 12.192 µm (48 gauge) metallized polyethylene terephthalate
film (i.e., a susceptor film) was joined to the construct overlying various components,
including at least a portion of the top faces 608 of the platforms 604.
EXAMPLE 7
[0124] A construct according to
FIGS. 7A-7D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.), H2 was about 0.940 cm (0.37 in.),
L1 was about 19.81 cm (7.8 in.),
L2 was about 13.21 cm (5.2 in.),
L3 was about 4.83 cm (1.9 in.),
L4 was about 5.59 cm (2.2 in.),
L5 was about 2,39 cm (0.94 in.),
L6 was about 4.83 cm (1.9 in.),
L7 was about 15.75 cm (6.2 in.),
L8 was about 16.26 cm (6.4 in.),
L9 was about 17.53 cm (6.9 in.),
L10 was about 2.54 cm (1.0 in.),
L11 was about 0.48 cm (0.19 in.),
R1 was about 0.635 cm (0.25 in.),
R2 was about 0.635 cm (0.25 in.),
R3 was about 0.635 cm (0.25 in.),
R4 was about 0.635 cm (0.25 in.),
R5 was about 0.635 cm (0.25 in.),
R6 was about 5.84 cm (2.3 in.),
R7 was about 4.57 cm (1.8 in.), and
A1 was about 18°. However, other suitable dimensions are contemplated hereby. A 12.192
µm (48 gauge) metallized polyethylene terephthalate film (i.e., a susceptor film)
was joined to the construct overlying various components, including at least a portion
of the top faces
708 of the platforms
704.
EXAMPLE 8
[0125] A construct according to
FIGS. 8A-8D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
H2 was about 0.152 cm (0.060 in.),
L1 was about 15.24 cm (6.0 in.),
L2 was about 13.97 cm (5.5 in.),
L3 was about 0.71 cm (0.28 in.),
L4 was about 2.39 cm (0.94 in.),
L5 was about 4.83 cm (1.9 in.),
L6 was about 15.75 cm (6.2 in.),
L7 was about 13.72 cm (5.4 in.),
L8 was about 1.07 cm (0.42 in.),
L9 was about 3.81 cm (1.5 in.),
L10 was about 2.54 cm (1.0 in.),
R1 was about 0.635 cm (0.25 in.),
R2 was about 0.635 cm (0.25 in.),
R3 was about 0.635 cm (0.25 in.), and
R4 was about 0.635 cm (0.25 in.). However, other suitable dimensions are contemplated
hereby. A 12.192 µm (48 gauge) metallized polyethylene terephthalate film (i.e., a
susceptor film) was joined to the construct overlying various components, including
at least a portion of the top faces
808 of the platforms
804.
EXAMPLE 9
[0126] A construct according to
FIGS. 9A-9E may have the following approximate dimensions:
H1 may be about 0.48 cm (0.19 in.),
H2 may be about 0.102 cm (0.040 in.),
L1 may be about 15.24 cm (6.0 in.),
L2 may be about 13.97 cm (5.5 in.),
L3 may be about 0.71 cm (0.28 in.),
L4 may be about 2.39 cm (0.94 in.),
L5 may be about 15.75 cm (6.2 in.),
L6 may be about 13.72 cm (5.4 in.),
L7 may be about 1.07 cm (0.42 in.),
L8 may be about 1.91 cm (0.75 in.),
R1 may be about 0.635 cm (0.25 in.),
R2 may be about 0.635 cm (0.25 in.),
R3 may be about 0.635 cm (0.25 in.), and
R4 may be about 0.635 cm (0.25 in.). However, other suitable dimensions are contemplated
hereby. A susceptor film or other microwave energy interactive element may overlie
at least a portion of the construct.
EXAMPLE 10
[0127] A construct according to
FIGS. 10A-10D was formed with the following approximate dimensions:
H1 was about 0.69 cm (0.27 in.),
H2 was about 0.152 cm (0.060 in.),
L1 was about 15.24 cm (6.0 in.), L2 was about 14.48 cm (5.7 in.),
L3 was about 0.43 cm (0.17 in.),
L4 was about 2.79 cm (1.1 in.),
L5 was about 4.83 cm (1.9 in.),
L6 was about 15.75 cm (6.2 in.),
L7 was about 13.97 cm (5.5 in.),
L8 was about 0.91 cm (0.36 in.),
L9 was about 3.81 cm (1.5 in.),
L10 was about 2.54 cm (1.0 in.),
R1 was about 0.635 cm (0.25 in.),
R2 was about 0.635 cm (0.25 in.),
R3 was about 0.635 cm (0.25 in.), and
R4 was about 0.635 cm (0.25 in.), However, other suitable dimensions are contemplated
hereby. A 12.192 µm (48 gauge) metallized polyethylene terephthalate film (i.e., a
susceptor film) was joined to the construct overlying various components, including
at least a portion of the top faces
1008 of the platforms
1004.
EXAMPLE 11
[0128] A construct according to
FIGS. 11A-11E was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
H2 was about 0.48 cm (0.19 in.),
H3 was about 0.635 cm (0.25 in.),
H4 was about 0.94 cm (0.37 in.),
L1 was about 19.30 em (7.6 in.),
L2 was about 13.72 cm (5.4 in.),
L3 was about 5.08 cm (2.0 in.),
L4 was about 5.59 cm (2.2 in.),
L5 was about 16.76 cm (6.6 in.),
L6 was about 15.75 cm (6.2 in.), L7 was about 13.97 cm (5.5 in.),
L8 was about 15.24 cm (6.0 in.), L9 was about 0.48 cm (0.19 in.),
R1 was about 5.59 cm (2.2 in.),
R2 was about 4.32 cm (1.7 in.),
R3 was about 1.27 cm (0.50 in.),
R4 was about 0.41 cm (0.16 in.),
R5 was about 0.203 cm (0.080 in.),
R6 was about 0.635 cm (0.25 in.),
R7 was about 0.48 cm (0.19 in.),
R8 was about 0.051 cm (0.020 in.),
R9 was about 0.635 cm (0.25 in.),
A1 was about 18°,
A2 was about 30°, and
A3 was about 15°. However, other suitable dimensions are contemplated hereby. A 12.192
µm (48 gauge) metallized polyethylene terephthalate film (i.e., a susceptor film)
was joined to the construct overlying various components, including at least a portion
of the top faces
1118 of the platforms 1110.
EXAMPLE 12
[0129] A construct according to
FIGS. 12A-12D was formed with the following approximate dimensions:
H1 was about 0.48 cm (0.19 in.),
H2 was about 0.94 cm (0.37 in.),
L1 was about 19.81 cm (7.8 in.),
L2 was about 13.97 cm (5.5 in.),
L3 was about 5.08 cm (2.0 in.),
L4 was about 5.59 cm (2.2 in.),
L5 was about 2.79 cm (1.1 in.),
L6 was about 17.53 cm (6.9 in.) (square),
L7 was about 16.26 cm (6.4 in.) (square),
L8 was about 2.54 cm (1.0 in.),
L9 was about 15.75 cm (6.2 in.) (square),
L10 was about 0.48 cm (0.19 in.),
R1 was about 5.84 cm (2.3 in.),
R2 was about 4.57 cm (1.8 in.),
R3 was about 1.27 cm (0.50 in.),
R4 was about 0.635 cm (0.25 in.),
R5 was about 0.635 cm (0.25 in.),
R6 was about 0.48 cm (0.19 in.),
R7 was about 0.48 cm (0.19 in.),
R8 was about 0.635 cm (0.25 in.),
R9 was about 0.635 cm (0.25 in.),
R10 was about 0.48 cm (0.19 in.), and
A1 was about 18°. However, other suitable dimensions are contemplated hereby. A 12.192
µm (48 gauge) metallized polyethylene terephthalate film (i.e., a susceptor film)
was joined to the construct overlying various components, including at least a portion
of the top faces
1218 of the platforms
1210.
EXAMPLE 13
[0130] A construct according to
FIGS. 14A-14E may be formed with the following approximate dimensions:
H1 may be about 0.635 cm (0.25 in.),
H2 may be about 2.54 cm (1 in.),
L1 may be about 23.37 cm (9.2 in.),
L2 may be about 24.38 cm (9.6 in.),
L3 may be about 23.37 cm (9.2 in.),
L4 may be about 17.78 cm (7.0 in.),
L5 may be about 21.59 cm (8.5 in.),
L6 may be about 17.78 cm (7.0 in.),
L7 may be about 16.76 cm (6.6 in.),
L8 may be about 11.18 cm (4.4 in.),
L9 may be about 14.99 cm (5.9 in.),
L10 may be about 0.48 cm (0.19 in.),
L11 may be about 17.02 cm (6.7 in.),
L12 may be about 16.23 cm (6.4 in.), L13 may be about 10.67 cm (4.2 in.),
L14 may be about 14.22 cm (5.6 in.),
R1 may be about 3,30 cm (1.3 in.),
R2 may be about 2.79 cm (1.1 in.),
R3 may be about 2.79 cm (1.1 in.),
R4 may be about 1.98 cm (0.78 in.),
R5 may be about 1.42 cm (0.56 in.),
R6 may be about 1.22 cm (0.48 in.),
R7 may be about 0.635 cm (0.25 in.),
R8 may be about 0.635 cm (0.25 in.), and
A1 may be about 21°. Other suitable dimensions are contemplated hereby. A susceptor
film or other microwave energy interactive element may overlie at least a portion
of the construct.
EXAMPLE 14
[0131] A construct according to
FIGS. 15A-15F may be formed with the following approximate dimensions:
H1 may be about 0.635 cm (0.25 in.),
H2 may be about 0.16 cm (0.063 in.),
H3 may be about 2.54 cm (1.0 in.),
L1 may be about 23.37 cm (9.2 in.),
L2 may be about 24.38 cm (9.6 in.),
L3 may be about 23.37 cm (9.2 in.),
L4 may be about 17.78 cm (7.0 in.),
L5 may be about 21.59 cm (8.5 in.),
L6 may be about 2.54 cm (1.0 in.),
L7 may be about 17.78 cm (7.0 in.),
L8 may be about 16.76 cm (6.6 in.),
L9 may be about 11.18 cm (4.4 in.),
L10 may be about 14.99 cm (5.9 in.),
L11 may be about
0.51 cm (0.2 in.),
L12 may be about 17.02 cm (6.7 in.),
L13 may be about 16.26 cm (6.4 in.),
L14 may be about 10.67 cm (4.2 in.),
L15 may be about 14.22 cm (5.6 in.),
R1 may be about 3.30 cm (1.3 in.),
R2 may be about 2.79 cm (1.1 in.),
R3 may be about 2.79 cm (1.1 in.),
R4 may be about 1.98 cm (0.78 in.),
R5 may be about 1.42 cm (0.56 in.),
R6 may be about 0.635 cm (0.25 in.),
R7 may be about 0.635 cm (0.25 in.),
R8 may be about 0.635 cm (0.25 in.), and
A1 may be about 21°. Other suitable dimensions arc contemplated hereby. A susceptor
film or other microwave energy interactive element may overlie at least a portion
of the construct.
EXAMPLE 15
[0132] A construct according to
FIGS. 16A-16F may be formed with the following approximate dimensions:
H1 may be about 0.635 cm (0.25 in.),
H2 may be about 0.16 cm (0.063 in.),
H3 may be about 2.54 cm (1.0 in.),
L1 may be about 23.37 cm (9.2 in.),
L2 may be about 24.38 cm (9.6 in.),
L3 may be about 23.37 cm (9.2 in.),
L4 may be about 17.78 cm (7.0 in.),
L5 may be about 21.59 cm (8.5 in.),
L6 may be about 2.54 cm (1.0 in.),
L7 may be about 17.78 cm (7.0 in.),
L8 may be about 16.76 cm (6.6 in.),
L9 may be about 11.18 cm (4.4 in.),
L10 may be about 14.99 cm (5.9 in.),
L11 may be about 0.51 cm (0.2 in.),
L12 may be about 17.02 cm (6.7 in.), L13 may be about 16.26 cm (6.4 in.),
L14 may be about 10.67 cm (4.2 in.),
L15 may be about 14.22 cm (5.6 in.),
R1 may be about 3.30 cm (1.3 in.),
R2 may be about 2.79 cm (1.1 in.),
R3 may be about 2.79 cm (1.1 in.),
R4 may be about 1.98 cm (0.78 in.),
R5 may be about 1.42 cm (0.56 in.),
R6 may be about 0.635 cm (0.25 in.),
R7 may be about 0.635 cm (0.25 in.),
R8 may be about 0.635 cm (0.25 in.), and
A1 may be about 21°. Other suitable dimensions are contemplated hereby. A susceptor
film or other microwave energy interactive element may overlie at least a portion
of the construct.
EXAMPLE 16
[0133] A construct according to
FIGS. 17A-17E may be formed with the following approximate dimensions:
H1 may be about 0.635 cm (0.25 in.),
L1 may be about 20.07 cm (7.9 in.),
L2 may be about 2.54 cm (1.0 in.),
L3 may be about 15.24 cm (6.0 in.),
L4 may be about 16.26 cm (6.4 in.),
R1 may be about 1.78 cm (0.70 in.),
R2 may be about 1.37 cm (0.54 in.),
R3 may be about 0.91 cm (0.36 in.),
R4 may be about 22.86 cm (9.0 in.),
R5 may be about 0.635 cm (0.25 in.),
R6 may be about 1.27 cm (0.50 in.),
R7 may be about 0.635 cm (0.25 in.), and
A1 may be about
45°. Other suitable dimensions are contemplated hereby. A susceptor film or other microwave
energy interactive element may overlie at least a portion of the construct.
EXAMPLE 17
[0134] A construct according to
FIGS. 18A-18E may be formed with the following approximate dimensions:
H1 may be about 0.635 cm (0.25 in.),
L1 may be about 20.07 cm (7.9 in.),
L2 may be about 2.54 cm (1.0 in.),
L3 may be about 15.24 cm (6.0 in.),
L4 may be about 16.26 cm (6.4 in.),
R1 may be about 1.78 cm (0.70 in.),
R2 may be about 1.37 cm (0.54 in.),
R3 may be about 0.91 cm (0.36 in.),
R4 may be about 22.86 cm (9.0 in.),
R5 may be about 0.635 cm (0.25 in.),
R6 may be about 1.27 cm (0.50 in.),
R7 may be about 0.635 cm (0.25 in.),
A1 may be about 45°, and
A2 may be about 18°. Other suitable dimensions are contemplated hereby. A susceptor
film or other microwave energy interactive element may overlie at least a portion
of the construct.
EXAMPLE 18
[0135] A construct according to
FIGS. 19A-19E may be formed with the following approximate dimensions:
H1 may be about 2.54 cm (1.0 in.),
H2 may be about 0.635 cm (0.25 in.),
L1 may be about 25.4 cm (10 in.),
L2 may be about 21.84 cm (8.6 in.), L3 may be about 19.05 cm (7.5 in.),
L4 may be about 2.54 cm (1.0 in.),
L5 may be about 0.30 cm (0.12 in.),
L6 may be about 20.07 cm (7.9 in.),
L7 may be about 19.05 cm (7.5 in.),
L8 may be about 13.46 cm (5.3 in.),
L9 may be about 17.02 cm (6.7 in.),
L10 may be about 21.08 cm (8.3 in.),
L11 may be about 20.07 cm (7.9 in.),
L12 may be about 14.48 cm (5.7 in.),
L13 may be about 18.29 cm (7.2 in.),
R1 may be about 3.30 cm (1.3 in.),
R2 may be about 2.79 cm (1.1 in.),
R3 may be about 2.79 cm (1.1 in.),
R4 may be about 1.98 cm (0.78 in.),
R5 may be about 1.42 cm (0.56 in.),
R6 may be about 0.635 cm (0.25 in.),
R7 may be about 0.635 cm (0.25 in.),
R8 may be about 1.27 cm (0.50 in.),
R9 may be about 0.635 cm (0.25 in.),
R10 may be about 0.635 cm (0.25 in.), and
A1 may be about 20°. Other suitable dimensions are contemplated hereby. A susceptor
film or other microwave energy interactive element may overlie at least a portion
of the construct.
EXAMPLES 19-30
[0136] Commercially available frozen Lean Cuisine
(™
) and Corner Bistro
(™
) panini type sandwiches were evaluated using various trays and microwave ovens. Each
sandwich was heated at full power for about 3 minutes and 20 seconds unless indicated
otherwise. The results of the evaluations are presented in
Table 1, where:
Control disk = a corrugated board with a susceptor overlying one surface and six elongated
apertures with rounded, enlarged ends extending through the thickness of the disk
(provided with the food items);
LC = Lean Cuisine(™);
CB = Corner Bistro(™);
A = 1000W Amana(™), 0.0255 m3 (0.9 cu. ft.), 31.75 cm (12.5 in.) turnable diameter;
B = 1100W Panasonic(™), 0.0283 m3 (1.0 cu. ft.), 34.29 cm (13.5 in.) turntable diameter;
C = 1200W Panasonic(™), 0.0255 m3 (0.9 cu. ft.), 34.29 cm (13.5 in.) turnable diameter;
D = 1000W Amana Radarange(™), 0.0311 m3 (1.1 cu. ft.), no turntable;
E = 800W Panasonic(™), 0.0198 m3 (0.7 cu. ft.), 24.13 cm (9.5 in.) turntable diameter;
F = 700W Samsung(™), 0.0198 m3 (0.7 cu. ft.), 27.94 cm (11 in.) turntable diameter; and
G = 1100W Panasonic(™), 0.0311 m3 (1.1 cu. ft.), 35.56 cm (14 in.) turntable diameter (cook time increased to 4 min);
and where:
0 = no browning and/or crisping;
7 = optimal browning and/or crisping; and
1, 2, 3, 4, 5, and 6 = various intermediate degrees of browning and/or crisping between
0 and 7.
Table 1.
| Example |
Food item |
Microwave oven |
Control disk |
Tray with tapered platforms (FIG. 2, Example 2) |
Tray with tapered platforms (FIG. 3, Example 3) |
Tray with tapered platforms (FIG. 4, Example 4) |
Tray with tapered platforms and slot apertures (FIG. 5, Example 5) |
Tray with tapered platforms and venting channels (FIGS. 8A-8D, Example 8) |
Tray with tapered platforms and venting channels (FIGS. 10A-10D, Example 10) |
| 19 |
LC |
A |
0 |
2 |
- |
- |
4 |
6 |
7 |
| 20 |
LC |
B |
0 |
5 |
- |
- |
5 |
6 |
6 |
| 21 |
LC |
C |
0 |
5 |
- |
- |
0 |
6 |
5 |
| 22 |
LC |
D |
0 |
5 |
- |
- |
2 |
7 |
6 |
| 23 |
LC |
E |
0 |
1 |
- |
- |
0 |
7 |
6 |
| 24 |
LC |
F |
0 |
3 |
- |
- |
1 |
2 |
2 |
| 25 |
LC |
G |
0 |
0 |
- |
- |
2 |
3 |
0 |
| 26 |
CB |
A |
0 |
- |
4 |
3 |
- |
5 |
7 |
| 27 |
CB |
B |
2 |
- |
5 |
7 |
- |
7 |
6 |
| 28 |
CB |
C |
3 |
- |
4 |
6 |
- |
5 |
6 |
| 29 |
LC |
A |
0 |
- |
4 |
1 |
- |
5 |
6 |
| 30 |
LC |
B |
1 |
- |
7 |
7 |
- |
5 |
6 |
| AVG |
- |
- |
0.5 |
3 |
4.8 |
4.8 |
2 |
5.3 |
3.6 |
EXAMPLE 31
[0137] Commercially available frozen Stouffer's Corner Bistro
(™
) grilled chicken Italian panini sandwiches were heated using various trays to compare
the level of browning achieved on the surface of the food item.
[0138] A first sandwich was placed in an open face configuration on the susceptor disk provided
with the sandwich (referred to as "Control disk" in Examples 19-30). The sandwich
was heated according to package directions for 3 minutes in an 1100W Panasonic
(™
) microwave oven.
[0139] A second sandwich was heated for 3 minutes in the same 1100W Panasonic
(™
) microwave oven using a tray according to the invention, substantially as shown in
FIGS. 8A-8D, having the dimensions provided in Example 8.
[0140] A Konica Minolta
(™
) BC-10 baking meter having an aperture size of about 1,111 cm (7/16 in. (0.4375 in.))
was used to measure the level of browning on the surface of each piece of bread at
designated locations, as indicated schematically in
FIG. 20. The measurements taken at each position were averaged for the two pieces of bread
in each sandwich. The results are presented in baking contrast units ("BCU"), where
the lower the BCU, the darker the color (i.e., the greater degree of browning). The
results of the evaluation are presented in
Table 2.
Table 2.
| Position |
Control disk |
Experimental disk |
| 1 |
3.85 |
2.85 |
| 2 |
3.88 |
2.67 |
| 3 |
3.40 |
1.95 |
| 4 |
3.67 |
2.77 |
| 5 |
3.92 |
3.33 |
| 6 |
3.90 |
2.88 |
| 7 |
4.02 |
3.39 |
| 8 |
4.10 |
3.25 |
| 9 |
4.09 |
3.55 |
| 10 |
4.03 |
2.14 |
| Average BCU |
3.90 |
2.96 |
[0141] Although certain embodiments of this invention have been described with a certain
degree of particularity, those skilled in the art could make numerous alterations
to the disclosed embodiments without departing from the scope of this invention. All
directional references (e.g., upper, lower, upward, downward, left, right, leftward,
rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise)
are used only for identification purposes to aid the reader's understanding of the
various embodiments of the present invention, and do not create limitations, particularly
as to the position, orientation, or use of the invention unless specifically set forth
in the claims. Joinder references (e.g., joined, attached, coupled, connected, and
the like) are to be construed broadly and may include intermediate members between
a connection of elements and relative movement between elements. As such, joinder
references do not necessarily imply that two elements are connected directly and in
fixed relation to each other.
[0142] It will be recognized by those skilled in the art, that various elements discussed
with reference to the various embodiments may be interchanged to create entirely new
embodiments coming within the scope of the present invention as defined by the claims.
It is intended that all matter contained in the above description or shown in the
accompanying drawings shall be interpreted as defined by the claims. Changes in detail
or structure may be made without departing from the scope of the invention as defined
in the appended claims.
[0143] Accordingly, it will be readily understood by those persons skilled in the art that,
in view of the above detailed description of the invention, the present invention
is susceptible of broad utility and application. Many adaptations of the present invention
other than those herein described, as well as many variations, modifications, and
equivalent arrangements will be apparent from or reasonably suggested by the present
invention and the above detailed description thereof, without departing from the substance
or scope of the present invention.