US20140339105A1 - Packaging for food product - Google Patents

Abstract

A package for a food product can include a single film formable using, e.g., flow-wrapping, to enclose the food product. At least one portion of the single film may be made up of an absorbent material laminated to the single film, the absorbent material adapted to absorb moisture within the package. The at least one portion may be utilized as a base upon which the food product can be placed. Fins or overlapping seals may be configured on at least two edges of the single film allowing a fin seal or overlapping seal to be created thereby further allowing the single film to substantially enclose the food product. Crimped seals may further be employed to completely seal the food product within the single film. The fin seal or the overlapping seal and the crimped seals may be self-venting to release accumulated steam/moisture during a cooking or preparation process.

Description

• This application claims the benefit of co-pending U.S. Provisional Application Ser. No. 61/838,179 (“the '179 provisional”) filed on Jun. 21, 2013. This application is also a continuation-in-part of co-pending U.S. patent application Ser. No. 14/022,137 (“the '137 application”) filed on Sep. 9, 2013 and a continuation-in-part of co-pending U.S. patent application Ser. No. 13/884,599 (“the '599 application”) filed on Jul. 22, 2013. The '137 application is a continuation of U.S. patent application Ser. No. 12/943,769 (“the '769 application”) filed on Nov. 10, 2010 and a continuation-in-part of U.S. patent application Ser. No. 12/116,109 (“the '109 application) filed on May 6, 2008. The '109 application claims the benefit of U.S. Provisional Application Ser. No. 60/928,547 (“the '547 provisional”) filed on May 10, 2007. The '599 application is a U.S. National Stage Entry of PCT Application Serial No. PCT/US11/060001 (“the '001 PCT application”) filed on Nov. 9, 2011 and a continuation-in-part of the '769 application. The '001 PCT application claims priority to U.S. Provisional Application Ser. No. 61/453,875 (“the '875 provisional”) filed on Mar. 17, 2011, U.S. Provisional Application Ser. No. 61/460,750 (“the '750 provisional”) filed on Feb. 24, 2011, and the '769 application. The '179 provisional, the '137 application, the '599 application, the '769 application, the '109 application, the '547 provisional, the 001 PCT application, the '875 provisional, and the '750 provisional are all hereby expressly incorporated by reference in their entirety for all purposes. This application is also related to co-pending U.S. application Ser. No. ______ (Attorney Docket No. 00052-0117) filed on even date herewith.
TECHNICAL FIELD
• The present disclosure relates generally to the field of packagings for food products, and more specifically, to packagings for food products that provide a more convenient means for preparing (e.g., microwave cooking, etc.) frozen or refrigerated food products for consumption by consumers.
BACKGROUND
• There are many challenges associated with providing consumers with an easy and effective means for preparing food products using microwave ovens. Some of the long unresolved problems associated with microwave cooking include inconveniences to consumers, dryness/sogginess of food products, and uneven cooking of food products, among others.
• For example, many packaged food products require users to open a packaging, remove a food product, wrap the food product in a separate covering such as paper towel, etc., and then place the wrapped food product into the microwave. Such additional steps take considerable time and are inconvenient for consumers. Further, food products often release moisture during microwave cooking Without proper control of the released moisture, the resulting food product may be soggy, or alternatively, overly dry, and undesirable for consumption. Further yet, many food products are unevenly heated when prepared in a microwave oven, due to improper control of moisture and/or other factors.
• It would be advantageous to provide an improved packaged food product that addresses and/or overcomes one or more of these challenges by providing a user-friendly, easy-to-use, one-step packaged food product that is also aesthetically pleasing in appearance. As such, various embodiments disclosed herein provide a packaged food product that may be microwaveably cooked in a “one-step” fashion, and that includes, among other features, venting and moisture absorption features to control the humidity within the packaging and provide for an optimal moisture content of multi-component food products.
SUMMARY
• One embodiment relates to a package. The package comprises a sheet of film formable about a food product, and an absorbent material laminated to at least one area of the sheet of film. A first edge and a second edge of the sheet of film are sealed together via at least one of a self-venting fin seal and an overlapping seal, creating at least a partially absorbent enclosure for the food product.
• Another embodiment relates to a package. The package comprises a sheet of film formable about a food product, and an absorbent material laminated to an interior surface of the sheet of film. A first edge and a second edge of the sheet of film are further formed into at least one of sealable fins or overlapping portions, the sealable fins or the overlapping portions, when sealed together, creating a moisture absorbent enclosure for the food product.
• Yet another embodiment relates to a packaged food product. The packaged food product comprises a food product, and a package having an interior area containing the food product. The package comprises a length of flow-wrap film, at least one portion of which includes a laminated area. At least two edges of the length of flow-wrap film are sealed together via at least one of a self-venting fin seal or an overlapping seal at least partially forming the interior area, such that the laminated area is configured to absorb moisture within the interior area.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a perspective view of a packaged food product according to an exemplary embodiment.
• FIG. 2 is an exploded perspective view of the packaged food product ofFIG. 1 according to an exemplary embodiment.
• FIG. 3 is an exploded view of a film used in the packaged food product ofFIG. 1 according to an exemplary embodiment.
• FIG. 4 is a cross-section side view of the packaged food product ofFIG. 1 according to an exemplary embodiment.
• FIG. 5 is a perspective view of a packaged food product according to an alternative exemplary embodiment.
• FIG. 6 is an exploded perspective view of the packaged food product ofFIG. 5 according to an exemplary embodiment.
• FIG. 7 is an exploded view of a film used in the packaged food product ofFIG. 5 according to an exemplary embodiment.
• FIG. 8 is a cross-section side view of the packaged food product ofFIG. 5 according to an exemplary embodiment.
• FIG. 9 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 10 is a side view of the packaged food product ofFIG. 9.
• FIG. 11 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 12 is a side view of the packaged food product ofFIG. 11.
• FIG. 13 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 14 is a side view of the packaged food product ofFIG. 13.
• FIG. 15 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 16 is a side view of the packaged food product ofFIG. 15.
• FIG. 17 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 18 is a side view of the packaged food product ofFIG. 17.
• FIG. 19 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 20 is a side view of the packaged food product ofFIG. 19.
• FIG. 21 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 22 is a side view of the packaged food product ofFIG. 21.
• FIG. 23 is a top view of a packaged food product according to an exemplary embodiment.
• FIG. 24 is a side view of the packaged food product ofFIG. 23.
• FIG. 25 is an exploded perspective view of the packaged food product ofFIG. 23.
• FIG. 26 is a schematic side view of a portion of a mechanism for forming a seal for a packaged food product according to an exemplary embodiment.
• FIG. 27 is perspective view of an absorbent member according to an exemplary embodiment.
• FIGS. 28,29,30,31A,31B,32A,32B,33,34,35,36,37A,37B,37C,37D,37E,38A,38B,39A,39B, and39C illustrate seal portions and vent portions usable with food packaging according to various exemplary embodiments.
• FIG. 40 is a perspective view of a packaged food product according to another exemplary embodiment.
• FIG. 41 is a top view of a portion of the packaged food product ofFIG. 40 according to an exemplary embodiment.
• FIG. 42 is a side view of a portion of the packaged food product ofFIG. 40 according to an exemplary embodiment.
• FIGS. 43A and 43B are perspective views of a package according to an exemplary embodiment.
• FIGS. 44A and 44B are perspective views of a package according to another exemplary embodiment.
• FIGS. 45A and 45B are perspective views of a package according to yet another exemplary embodiment.
• FIGS. 46A and 46B are perspective views of a package according to an exemplary embodiment.
• FIGS. 47A and 47B are perspective views of a package according to another exemplary embodiment.
• FIG. 48A and 48B are perspective views of a package according to another exemplary embodiment.
• FIG. 49 is a perspective view of a package according to another exemplary embodiment.
• FIG. 50 is a perspective view of a package according to another exemplary embodiment.
• FIG. 51 is a perspective view of a package according to another exemplary embodiment.
• FIG. 52 is a perspective view of a package according to another exemplary embodiment.
• FIG. 53 is a perspective view of a package according to another exemplary embodiment.
• FIG. 54 is a perspective view of a package according to yet another exemplary embodiment.
DETAILED DESCRIPTION
• Referring toFIG. 1, a packaged food product10 (e.g., a breakfast product, a snack product, etc.) is shown according to an exemplary embodiment. Packagedfood product10 may be any of a variety of packaged food products, including, but not limited to, breakfast items such as breakfast sandwiches, etc., lunch items such as lunch sandwiches, etc., dinner items, snack portions, and the like. As shown inFIG. 1, packagedfood product10 includes afood product12 provided within the interior ofpackaging14.Food product12 may naturally contain moisture that is released whenfood product12 is heated as a result of undergoing a cooking process (e.g., microwave cooking, etc.).
• Referring toFIGS. 1 and 2, according to an exemplary embodiment,food product12 is a multi-component food product and includes a plurality of physically separate food components shown ascomponents16,18, and20. For example, in some embodiments,food product12 may be a breakfast sandwich, such thatcomponent16 may be one or more pieces of biscuit, bun, or similar bread item,component18 may be a sausage, bacon, or other meat item, andcomponent20 may be a cheese, sauce, or other topping item. According to various other embodiments,food product12 may be any of a wide variety of other products, including a lunch sandwich, a snack item, etc. As such,components16,18, and20 may be any of a variety of different components. According to yet other embodiments,food product12 may include fewer or more components than those shown inFIG. 2 (e.g., a single food component, two food components, four or more food components, etc.)
• Further, while in someembodiments food product12 may be intended to be sold to consumers in a frozen state, in otherembodiments food product12 may be intended to be sold to consumers in a refrigerated or other state. Thus, the embodiments herein may extend to preparing packaged food products having food products in either a frozen or refrigerated state.
• According to one embodiment, packaging14 includes a first film22 (e.g., a top film or portion, a formed portion, a forming film, etc.) and a second film24 (e.g., a second film or portion, a flat portion, a non-forming film, etc.). First and/orsecond films22,24 may be formed using any suitable process, including a vacuum-forming process, a flow-wrapping process, etc.First film22 includes a recess28 (e.g., a pocket, receptacle, formed portion, etc.) and a generallyflat portion30 extending aboutrecess28. As discussed in greater detail below, in one embodiment,recess28 is sized to provide a space, or gap42 (e.g., “a steam dome”) aboutfood product12 whenfood product12 is heated in a microwave oven.First film22 may be made from a semi-rigid film material, such as polyesters (e.g., amorphous polyethylene terephthalate (APET), polyethylene terephthalate (PETG), etc.), polyvinyl chloride (PVC), polypropylene (PP) or reduced density PP, high impact polystyrene, and the like. As such,first film22 may have sufficient rigidity to supportfood product12 after heating and during consumption of food product12 (e.g., after removal ofsecond film24 from first film22). In other embodiments,first film22 may be made from a variety of other materials, including various polymer or other materials.
• Referring now toFIGS. 2-4,second film24 is a generally flat film. According to an exemplary embodiment,second film24 includes an absorbent layer configured to absorb at least a portion of the moisture released fromfood product12 during heating of food product12 (e.g., such that liquids, etc. may travel along a path such as that indicated byarrows48,49 shown inFIG. 4). For example, as shown inFIG. 3,second film24 may include an absorbent layer36 (e.g., a paper material, etc.). In one embodiment,second film24 may be a substantially rigid film. In other embodiments, part or all ofsecond film24 may be a semi-rigid or flexible film.
• Referring toFIG. 3, according to an exemplary embodiment,second film24 is a laminated film having different layers of material laminated together. For example, as shown inFIG. 3,second film24 may include absorbent layer36 (e.g., a first layer, an absorbent layer, a paper-based layer, etc.), a middle layer35 (e.g., an adhesive layer, a second layer, etc.) and an outer layer38 (e.g., a third layer, a plastic layer, an outer barrier, etc.).Layers35,36,38 may be laminated (e.g., bonded, sealed, adhered, coupled, etc.) together using any suitable methods. According to an exemplary embodiment,absorbent layer36 includes an inner-facing cellulose side37 (e.g., a paper-based side) and an outer-facing polypropylene side39 (e.g., a polymer-based side).Middle layer35 may be a polyethylene adhesive or similar material.Outer layer38 may be a thermoplastic polymer such as oriented polyethylene terephthalate (e.g., a 48 gauge OPET material, etc.) or similar material.
• According to one embodiment,first film22 andsecond film24 are sealed by way of melting a portion ofabsorbent layer36, for example, during a heat sealing process. For example,absorbent layer36 may include an inner-facing paper-based layer that also includes polypropylene fibers. As such, first andsecond films22,24 may be heat sealed together (e.g., at seal portion26) such that the polypropylene fibers present inabsorbent layer36 at least partially melt during the heat sealing process, thereby bonding first andsecond films22,24 together. In sealingfilms22 and24, the seal is formed through the paper-based layer ofabsorbent layer36 and with the polypropylene material. The strength of the seal may in some embodiments be varied by changing the paper content of the absorbent layer, as paper fibers tend to degrade the strength of the seal.
• According to one embodiment,absorbent layer36 may be positioned such thatabsorbent layer36 facesfood product12. According to other embodiments, one or both oflayers35,38 may be omitted fromsecond film24, such thatabsorbent layer36 may act as both an inner and/or outer layer forsecond film24.Absorbent layer36 is configured to absorb moisture (e.g., heated water vapor, steam, liquids such as water, oils, grease, etc.) released fromfood product12 during heating (e.g., exposure to microwave energy) offood product12. As such,absorbent layer36 acts to control the moisture content offood product12 and preventfood product12 from becoming too soggy (due to excessive moisture) or too dry (due to lack of moisture). In one embodiment,absorbent layer36 may be or include an absorbent paper material, such as cellulose. In other embodiments,absorbent layer36 may be or include a variety of other materials.
• According to one embodiment,outer layer38 is provided to an opposite side ofabsorbent layer36 fromfood product12.Outer layer38 acts as an outer barrier forpackaging14 and prevents unwanted moisture, gases, and other products from entering/exitingpackaging14. In one embodiment,outer layer38 is or includes a plastic material, such as 48 gauge OPET. In other embodiments,outer layer38 may be or include a variety of other materials.
• Referring further toFIGS. 1-4, according to an exemplary embodiment,first film22 is sealed (e.g., releasably sealed and/or resealably sealed, coupled, etc.) tosecond film24 along a seal portion26 (seeFIGS. 2 and 4) such that after heating of packagedfood product10,second film24 may be removed fromfirst film22, providing consumers access tofood product12.Food product12 is contained with the interior ofpackaging14 formed by first andsecond films22,24.Seal portion26 may include any of a number of seal types, including heat sealing, adhesives, ultrasonic welding, and the like. In one embodiment, some or all ofseal26 is a non-hermetic heat seal that permits passage of fluids (e.g., steam, moisture, etc.) throughseal26. In some embodiments,seal portion26 may extend around the entire periphery ofrecess28 offirst film22. As discussed below, certain portions ofseal portion26 may provide a self-venting feature for packagedfood product10 to provide for the release of steam during heating offood product12.
• Referring now toFIG. 4, according to an exemplary embodiment, packaging14 is configured to provide a “steam dome” around portions offood product12 during heating offood product12. For example, as shown inFIG. 4, a steam dome shown as gap orspace42 is provided betweenfood product12 andrecess28 offirst film22. Asfood product12 is heated, steam is generated and “inflates”first film22.Space42 provides an area through which this steam is able to travel and continue to provide heat to food product12 (e.g., acting as an insulator to keep the food product heated longer by conducting heat) and to provide for “steam-assisted cooking,” or “steam-conductive heating.” This may serve to equilibrate the moisture withinpackaging14 and ensure faster and more even cooking offood product12 relative to more traditional means of microwave cooking, where steam is simply released into the interior of the microwave oven. Further, providingspace42 also permits moisture to uniformly re-enterfood product12 to avoid over-drying offood product12, resulting in an optimal moisturecontent food product12.
• According to some embodiments, an anti-fog layer feature or layer50 (e.g., an anti-fog treatment or feature, etc.) may be provided as part of or on the inner surface offirst film22.Anti-fog layer50 may be a separate layer of material, or may be provided as an integral part offirst film22. For example, in some embodiments, anti-fog material may be added to a resin (e.g., as resin chips or the like) used to make one or more films ofpackaging14. Providing an anti-fog surface onfirst film22 eliminates and/or prevents the formation of water beads or droplets that may otherwise form onfirst film22 during heating offood product12. The anti-fog treatment is not being used to merely resist fog from appearing on the film, but to cause water to run or drain from the film toward the absorbent layer (i.e., to “pass” or guide water toward the absorbent layer).
• Furthermore,anti-fog layer50 resists fogging (clouding, discoloring, etc.) of the films due to extreme or sudden temperature changes. An anti-fog surface also maintains an aesthetically appealing visual appearance to packagedfood product10 prior to, during, and after heating of packagedfood product10, as the packaging does not “fog up” (e.g., the packaging remains substantially transparent if a transparent packaging material is used). According to various alternative embodiments, an anti-fog treatment may be provided on or as a part of one or both offirst film22 andsecond film24. In one embodiment, as water condenses on the films, the anti-fog treatment causes the water to run (e.g., drain, flow, wick, etc.) towardabsorbent layer36, where it may remain and/or be regenerated back into steam (i.e., to “pass” or guide water toward the absorbent layer). As a result of the anti-fog treatment, rather than water beads or droplets forming, the anti-fog treatment reduces the surfaces tension of the film (i.e., “wetting” the film) such that only a fine layer of water forms (e.g., a “non-scattering” film of water) and runs down the sides of the film.
• As indicated earlier, one or more vent portions may be provided as part ofpackaging14. For example,seal portion26 may provide a self-venting feature forpackaging14, such that one or more portions of seal portion26 (e.g., the interface between first andsecond films22,24) may be configured to permit a desired amount of steam or moisture to escape from the interior ofpackaging14 during heating of food product12 (e.g., along a path indicated byarrow46 shown inFIG. 4). In some embodiments, one or more portions ofseal portion26 may be “weakened” to provide venting of steam and/or moisture. Furthermore,first film22 may be shaped or sized to direct moisture to weakened portions ofseal portion26. For example,first film22 may include one or more flutes (e.g., corrugations, etc.) or other features to direct moisture to specific portions ofseal portion26.
• In yet other embodiments, packaging14 may be configured such that a user may “peel back” a portion offirst film22 from second film24 (e.g., using an “easy peel” feature) to provide an opening through which steam may escape from the interior ofpackaging14 during heating offood product12. For example, due to the presence of paper fibers (e.g., non-woven, porous paper) in the films,seal portion26 may be weakened as the moisture (e.g., steam) escaping from the package reduces the tensile strength of the paper fibers. According to yet further embodiments, one or more vent portions may be configured to provide venting only upon heating of packaged food product10 (e.g., such that the vent portions are otherwise substantially impermeable to liquids and/or gases).
• In some embodiments, excess moisture may be directed through specific portions ofseal portion26 to areas ofpackaging14 outside ofseal portion26. For example, weakened portions or channels may be used to direct moisture toareas21 ofpackaging14 to take advantage of the absorbency of those areas that may otherwise not by utilized. Weakened portions ofseal26 may be provided in a variety of ways, including narrowing the “width” of the seal and/or reducing the “thickness” of the seal. Other ways of providing weakened areas ofseal26 may be utilized according to various other embodiments. For example, various parameters of packaging machinery (e.g., pressure, temperature, dwell time, etc.) may be varied in order to provide a seal of a desired strength (e.g., a “controllable seal” formed through “fiber intervention,” where the presence of papers fibers in the seal area can be increased or decreased to control the strength of the seal).
• As shown inFIG. 1,areas21 may be provided in one or more of the “corners” ofpackaging14. According to various alternative embodiments, the location and number ofareas21 may be varied to suit a particular packaging configuration (e.g., variations in size, shape, etc.). In some embodiments, a scented material may be provided inareas21, and the scented material may be activated by heat and/or moisture, such that as the food product is prepared and moisture and/or heat travels toareas21, a scent (e.g., a fresh bread scent, a sage sausage scent, etc.) may be activated and/or released. In one embodiment, the scented material is provided in one or more absorbent layers of the packaging, although the scented material may be provided using different methods according various other embodiments. As indicated above, the scented material may release a scent (e.g., a fresh bread scent) that is normally associated by consumers with the food product (e.g., a bread food product) being prepared, to enhance the consumer experience. The scent may be activated by the contact with the moisture, the heat, air, or the like or combinations thereof
• In combination with the absorbent features ofsecond film24, the venting features ofpackaging14 are intended to control the humidity and/or temperature and equilibrate the moisture content (e.g., maintain a consistent, even, or desired level of moisture) within the interior ofpackaging14 during heating offood product12 such that, for example, the humidity level within the interior ofpackaging14 remains at or below a predetermined level during the dynamic heating cycle offood product12. The absorbent layer acts as a “buffer” or “moisture sink” to control the amount of steam/moisture within the packaging. For example, one or more venting features ofpackaging14 may be configured to “delay” any venting of steam or moisture until a predetermined temperature, pressure, or moisture content is reached within the interior ofpackaging14. This may help to provide for faster cooking cycles and ensure a proper moisture content forfood product12 and avoid an over-dry or soggy food product.
• In order to prepare the packaged food product of the present disclosure, a consumer may first simply place the packaged food product in a microwave oven, with the “flat” portion (e.g., second film24) facing downward (to permit formation of the “stream dome”). The consumer may then heat the packaged food product in the microwave oven for an appropriate amount of time (e.g., 1 minute, 2 minutes, etc.). During heating, steam may be released from the food product and form a “steam dome” around the exterior of the food product (e.g., inflatingfirst film22 to define space42). A portion of the moisture from the steam may be reabsorbed by the food product, a portion may be vented to the outside environment, and a portion may be absorbed by the absorbent layer of the packaging. Additional moisture (e.g., liquids such as oils, grease, etc.) released by the food product may further be absorbed by the absorbent layer of the packaging. The food product construction; the moisture content of the food product; the size ofspace42; the type, amount of, and performance of the absorbent layer; and the size, location, and performance of the vent portions are balanced to provide the proper level of moisture withinpackaging14 during preparation offood product12. Upon completion of the heating cycle, the consumer may simply remove the packaged food product from the microwave oven, remove the flat film (e.g. second film24) and consume the food product directly from the remaining packaging. If desired, a portion of the packaging may be used to hold the food product during consumption.
• Referring now toFIGS. 5-8, a packaged food product110 (e.g., a breakfast product, a snack product, etc.) is shown according to an alternative exemplary embodiment. Packagedfood product110 may be similar to packagedfood product10 and include any of a variety of packaged food products, including, but not limited to, breakfast items such as breakfast sandwiches, etc., lunch items such as lunch sandwiches, etc., dinner items, snack portions, and the like. As shown inFIG. 5, packagedfood product110 includes afood product112 provided within the interior ofpackaging114.
• Referring toFIGS. 5 and 6, according to an exemplary embodiment,food product112 is a multi-component food product and includes a plurality of physically separate food components shown ascomponents116,118, and120. For example, in some embodiments,food product112 may be a breakfast sandwich, such thatcomponent116 may be one or more pieces of biscuit, bun, or similar bread item,component118 may be a sausage, bacon, or other meat item, andcomponent120 may be a cheese, sauce, or other topping item. According to various other embodiments,food product112 may be any of a wide variety of other products, including a lunch sandwich, a snack item, etc. As such,components116,118, and120 may be any of a variety of different components. According to yet other embodiments,food product112 may include fewer or more components than those shown inFIG. 6 (e.g., a single food component, two food components, four or more food components, etc.)
• Further, while in someembodiments food product112 may be intended to be sold to consumers in a frozen state, in otherembodiments food product112 may be intended to be sold to consumers in a refrigerated or other state. Thus, the embodiments herein may extend to preparing packaged food products having food products in either a frozen or refrigerated state.
• According to one embodiment,packaging114 includes a first film122 (e.g., a top film or portion, a formed portion, etc.) and a second film124 (e.g., a second film or portion, a flat portion, etc.). First andsecond films122,124 may be formed using any suitable process, including a vacuum-forming process, a flow-wrapping process, etc.First film122 includes a recess128 (e.g., a pocket, receptacle, formed portion, etc.) and a generallyflat portion130 extending aboutrecess128. As discussed in greater detail below, in one embodiment,recess128 is sized to provide a space, or gap142 (e.g., “a steam dome”) aboutfood product112 whenfood product112 is heated in a microwave oven.First film122 may be made from a semi-rigid film material, such as polyesters (e.g., amorphous polyethylene terephthalate (APET), polyethylene terephthalate (PETG), etc.), polyvinyl chloride (PVC), polypropylene (PP) or reduced density PP, high impact polystyrene, and the like. As such,first film122 may have sufficient rigidity to supportfood product112 after heating and during consumption of food product112 (e.g., after removal ofsecond film124 from first film122). In other embodiments,first film122 may be made from a variety of other materials, including various polymer or other materials.
• Referring now toFIGS. 6-8,second film124 is a generally flat film. According to an exemplary embodiment,second film124 includes an absorbent layer configured to absorb at least a portion of the moisture released fromfood product112 during heating of food product112 (e.g., such that liquids, etc. may travel along a path such as that indicated byarrow148 shown inFIG. 8). For example, as shown inFIG. 7,second film124 may include an absorbent layer136 (e.g., a paper material, etc.). In one embodiment,second film124 may be a substantially rigid film. In other embodiments, part or all ofsecond film124 may be a semi-rigid or flexible film.
• Referring toFIG. 7, according to an exemplary embodiment,second film124 is a laminated film having different layers of material laminated together. For example, as shown inFIG. 7,second film124 may include an inner layer134 (e.g., a first layer, a plastic layer, a perforated layer, etc.), absorbent layer136 (e.g., a second layer, an absorbent layer, a paper-based layer, etc.), and an outer layer138 (e.g., a third layer, a plastic layer, an outer barrier, etc.).Layers134,136,138 may be laminated (e.g., bonded, sealed, adhered, coupled, etc.) together using any suitable methods.
• According to one embodiment,inner layer134 is positioned such thatinner layer134 facesfood product112. In some embodiments,inner layer134 may include one or more perforations140 (e.g., slits, slots, apertures, micro-perforations, etc.) that are configured to permit moisture released fromfood product112 during heating offood product112 to travel throughinner layer134 to be absorbed byabsorbent layer136.Perforations140 may be provided in any desired configuration, with any of a variety of sizes, shapes, etc., and the configuration ofperforations140 may be based on the food product to be contained withinpackaging114. In one embodiment,inner layer134 may be made from a food-grade plastic material, such as polyethylene (PE). In other embodiments,inner layer134 may be or include a variety of other materials.
• According to one embodiment,absorbent layer136 may be provided betweeninner layer134 andouter layer138. According to other embodiments, one or both oflayers134,138 may be omitted fromsecond film124, such thatabsorbent layer136 may also act as an inner and/or outer layer forsecond film124.Absorbent layer136 is configured to absorb moisture (e.g., liquids such as water, oils, grease, etc.) released fromfood product112 during heating offood product112. As such,absorbent layer136 acts to control the moisture content offood product112 and preventfood product112 from becoming too soggy (due to excessive moisture) or too dry (due to a lack of moisture). In one embodiment,absorbent layer136 may be or include an absorbent paper material, such as cellulose. In other embodiments,absorbent layer136 may be or include a variety of other materials. The amount of moisture absorbed byabsorbent layer136 may be controlled at least in part by controlling the configuration (number, size, spacing, etc.) ofperforations140 ininner layer134.
• According to one embodiment,outer layer138 is provided to an opposite side ofabsorbent layer136 frominner layer134.Outer layer138 acts as an outer barrier forpackaging114 and prevents unwanted moisture, gases, and other products from entering/exitingpackaging114. In one embodiment,outer layer138 is or includes a plastic material, such as 48 gauge OPET. In other embodiments,outer layer138 may be or include a variety of other materials.
• Referring further toFIGS. 5-8, according to an exemplary embodiment,first film122 is sealed (e.g., releasably sealed and/or resealably sealed, coupled, etc.) tosecond film124 along a seal portion126 (seeFIGS. 6 and 8) such that after heating of packagedfood product110,second film124 may be removed fromfirst film122, providing consumers access tofood product112.Food product112 is contained with the interior ofpackaging114 formed by first andsecond films122,124.Seal portion126 may include any of a number of seal types, including heat sealing, adhesives, ultrasonic welding, and the like. In some embodiments,seal portion126 may extend around the entire periphery ofrecess128 offirst film122. As discussed below, certain portions ofseal portion126 may provide a self-venting feature for packagedfood product110 to provide for the release of steam during heating offood product112.
• Referring now toFIG. 8, according to an exemplary embodiment,packaging114 is configured to provide a “steam dome” around portions offood product112 during heating offood product112. For example, as shown inFIG. 8, a steam dome shown as gap orspace142 is provided betweenfood product112 andrecess128 offirst film122. Asfood product112 is heated, steam is generated.Space142 provides an area through which this steam is able to travel and continue to provide heat tofood product112. This may serve to equilibrate the moisture withinpackaging114 and ensure faster and more even cooking offood product112 relative to more traditional means of microwave cooking, where steam is simply released into the interior of the microwave oven. Further, providingspace142 also permits moisture to uniformly re-enterfood product112 to avoid over-drying offood product112, resulting in an optimal moisturecontent food product112.
• According to some embodiments, an anti-fog layer150 (e.g., an anti-fog treatment or feature, etc.) may be provided as part of the inner surface offirst film122.Anti-fog layer150 may be a separate layer of material, or may be provided as an integral part offirst film122. Providing an anti-fog surface onfirst film122 prevents the formation of water beads or droplets that may otherwise form onfirst film122 during heating offood product112. An anti-fog surface also maintains an aesthetically appealing visual appearance to packagedfood product110 prior to, during, and after heating of packagedfood product110. According to various alternative embodiments, an anti-fog treatment may be provided on one or both offirst film122 andsecond film124.
• As indicated earlier, one or more vent portions may be provided as part ofpackaging114. For example,first film122 may be provided withperforations132 to permit a desired amount of steam to escape from the interior ofpackaging114 during heating of food product112 (e.g., along a path indicated by arrow144 inFIG. 8).Perforations132 may be provided in any of a variety of shapes, sizes, locations, number and so on to suit a particular food product. Alternatively or in addition,seal portion126 may provide a self-venting feature forpackaging114, such that one or more portions of seal portion126 (e.g., the interface between first andsecond films122,124) may be configured to permit a desired amount of steam to escape from the interior ofpackaging114 during heating of food product112 (e.g., along a path indicated byarrow146 shown inFIG. 8).
• In yet other embodiments,packaging114 may be configured such that a user may “peel back” a portion offirst film122 from second film124 (e.g., using an “easy peel” feature) to provide an opening through which steam may escape from the interior ofpackaging114 during heating offood product112. For example, due to the presence of paper fibers in the films, the seal may be weakened as the moisture (e.g., steam) escaping from the package reduces the tensile strength of the paper fibers. According to yet further embodiments, one or more vent portions may be configured to provide venting only upon heating of packaged food product110 (e.g., such that the vent portions are otherwise substantially impermeable to liquids and/or gases).
• It should be noted that any of the features shown in the embodiments illustrated inFIGS. 5-8 may be used alone or in any number of combinations with the features shown in the embodiments illustrated inFIGS. 1-4. All such features and combinations of features are to be understood to be within the scope of the present disclosure.
• In some embodiments, one or both of the top and bottom films may have a structure different than that disclosed herein. For example, one or more portions of the laminated films may be heat sealed, for example, to provide “channels” or “pathways” that direct moisture along portions of the films and/or to “trap” moisture in desired portions of the films. Other variations in the structure of the films disclosed herein may be made according to various other embodiments.
• Referring now toFIGS. 9-25, various alternative embodiments of packaged food products are shown. It should be noted that the features of the embodiments shown in any ofFIGS. 9-25 may be used alone or in combination with any of the other features of packaged food products discussed herein, including those features discussed with respect to the embodiments shown inFIGS. 1-8. The packaging used will generally depend on the food product being contained therein and the quantity of food items.
• Referring toFIGS. 9-10, a packagedfood product210 is shown according to an exemplary embodiment, and includes apackaging214 having afirst film222 and asecond film224 sealed together via aseal226.First film222 defines a recess, ordome228, and made from a variety of thin plastic films or laminates. The film may be sufficiently thin and flexible to allow compaction yet protect the food product and perform the desired containment during manufacturing, transportation, heating, and handling by the consumer. Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 9-10 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. According to exemplary embodiments, the second film may be square, rectangular, circular, elliptical, elongated, or combinations thereof. As shown inFIG. 9,second film224 has a planar film having a square or rectangular perimeter. In one embodiment,second film224 defines a square havingsides254,256, which may have a variety of dimensions. Thesides254,256 ofsecond film224 andheight266 ofrecess228 may be any suitable dimension for a particular food product (not shown).
• According to an exemplary embodiment, seal226 may have awidth264 of approximately 4-6 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess228 during heating of the food product, the width of the seal may be increased.Seal226 may generally track the perimeter ofsecond film224, such as having a generally square shape, and may include anangled corner portion257 that defines anarea221.Area221 may provide a graspable tab for a user to peel apart first andsecond films222,224. According to an exemplary embodiment, a there is no bonding between first and second films atarea221 to provide the graspable tab. A portion ofarea221 may be bonded to inhibit excessive or the appearance of inadvertent peeling of the films (e.g., within the triangular broken line region inFIG. 9, the circular region inFIG. 40, etc.). According to an exemplary embodiment, the base first film includes a projection (e.g., bump, etc.) extending away from the recess interior in area221 (or321,421,521,621,721,821,1240, etc.) to provide a small separation between the first film and the second film so that the first film and the second film can be easily separated by the consumer. One or more portions ofseal226 may extend about the outermost portion ofsecond film224, while in other embodiments, one or more portions ofseal226 may be inset (a suitable dimension) from the outermost portions ofsecond film224. According to other embodiments, the seal shown inFIGS. 9-10 and any of the other embodiments herein may have any of a variety of shapes or configurations (e.g., zig-zag, sinusoidal, stepped, etc.) depending on the available space (as determined by the outer dimension and the size of the recess/dome), desired sealing performance, and the like. Also, instead of being formed by a single annular seal, the seal may be formed by two or more annular seal rings. According to an exemplary embodiment, first and second films may have a generally rectangular perimeter and a generally circular dome orrecess228, and be bonded together by linear (and substantially rectangular/square) seal226 (with the exception of portion257).Such seal226 extends along the outer area of thefilms222,224. Alternatively, the seal (and outer periphery of the bonded films) may be circular as shown in other embodiments herein. Alternatively, the seal may extend from the outer periphery (whether linear or curved) inward until the first film begins its special separation from the second film to form the recess.
• According to an exemplary embodiment,recess228 may have a generallycircular cross section252 along its height (e.g., cylindrical, etc.). In some embodiments, the perimeter ofrecess228 substantially abuts or is adjacent to the interior portion or edge ofseal226. For example, there may be a distance of approximately 1 to 2 mm or less between portions ofrecess228 andseal226. In other embodiments a greater space may be defined betweenrecess228 andseal226.
• Referring now toFIGS. 11-12, a packagedfood product310 is shown according to an exemplary embodiment, and includes apackaging314 having afirst film322 and asecond film324 sealed together via aseal326.First film322 defines a recess, or dome,328. Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 11-12 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 11,second film324 may be a planar film having a square or rectangular perimeter. Alternatively,second film324 may be rectangular, circular, elliptical, elongated, or combinations thereof. In one embodiment,second film324 defines arectangle having sides354,356 which may have a variety of dimensions. Thesides354,356 andheight366 ofrecess328 may be any suitable dimension for a particular food product (not shown).
• According to an exemplary embodiment, seal326 may have awidth364 of approximately 6-8 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess328 during heating of the food product, the width of the seal may be increased.Seal326 may generally track the perimeter ofsecond film324, such as having a generally rectangular shape, and may include anangled corner portion357 that defines anarea321.Area321 may provide a graspable tab for a user to peel apart first andsecond films322,324. One or more portions ofseal326 may extend about the outermost portion ofsecond film324, while in other embodiments, one or more portions ofseal326 may be inset a suitable dimension from the outermost portions ofsecond film324.
• According to one embodiment,seal326 is configured to vent at the approximate midpoint of the longer straight sections ofseal326, such that the vent occurs along the side portions of the seal rather than at, for example, the corners. In some embodiments,seal326 may vent along a longest of a plurality of sides, while in other embodiments,seal326 may vent along each of a plurality of straight-sided seal sections. In various embodiments, seal326 vents at an approximate mid-point of one or more straight-sided sections.
• According to an exemplary embodiment,recess328 may have a generallyrectangular cross section352 with rounded corners along its height and have afirst width360 of approximately 108.41 mm (4.268 inches) and asecond width362 of approximately 103.86 mm (4.089 inches) while other dimensions may be used according to other embodiments. In some embodiments, the perimeter ofrecess328 substantially abuts or is adjacent to the interior portion or edge ofseal326. For example, there may be a distance of approximately 1-2 mm or less between portions ofrecess328 andseal326. In other embodiments a greater space may be defined betweenrecess328 andseal326. The seal shown inFIG. 11 differs from the seal shown inFIG. 9 in that the seal width is greater. For example, if an increased seal strength is desired; the width of the seal is increased, which will tend to require a reduction in the diameter of therecess326. The shape or configuration of therecess328 is non-circular so that the recess extends along adjacent (e.g., compareFIG. 9 andFIG. 11) to the seal rather than being tangentially adjacent to the seal (i.e., provides pockets or space to receive a consumer's fingers inserted to remove from the packaging).
• Referring now toFIGS. 13-14, a packagedfood product410 is shown according to an exemplary embodiment, and includes apackaging414 having afirst film422 and asecond film424 sealed together via aseal426.First film422 defines a recess, or dome,428. Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 13-14 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 13,second film424 may be a planar film having a square or rectangular perimeter. Alternatively, the second film may be circular, elliptical, elongated, or combinations thereof. In one embodiment,second film424 defines arectangle having sides454,456 which may be of various dimensions. Thesides454,456, andheight466 ofrecess428 may be any suitable dimension for a particular food product (not shown).
• In some embodiments,second film424 may include ventingportions455. For example, ventingportions455 may include a plurality of perforations (e.g., scores, micro-perforations, slots, slits, apertures, etc.). In one embodiment, as shown inFIG. 13, venting portions may include a plurality (e.g., 2, 3, etc.) of rows of perforations, which may be generally parallel, or may be oriented relative to one another in a non-parallel fashion. For example, according to one embodiment, ventingportions455 comprise three parallel lines of perforations extending across the width ofsecond film424. Ventingportions455 may be produced via a laser-scoring process or any other suitable process, and may extend partially or fully through one or more layers ofsecond film424. For example, in one embodiment, only the outer layer ofsecond film424 is perforated. Ventingportions455 may be configured to permit steam/moisture to release from the packaging (e.g., by expanding, rupturing, bursting, etc.) upon a predetermined pressure being reached within the packaging. It should be noted that ventingportions455 may be usable with any of the other embodiments disclosed herein. Furthermore, venting portions similar to ventingportions455 may be utilized on other portions of the packing and/or in the first film, including the top of the recess, the sides of the recess, etc.
• According to an exemplary embodiment, seal426 may have awidth464 of approximately 4 to 6 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess428 during heating of the food product, the width of the seal may be increased.Seal426 may have a generally square shape with rounded corners and may define anarea421.Area421 may provide a graspable tab for a user to peel apart first andsecond films422,424. One or more portions ofseal426 may extend about the outermost portion ofsecond film424, while in other embodiments, one or more portions ofseal426 may be inset from the outermost portions ofsecond film424.Area421 for grasping by the consumer may be provided in one or more or four of the corners of the packaging.
• According to an exemplary embodiment,recess428 may have a generallycircular cross section452 along its height. In some embodiments, portions of the perimeter ofrecess428 substantially abut or are tangentially adjacent to the interior portion or edge ofseal426. For example, there may be a distance of approximately 1-2 mm or less between portions ofrecess428 andseal426. In other embodiments a greater space may be defined betweenrecess428 andseal426.
• Referring now toFIGS. 15-16, a packagedfood product510 is shown according to an exemplary embodiment, and includes apackaging514 having afirst film522 and a second film524 sealed together via aseal526.First film522 defines a recess, or dome,528. Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 15-16 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 15, second film524 may be a planar film having a square or rectangular perimeter. Alternatively, the second film may be circular, elliptical, elongated, or combinations thereof. In one embodiment, second film524 defines arectangle having sides554,556 which may have a variety of dimensions. Thesides554,556, andheight566 ofrecess528 may be any suitable dimension for a particular food product (not shown).
• According to one embodiment, seal526 may have awidth564 of approximately 6-8 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess528 during heating of the food product, the width of the seal may be increased.Seal526 may have a generally rectangular shape with rounded corners, and may define an area521. Area521 may provide a graspable tab for a user to peel apart first andsecond films522,524. One or more portions ofseal526 may extend about the outermost portion of second film524, while in other embodiments, one or more portions ofseal526 may be inset from the outermost portions of second film524.
• According to an exemplary embodiment,recess528 may have a generallyrectangular cross section552 with rounded corners along its height and have afirst width560 having a different dimension from asecond width562. Utilizing differing widths may, for example, provide clearance for a user to grasp a food product, etc. In some embodiments, the perimeter ofrecess528 substantially abuts or is adjacent to the interior portion or edge ofseal526. For example, there may be a distance of approximately 1-2 mm or less between portions ofrecess528 andseal526. In other embodiments a greater space may be defined betweenrecess528 andseal526.
• Referring now toFIGS. 17-18, a packagedfood product610 is shown according to an exemplary embodiment, and includes apackaging614 having afirst film622 and asecond film624 sealed together via aseal626.First film622 defines a recess, or dome,628. Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 17-18 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 17,second film624 may be a planar film having a square or rectangular perimeter. Alternatively, the second film may be circular, elliptical, elongated, or combinations thereof. In one embodiment,second film624 defines arectangle having sides654,656 which may have a variety of dimensions. Thesides654,656, andheight666 ofrecess628 may be any suitable dimension for a particular food product (not shown).
• According to an exemplary embodiment, seal626 may have awidth664 of approximately 6 to 8 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess628 during heating of the food product, the width of the seal may be increased.Seal626 may have a generally rectangular shape with rounded corners, and may define anarea621.Area621 may provide a graspable tab for a user to peel apart first andsecond films622,624. One or more portions ofseal626 may extend about the outermost portion ofsecond film624, while in other embodiments, one or more portions ofseal626 may be inset from the outermost portions ofsecond film624.
• According to an exemplary embodiment,recess628 may have a generallyrectangular cross section652 with rounded corners along its height and have a first width with a different dimension from a second width. In some embodiments, the perimeter ofrecess628 substantially abuts or is adjacent to the interior portion or edge ofseal626. For example, there may be a distance of approximately 1 to 2 mm or less between portions ofrecess628 andseal626. In other embodiments a greater space may be defined betweenrecess628 andseal626.
• According to an exemplary embodiment, a relief668 (e.g., gap, vent, passage, weakened portion, etc.) is formed inseal626.Relief668 may provide a self-venting feature forpackaging614 by permitting a desired amount of steam or moisture to escape from the interior ofpackaging614 during heating of food product612. As shown inFIG. 17,relief668 may be a break or weakened area inseal626 with awidth670 of approximately 6.35 mm (0.250 inches) while other dimensions may be used according to other embodiments (e.g., 0.375 inches, etc.). Alternatively, a relief may be provided by having a seal with a varying seal width.
• Referring now toFIGS. 19-20, a packagedfood product710 is shown according to an exemplary embodiment, and includes a packaging714 having afirst film722 and asecond film724 sealed together via aseal726.First film722 defines a recess, or dome,728. Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 19-20 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 19,second film724 may be a planar film having a square or rectangular perimeter. Alternatively, the second film may be circular, elliptical, elongated, or combinations thereof. In one embodiment,second film724 defines arectangle having sides754,756 which may have a variety of dimensions. Thesides754,756, andheight766 ofrecess728 may be any suitable dimension for a particular food product (not shown).
• According to an exemplary embodiment, seal726 may have awidth764 of approximately 6-8 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess728 during heating of the food product, the width of the seal may be increased.Seal726 may have a generally rectangular shape with rounded corners, and may define anarea721.Area721 may provide a graspable tab for a user to peel apart first andsecond films722,724. One or more portions ofseal726 may extend about the outermost portion ofsecond film724, while in other embodiments, one or more portions ofseal726 may be inset from the outermost portions ofsecond film724.
• According to an exemplary embodiment,recess728 may have a generallyrectangular cross section752 with rounded corners along its height and have afirst width760 and asecond width762 which may be a variety of dimensions. In some embodiments, the perimeter ofrecess728 substantially abuts or is adjacent to the interior portion or edge ofseal726. For example, there may be a distance of approximately 1-2 mm or less between portions ofrecess728 andseal726. In other embodiments a greater space may be defined betweenrecess728 andseal726.
• According to an exemplary embodiment, a relief768 (e.g., gap, vent, passage, weakened portion, etc.) is formed inseal626.Relief768 may provide a self-venting feature for packaging714 by permitting a desired amount of steam or moisture to escape from the interior of packaging714 during heating of food product712. As shown inFIG. 19,relief768 may be a break or weakened area inseal726 with awidth770 of approximately 0.125 to 0.50 inches (e.g., 0.250 inches), while other dimensions may be used according to other embodiments.
• Referring now toFIGS. 21-22, a packagedfood product810 is shown according to an exemplary embodiment, and includes apackaging814 having afirst film822 and asecond film824 sealed together via aseal826.First film822 defines a recess, or dome,828. Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 21-22 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 21,second film824 may be a planar film having a square or rectangular perimeter. Alternatively, the second film may be circular, elliptical, elongated, or combinations thereof. In one embodiment,second film824 defines arectangle having sides854,856 which may have a variety of dimensions. Thesides854,856, andheight866 ofrecess828 may be any suitable dimension for a particular food product (not shown).
• According to an exemplary embodiment, seal826 may have a width864 of approximately 6-8 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess828 during heating of the food product, the width of the seal may be increased.Seal826 may have a generally rectangular shape with rounded corners, and may define anarea821.Area821 may provide a graspable tab for a user to peel apart first andsecond films822,824. One or more portions ofseal826 may extend about the outermost portion ofsecond film824, while in other embodiments, one or more portions ofseal826 may be inset from the outermost portions ofsecond film824.
• According to an exemplary embodiment,recess828 may have a generallyrectangular cross section852 with rounded corners along its height and have afirst width860 and asecond width862 which may have a variety of dimensions. In some embodiments, the perimeter ofrecess828 substantially abuts or is adjacent to the interior portion or edge ofseal826. For example, there may be a distance of approximately 1-2 mm or less between portions ofrecess828 andseal826. In other embodiments a greater space may be defined betweenrecess828 andseal826.
• According to an exemplary embodiment, multiple reliefs868 (e.g., gaps, vents, passages, weakened portions, etc.) are formed inseal826.Reliefs868 may provide a self-venting feature forpackaging814 by permitting a desired amount of steam or moisture to escape from the interior ofpackaging814 during heating of food product812. As shown inFIG. 19, eachrelief868 may be a break or weakened area inseal826 with a width870 of approximately 6.35 mm (0.250 inches) while other dimensions may be used according to other embodiments. For example,different reliefs868 may have different widths based on the position of the relief, the type of food product, or other factors. As shown inFIG. 19,multiple reliefs868 may be generally equally distributed alongseal826, while inother embodiments reliefs868 may be otherwise distributed along seal826 (e.g., unequally spaced, etc.).
• Referring now toFIGS. 23-25, a packagedfood product910 is shown according to an exemplary embodiment, and includes apackaging914 having afirst film922 and asecond film924 sealed together via aseal926.First film922 defines a recess, or dome,928. Recess928 may be shaped to generally conform to a food product (e.g., a hot dog, one or two hamburgers/cheeseburgers, etc.). Except as otherwise discussed herein, the packaging, films, recess, and seal shown inFIGS. 23-25 may have any or all of the features discussed with respect toFIGS. 1-8 or any of the other embodiments disclosed herein. As shown inFIG. 23,second film924 may be a planar film having a square or rectangular perimeter. Alternatively, the second film may be circular, elliptical, elongated, or combinations thereof. In one embodiment,second film924 defines a rectangle having afirst side954 between and asecond side956 which may have a variety of dimensions. Thesides954,956 and height966 ofrecess928 may be any suitable dimension for a particular food product (not shown).
• According to an exemplary embodiment, seal926 may have awidth964 of approximately 7-8 mm. According to other exemplary embodiments, the width of the seal may be based on the desired performance of the seal during heating of the food product. If early venting is desired, the seal width may be reduced. If increased sealing performance to inhibit venting of steam built up within therecess928 during heating of the food product, the width of the seal may be increased. In some embodiments,seal926 may have a generally rectangular shape. One or more portions ofseal926 may extend about the outermost portion ofsecond film924, while in other embodiments, one or more portions ofseal926 may be inset from the outermost portions ofsecond film924.
• According to an exemplary embodiment,recess928 may have a generallyrectangular cross section952 with rounded corners along its height and have afirst width960 and asecond width962 which may be a variety of dimensions. In some embodiments, the perimeter ofrecess928 substantially abuts or is adjacent to the interior portion or edge ofseal926. For example, there may be a distance of approximately 1-2 mm or less between portions ofrecess928 andseal926. In other embodiments a greater space may be defined betweenrecess928 andseal926.
• Referring toFIG. 26, a portion of a mechanism for forming a seal such asseal26 for packagedfood product10 is shown schematically according to an exemplary embodiment. The mechanism includes aplate1000 with a recess1002 (e.g., gap, void, etc.).Plate1000 is lowered ontofirst film22 andsecond film24. Energy (e.g., heat, ultrasonic vibrations, etc.) and pressure couplesfirst film22 tosecond film24 to formseal26. In some embodiments, arelief portion68 is formed by the portion offirst film22 andsecond film24 aligned withrecess1002 that are not contacted byplate1000. The depth, width, and number ofrecesses1002 provided inplate1000 may be varied to provide the appropriate number of weakened areas of the seal (e.g., for venting, ease of opening, etc.). According to an exemplary embodiment,relief portion68 has a height, or depth,1003 of approximately 0.010 inches, although this dimension may be varied to provide a relatively stronger or weaker seal strength at the vent portion.
• According to various embodiments shown herein, an absorbent or paper layer may be provided as part of a lamination or film (e.g., as part of first orsecond films22,24). According to alternative embodiments, rather than or in addition to providing an absorbent layer as part of a film or lamination, a separate absorbent member may be provided. For example, referring toFIG. 27, an absorbent pad ormember1004 may be provided as a loose article within the recess (i.e., not attached to the other components of the packaging). In one embodiment,absorbent member1004 may be disk-shaped. According to other embodiments, absorbent member may take other shapes, and may be shaped to conform to or have a shape corresponding to a packaging recess, a food product, etc. Furthermore,absorbent member1004 may include alabel1006, which may include printed text and/or graphics, etc., that may be printed ontoabsorbent member1004 or may be provided as a separate label material. When the absorbent member also serves as a label, the absorbent member may be coupled to thefirst film222 and/or thesecond film224.
• As shown in various embodiments herein, the inner perimeter of the recess or dome of the packaging may extend from adjacent to or proximate to the seal portion. In other embodiments, a space may be provided between the recess and the seal along all or a portion of the periphery of the recess. The shape of the seal may also be varied to suit particular applications. Utilizing a generally square or rectangular seal may provide increased seal strength (e.g., by increasing the distance from the seal to the recess). Furthermore, the size and shape of the recess may be any of a wide variety. For example, providing a recess having differing width/length dimensions may provide room for users to grasp food products with fingers, utilize utensils, etc.
• Referring now toFIGS. 28-39C, various schematic representations are provided according to exemplary embodiments to illustrate different seal portions (e.g., portions where the first and second films are sealed together) and vent portions (e.g., portions having a relatively weaker seal between the first and second films, or alternatively, portions void of a seal between the first and second films). According to any of the various embodiments disclosed herein, vent portions may provide venting of steam/pressure through the interface of the first and second films in a variety of ways. For example, a width of a seal may be narrowed to provide a vent portion having a relatively weaker seal strength. Alternatively, the strength of the seal may be lessened by providing a “relief” in a seal bar used to form the seal (see e.g.,FIG. 26), thereby forming a vent portion having a relatively weaker seal strength. Further, a wide variety of dimensions may be varied (e.g., the length and/or width of a narrowed portion of seal, the length, width, and/or depth of a relief formed in a seal bar, etc.) to vary the strength of a seal at a seal portion. Such variation in the seal configuration, dimensions, and geometry are provided in exemplary embodiments because the packaging uses polymer film layers that seal through an absorbent layer (which is possible due to polymer fibers in the absorbent layer).
• It should also be noted that the sealing and venting features disclosed herein may be used with any suitable recess, or “dome,” that receives food products, including domes having a generally circular cross-section, square cross-section, rectangular cross-section, square/rectangular with rounded corners cross-section, multi-sided polygonal cross-section, etc. as shown in the FIGURES herein. Further, the seal portions may be spaced apart from (e.g., in the case of a square/rectangular seal around a circular dome) or adjacent to (in the case of a circular seal around a circular dome) the dome. All such combinations of domes, seal portions, and vent portions are within the scope of the present disclosure. Greater details of various sealing/venting combinations are provided below with respect toFIGS. 28-39C. It should be understood that unless otherwise provided herein, the sealing/venting features shown inFIGS. 28-39C may be included as a part of any of the food packages shown herein and/or utilized with any other features disclosed herein. For example, any of the seals may be used with a generally circular cross section dome (seeFIG. 17) or with a square/rectangular with rounded corners cross section dome (seeFIG. 19).
• According to various embodiments, the seal portions may have various widths. For example, according to one embodiment, when using a generally circular dome, the seal portion may have a width of approximately 5 mm; when using a square/rectangle with rounded edges dome, the seal portion may have a width of approximately 7 mm; and when using a seal portion with inner/outer seal portions (see e.g.FIG. 37,FIG. 39, and the other FIGURES herein) the inner and outer seal portions may each have a width of approximately 2 mm and be spaced approximately 3 mm apart, for a total seal portion width of 7 mm. According to various other embodiments, other widths for the various seal portions may be used.
• Referring now toFIG. 28, aseal portion990 is shown according to an exemplary embodiment and includes a number ofvent portions992. As shown inFIG. 28,seal portion990 may be circular, or square/rectangular with rounded corners. In one embodiment,seal portion990 may include threevent portions992 on opposing sides of seal portion990 (e.g., in the case of generally square/rectangle seal) although according to various other embodiments, more or fewer vent portions may be utilized, and the size, spacing, placement, and shape ofvent portions992 may be varied to suit a particular application. In one embodiment, ventportions992 have a length of approximately 0.250 inches, although other dimensions may be used to provide a larger or smaller vent portion (e.g., 0.125 inches, 0.375 inches, 0.500 inches, etc.).
• Referring toFIG. 29, aseal portion1010 is shown according to an exemplary embodiment. As shown inFIG. 29, a portion ofseal portion1010 is formed by straight sides joined perpendicularly, and haslongest sides1014,1016.Vent portion1012 may be formed in one or both ofsides1014,1016 and may have a length of 0.375 inches. Furthermore, in some embodiments, additional sides may have further vent portions. For example, referring toFIG. 30, aseal portion1020 is shown according to an exemplary embodiment and includes fourvent portions1022, each having a length of 0.250 inches.
• Referring toFIGS. 31A-32B, aseal portion1030 has a number ofvent portions1032.Vent portion1032 is formed by a portion ofseal portion1030 having a reduced width (e.g., forming a recess, or notch, in seal portion1030). The notch may provide a weakened seal area or a void in the seal portion. Whilevent portion1032 is shown formed by a generally curved, or chamfered, notch inseal portion1030,vent portion1032 may be formed with other shapes (e.g., V-shapes, U-shapes, rectangular shapes, etc.). In some embodiments, ventportions1032 may be formed by reducing a seal width from 7 mm to 3 mm, or alternatively, from 5 mm to 2 mm, and the notch, or recess, may have a width of approximately 0.187 inches on the inner edge of the seal portion, as shown inFIG. 31B.Seal portion1030 may be generally circular, or alternative square/rectangular with rounded corners. Further, a number (e.g., 3, 4, etc.) of vents may be provided on opposing sides of seal portion1030 (e.g., on opposite sides of a rectangular seal, etc.). According to other embodiments, ventportions1032 may be provided around the entire perimeter ofseal portion1030, and may be spaced at regular or irregular intervals. Referring toFIG. 32, a straight-sided seal portion1040 may include one ormore vent portions1042 on one or more of each of the sides (e.g., on the four longer of the five straight sides, on the two longest sides, etc.).Vent portions1042 may be formed in a similar manner to ventportions1032 shown inFIG. 31.
• Referring now toFIG. 33, aseal portion1050 is shown according to an exemplary embodiment and is a straight-sided seal having ashortest side1059, twointermediate length sides1056, and twolong sides1058.Vent portions1052 may be provided on each of theintermediate sides1056 andlong sides1058. According to one embodiment, ventportions1052 are provided at the midpoint along the length of each ofsides1056,1058. Furthermore,additional vent portions1054 may be provided, for example, equally spaced to either side ofvent portions1052 onlong sides1058. Alternatively, additional vents could be provided on either side ofvent portions1052 onintermediate sides1056. In one embodiment, ventportions1052,1054 have a length of approximately 0.25 inches.
• Referring toFIG. 34, aseal portion1060 is shown according to an exemplary embodiment. As shown inFIG. 34, the entire portions of the first and second films (except the recess, or dome portion), may be sealed together except for apeelable corner portion1064.Vent portions1062 may be provided at four equally spaced locations about the dome (e.g., a circular cross-section dome), although more or fewer vent portions may be provided and the vent portions may be equally or unequally spaced about the perimeter of the dome. According to one embodiment, each vent portion tapers from afirst width1066 adjacent the dome to asecond width1068 at the edge of the packaging. In one embodiment,first width1066 may be about twice second width1068 (e.g., providing a 2:1 ratio), although other dimensions (e.g., a 3:2 ratio, etc.) may be used according to various alternative embodiments. For example,first width1066 may be approximately 0.5 inches, andsecond width1068 may be approximately 0.25 inches. Alternatively,first width1066 may be approximately 0.375 inches andsecond width1068 may be approximately 0.25 inches. In some embodiments, ventportions1062 are provided at the narrowest portions of seal portion1060 (e.g., at the approximate midpoint along each of the straight edges of the first and second films).FIG. 35 is similar toFIG. 34, except thatseal portion1070 shown inFIG. 35 has no venting such asvent portions1062 shown inFIG. 34.
• Referring now toFIG. 36, aseal portion1080 is shown according to an exemplary embodiment and is similar to sealportion1060 shown inFIG. 34 except thatvent portions1082 are straight-sided vent portions rather than tapered. The length (e.g., 0.25 in., 0.375 in., 0.50 in., etc.) ofvent portions1082 may be varied to suit a particular application, and the number (e.g., more or less than four) and spacing (regular-spaced, irregular-spaced) of vent portions may be varied.
• Referring toFIG. 37A-37E, aseal portion1090 is shown according to an exemplary embodiment and includes aninner seal portion1091 and anouter seal portion1093 in a generally parallel fashion. According to one embodiment, inner andouter seal portions1091,1093 may be concentric circles, although according to various other embodiments, inner andouter seal portions1091,1093 may take any suitable shape, with inner seal portion running along the inside ofouter seal portion1093. According to one embodiment,seal portions1091,1093 each includes 4vent portions1092 equally spaced aboutseal portions1091,1093. In some embodiments, ventportions1092 oninner seal portion1091 may be staggered apart from (e.g., located midway between)vent portions1092 onouter seal portion1093. According to other embodiments, the vent portions onseal portions1091,1093 may be generally aligned (FIG. 37E), or offset in a different fashion than as shown inFIG. 37A.FIG. 37B shows a profile of inner andouter seal portions1091,1093 according to an exemplary embodiment.
• While as shown inFIG. 37A each of inner andouter seal portions1091,1093 may include 4 vent portions, more or fewer vent portions may be utilized. For example, in some embodiments, sixvent portions1092 may be provided on each ofseal portions1091,1093, and the vent portions may be staggered (seeFIG. 37C). In other embodiments, differing numbers ofvent portions1092 may be provided on each ofinner seal portion1091 andouter seal portion1093. For example,inner seal portion1091 may include sixvent portions1092 andouter seal portion1093 may include 4vent portions1092, and one or more “pairs” of vent portions onseal portions1091.1093 may be staggered and/or aligned (seeFIG. 37E).
• Referring toFIGS. 38A-38B, aseal portion1100 is shown according to an exemplary embodiment, and includes a number ofvent portions1102.Seal portion1100 covers the entire interface between the first and second films except apeelable portion1104 at one or more corners. As shown inFIG. 38, fourvent portions1102 are provided in the form of narrowed portions of seal portion1100 (e.g., in a manner similar to ventportions1032 shown inFIG. 31). The size, shape, number, and spacing ofvent portions1102 may be varied according to various alternative embodiments. As shown inFIG. 38B, eachvent portion1102 may be formed by providing a chamfered notch or recess that reduces the width of a seal from, for example, 5 mm to 2 mm and has a width at the inner edge of the seal portion of approximately 0.5 inches. As noted herein, the notch may be provided by a relatively weaker seal portion, or alternatively, a void in the seal portion.
• Referring toFIG. 39A, aseal portion1110 is shown according to an exemplary embodiment, and includes aninner seal portion1111 and anouter seal portion1113. Inner andouter seal portions1111 and1113 generally include straight sides that run along each other in a generally parallel fashion. As shown inFIG. 39A, each ofseal portions1111,1113 includes four seal portions1112 (e.g., one vent portion on each intermediate length side, and one vent portion on each long side) provided at the midpoint of sides ofseal portion1110. The size, number, placement, and spacing ofvent portions1112 may be varied according to various alternative embodiments. In one embodiment, inner andouter seal portions1111,1113 may each include six vent portions1112 (seeFIG. 39B). For example, inner andouter seal portions1111 and1113 may include asingle vent portion1112 on each of the intermediate length sides and twovent portions1112 on each of the longer length sides. Thevent portions1112 may be staggered relative to each other and may be positioned based on a desired venting configuration (e.g., with the vents on the long sides ofinner seal1111 staggered to the inside of thevent portions1112 on the long sides ofouter seal portion1113, etc.,). Furthermore, inner andouter seal portions1111 and1113 may have differing numbers of vent portions (e.g.,inner seal portion1111 may have sixvent portions1112 while outer seal portion may have fourvent portions1112, vice-versa, etc.) as shown inFIG. 39C.
• Referring now toFIGS. 40-42, a packagedfood product1210 is shown according to an exemplary embodiment.Product1210 includes apackaging1214 configured to hold a food product (not shown). Packagedfood product1210 andpackaging1214 may include one or more of the features described in the various other embodiments described herein. According to an exemplary embodiment,packaging1214 includes a top, or upper portion1224 (e.g., a flat film, etc.) and a bottom, or lower portion1222 (e.g., a formed member, receptacle cup, etc.).
• Top portion1224 is sealed tobottom portion1222 via aseal portion1226 to form an interior1228. A food product is sealed within interior1228 via top andbottom portions1224,1222 andseal portion1226. The food product may be any of a variety of food products intended to be heated in a microwave oven, including any of the food products described with respect tofood product12 discussed herein, such as hamburgers, hot dogs, hot dogs wrapped in dough, sandwiches, etc.
• Top film1224 may be a generally flat film similar tofilm24. In some embodiments,film1224 may be a flexible film, while according to other embodiments,film1224 may be all or partially made up of semi-flexible or rigid portions.Film1224 may generally be sized and shaped such that the outer periphery oftop film1224 is generally aligned with the outer periphery ofbottom film1222.Top film1224 may form apull tab1240 configured to enable a user to pealtop film1224 away frombottom film1222. According to some embodiments,top film1224 may be made of a lamination of materials, including an absorbent layer, various sealants, and/or polymer films. For example, the film may be a co-extruded laminate of a barrier film (e.g., ethylene vinyl alcohol copolymer or EVOH, etc.), a sealant (e.g., ionomer, polyethylene, ethyl vinyl acetate or EVA, etc.), and structural layers (e.g., nylon, polypropylene, etc.). The non-conforming or base film includes oriented polyethylene terephthalate (OPET) layer, adhesive (e.g., polyethylene), and a woven or a non-woven absorbent material layer (e.g., cellulose and polypropylene).
• Bottom film1222 may be formed using any suitable process, including vacuum-forming, flow-wrapping, etc.Bottom film1222 forms interior1228 and includes a flat portion1230 (e.g., a rim, flange, lip, etc.) extending about the upper periphery of interior1228. The shape and size of interior1228 and/orflat portion1230 may be varied to provide a desired packaging type and/or to accommodate a specific food product. In some embodiments, the outer periphery offlat portion1230 forms a rectangular or square shape, while in other embodiments, other shapes may be formed, including circular, oval, irregular, etc. For example, as shown inFIGS. 40-42, interior1228 may have a generally rectangular cross-section except that one corner is instead rounded, providing a shape having two substantially straight sides and one curved side (e.g., a curved “side” formed by two substantially straight portions joined by a curved portion). According to exemplary embodiments, the curved side helps to focus the pulling force on the sealant by the consumer when separating the films due the reduced area that initially absorbs the force when the pulling/separation begins. The depth of interior1228 may be varied to provide a packaging having a suitable depth for a particular food product. The curved side may conform to a food product, form a space for a pull-tab, etc.
• Bottom film1222 may be made of any suitable material, including a number of flexible, semi-rigid, or rigid polymers, including any of the materials described herein in connection withfilm22. In some embodiments,bottom film1222 may be semi-rigid and have sufficient rigidity to maintain its shape and support the food product during sale, preparation, and consumption of the food product. In some embodiments,bottom film1222 is made from a lamination of materials, including various sealants and/or polymer films.
• According to an exemplary embodiment,seal portion1226 is configured to provide a gas and/or moisture seal between interior1228 and the exterior environment.Seal1226 may be formed in a variety of ways, including heat sealing the top and bottom films together, welding operations, using one or more adhesives, or combinations thereof. In some embodiments,seal portion1226 is formed by melting the top and bottom films together using an appropriate heat, pressure, etc.
• According to an exemplary embodiment,seal1226 is configured to provide venting features to the packaging to release gas, steam, and/or moisture from interior1228 during preparation (e.g., heating) of the food product (e.g., by way of a microwave oven). For example, one or more portions ofseal1226 may be configured to provide a “vent” to permit the release of steam, moisture, etc.
• In one embodiment,seal1226 is configured such thatseal1226 vents at the approximate midpoints along straight sections ofseal1226. For example, referring toFIG. 41,seal1226 may include two relatively longerstraight sections1232,1234, and two relatively shorterstraight sections1236,1238. Upon heating ofproduct1210,seal1226 may be configured to vent at the approximate midpoints ofsections1232,1234 (e.g., the longer straight sides). In some embodiments, a weakened portion ofseal1226 may be provided at one or more locations aboutseal1226 to promote venting, while in other embodiments,seal1226 may have a generally uniform size, shape, and seal strength about its periphery, andseal1226 may tend to rupture at desired locations due to the geometry of seal1226 (e.g., by providing an elongated packaging having corresponding elongated straight seal portions configured to provide vents at their approximate midpoints).
• Whileseal1226 is shown inFIG. 41 to have two relatively longer sections (sections1232,1234), accordingly to other embodiments, other configurations and/or geometries may be used to control the venting ofproduct10. For example,seal1226 may be generally square, multi-sided, etc., and the venting may be directed through the seal by providing one or more relatively longer straight sections (one or more of which provide venting at an approximate mid-section of the straight portion). As such, one or more vent portions may be provided by the approximate mid-sections of various straight-sided sections of the seal without having to provide any weakened portions of seal. In yet further embodiments,seal1226 may be configured to vent at discreet locations along one or more sections of the vent (e.g., by weakened portions, etc.) as discussed with respect to various other embodiments disclosed herein.
• In some embodiments,seal1226 may extend about the upper periphery of interior1228, while in other embodiments, one or more positions ofseal1226 may be offset or spaced apart fromseal1226. For example, referring back toFIGS. 9-11, a straight-sided (e.g., square, polygonal, etc.) seal may be provided about a circular or rounded interior, such that the seal tends to vent at the midpoint of the longer sides rather than, for example, at the corners of the seal. Further, whileseal1226 is shown as having a generallyconstant width1242 about interior1228, according to other embodiments the width ofseal1226 may be varied at one or more sections along its length.
• Referring now toFIGS. 43-45, a package or packaging for, e.g., a food product, is shown according to various exemplary embodiments, where the packaging may be a “single” film (e.g., sheet or length of film), or other material configured or formed by, e.g., a flow-wrapping process, similar, for example, to that described previously with respect tobottom film1222. In particular,FIG. 43A illustrates afilm1302, which may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system in the direction ofarrow1305, for example.Film1302 may includelaminated areas1304 along at least two edges of thefilm1302. For example,laminated areas1304 may be made up of a lamination of materials, by laminating an absorbent or paper layer tofilm1302, as previously discussed for, e.g., absorbing moisture during a food product preparation or cooking process, as also previously described, controlling the amount of steam/moisture within the packaging, etc. It should be noted that thelaminated areas1304 may include or be made up of other materials, such as various sealants, polymer films, etc., whereas thefilm1302 itself may be any suitable material, such as flexible film, semi-rigid polymers, etc. Additionally,film1302 may include a non-laminated and/or “clear”area1306 through which a food product packaged in the packaging may be viewed, as also previously described. The non-laminated/clear area1306 may have an anti-fog feature or layer provided thereon as part of the inner surface of the non-laminated/clear area1306. Further still, thelaminated areas1304 and the non-laminated/clear area1306 can be configured to have shapes other than the “strip-like” shapes illustrated inFIGS. 43A and 43B.
• FIG. 43B illustratesfilm1302 as it may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose a food product. That is,film1302 may progress through the flow-wrapping apparatus or system in the direction ofarrow1305. In formingfilm1302, a fin seal may be created by formingfins1308 on either side offilm1302, and sealingfins1308 together.Fins1308 can be mated and sealed to form a fin seal by, e.g., pulling film1302 (as well as a food product enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins1308 by way of heat and pressure, or a cold seal, etc.
• As can be appreciated, after formingfilm1302 about the food product, two open ends can result, which may be crimped to fully seal the food product withinfilm1302. It should be noted that the resulting fin seal can be folded down or againstfilm1302, allowing the food product to ultimately sit or rest onlaminated areas1304, and seen by a consumer through the non-laminated/clear area1306. That is, and for example, the food product can be laid or positioned upside down onfilm1302 as it is formed, and the packaging including the food product may be “turned over” after forming and crimping is complete for presentation. Additionally, and during a food product preparation or cooking process, the non-laminated/clear area1306 may act as a steam dome, as previously described. Moreover, the resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described.
• FIGS. 44A and 44B illustrate a package in accordance with another exemplary embodiment, where the packaging may again be a single film (e.g., sheet or length of film) or other material configured or formed by, e.g., a flow-wrapping process, similar, for example, to that described previously with respect tobottom film1222. In particular,FIG. 44A illustrates afilm1310, which may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system in the direction ofarrow1315, for example.Film1310 may be any suitable material, such as flexible film, semi-rigid polymers, etc.Film1310 may include alaminated area1312 located substantially in a center area offilm1310, which can include an absorbent or paper layer laminated to film1310 for absorbing moisture during a food product preparation or cooking process, controlling the amount of steam/moisture within the food product packaging, etc. It should be noted that thelaminated area1312 may include or be made up of other materials, such as various sealants, polymer films, etc.Film1310 may further include non-laminated and/orclear areas1314 that can border either side of thelaminated area1312 through which a food product packaged in the packaging may be viewed, and which may act as a steam dome. The non-laminated/clear areas1314 may have an anti-fog feature or layer provided thereon as part of the inner surface of the non-laminated/clear areas1314. It should be noted that thelaminated area1312 and the non-laminated/clear areas1314 can be configured to have shapes other than the “strip-like” shapes illustrated inFIGS. 44A and 44B.
• FIG. 44B illustratesfilm1310 as it may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose a food product, as it progresses through the flow-wrapping apparatus or system in the direction ofarrow1315. Similar to the embodiment illustrated inFIGS. 43A and 43B, a fin seal may be created by formingfins1316 on either side offilm1310, and sealingfins1316 together.Fins1316 can be mated and sealed to form a fin seal by, e.g., pulling film1310 (as well as a food product enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins1316 by way of heat and pressure, or a cold seal, etc.
• As can be appreciated, after formingfilm1310 about the food product, the resulting open ends can be crimped to fully seal the food product withinfilm1310. It should be noted that the resulting fin seal can be folded down or againstfilm1310. In this particular embodiment, the food product may rest on laminated area1312 (without needing to be turned over), and seen by a consumer through the non-laminated/clear areas1314, which may again, act as a steam dome, as previously described. Moreover, the resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting.
• FIGS. 45A and 45B illustrate a package in accordance with still another exemplary embodiment, where the packaging may again be a single film (e.g., sheet or length of film) or other material configured or formed by, e.g., a flow-wrapping process, similar, for example, to that described previously with respect tobottom film1222. In particular,FIG. 45A illustrates afilm1318, which may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system in the direction ofarrow1320, for example.Film1318 may be any suitable material, such as flexible film, semi-rigid polymers, etc.Film1318 may be laminated in its entirety, such thatfilm1318 can include an absorbent or paper layer laminated thereon for absorbing moisture during a food product preparation or cooking process, controlling the amount of steam/moisture within the food product packaging, etc., and/or other materials, such as various sealants, polymer films, etc.
• FIG. 45B illustratesfilm1318 as it may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose a food product, as it progresses through the flow-wrapping apparatus or system in the direction ofarrow1320. Similar to the embodiments illustrated inFIGS. 43-44, a fin seal may be created by formingfins1322 on either side offilm1318, and sealingfins1322 together.Fins1322 can be mated and sealed to form a fin seal by, e.g., pulling film1318 (as well as a food product enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins1322 by way of heat and pressure, or a cold seal, etc.
• As can be appreciated, after formingfilm1318 about the food product, the resulting open ends can be crimped to fully seal the food product withinfilm1318. It should be noted that the resulting fin seal can be folded down or againstfilm1318. In this particular embodiment, the food product may rest on either the fin seal side offilm1318 or on the opposite side offilm1318. Moreover, the resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting. The embodiment illustrated inFIGS. 45A and 45B may be particularly applicable to food products and/or food product preparation or cooking processes that require a greater level of moisture or steam absorbency.
• It should be noted that the various embodiments illustrated inFIGS. 43-45 and described herein, and implemented utilizing a single, e.g., flow-wrap film, may incorporate one or more features of other embodiments illustrated inFIGS. 1-42 and described above.
• Referring now toFIGS. 46-54, a package or packaging for, e.g., a food product, is shown according to various exemplary embodiments, where the packaging may be an insert contained within a “single” film (e.g., sheet or length of film), or other material configured or formed by, e.g., a flow-wrapping process, similar, for example, to that described previously with respect tobottom film1222 orfilms1302,1310 and1318. In particular,FIGS. 46A and 46B illustrate aninsert1402 to be contained within afilm1420. Theinsert1402 may include an absorbent layer, a paper layer, or an absorbent layer laminated on a paper backing (or plastic backing) Theinsert1402 may include abase1415, a first side1410-1 and a second side1410-2. Thebase1415 may be designed to support the bottom of a food product while the sides1410 may extend up (e.g., perpendicular) from thebase1415 to contain the food product, e.g., prevent motion, from moving in a direction perpendicular to the sides1410. Having only two sides1410 may allow the food product to be easily slid out of an open end of the package to fully remove the food product or, alternatively, may allow the food product to be slid out gradually while one is eating the food product, and while the insert is still absorbing moisture. Theinsert1402 may also provide additional stability to the package. In some embodiments, the sides1410 may be omitted.
• Thefilm1420 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film1420 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert1402 may be sufficient to absorb any moisture given off by the food product during heating.
• Theinsert1402 may be made up of a lamination of materials, by laminating an absorbent layer on a paper backing layer, e.g., for absorbing moisture during a food product preparation or cooking process, or for controlling the amount of steam/moisture within the packaging, etc. It should be noted that theinsert1402 may include or be made up of other materials, such as various sealants, polymer films, etc., whereas thefilm1420 itself may be any suitable material, such as flexible film, semi-rigid polymers, etc. Additionally,insert1402 may include a plastic backing layer such as a thermoplastic polymer such as oriented polyethylene terephthalate (e.g., a 48 gauge OPET material, etc.) or similar material with an absorbent layer laminated thereon. For example, theinsert1402 may include an absorbent layer comprising 60% cellulose and 40% polypropylene laminated on a 48 gauge OPET material. Multiple layers of such plastic backing layers may be used for added rigidity.
• As illustrated inFIG. 46B, theinsert1402, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm1420. Thefilm1420 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert1402 and the food product. That is,film1420 and theinsert1402 may progress through the flow-wrapping apparatus or system in the direction ofarrow1430. In formingfilm1420, a fin seal may be created by formingfins1422 on either side offilm1420, and sealingfins1422 together.Fins1422 can be mated and sealed to form a fin seal by, e.g., pullingfilm1420 and insert1402 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins1422 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm1420 about theinsert1402 and food product, two open ends can result, which may be crimped to fully seal the food product withinfilm1420 and supported by theinsert1402. It should be noted that the resulting fin seal can be folded down or againstfilm1420, allowing theinsert1402 to ultimately sit or rest on a bottom offilm1420. The resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. The resulting package could be moisture and/or gas impermeable.
• FIGS. 47A and 47B illustrate aninsert1502 to be contained within afilm1530. Theinsert1502 may include an absorbent layer, a paper layer, or an absorbent layer laminated on a paper backing (or plastic backing) Theinsert1502 may include abase1520, a first long side1510-1, a second long side1510-2, a first short side1515-1 and a second short side1515-2. Thebase1520 may be designed to support the bottom portion of a food product while the sides1510 and1515 may extend upward (e.g., perpendicular) from thebase1520 to contain the food product, e.g., prevent motion in two directions perpendicular to the long sides1510 as well as the short sides1515. Having both the long sides1510 and the short sides1515 may allow both the food product and theinsert1502 to be easily slid out of an open end of the package to fully remove both theinsert1502 and the food product. In this way, theinsert1502 may also provide additional stability to both the package, while within the package, and to the food product when theinsert1502 and food product are removed from the package.
• Thefilm1530 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film1530 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert1502 may be sufficient to absorb any moisture given off by the food product during heating.
• Theinsert1502 may be made up of a lamination of materials, by laminating an absorbent layer on a paper backing layer, e.g., for absorbing moisture during a food product preparation or cooking process, or for controlling the amount of steam/moisture within the packaging, etc. It should be noted that theinsert1502 may include or be made up of other materials, such as various sealants, polymer films, etc., whereas thefilm1530 itself may be any suitable material, such as flexible film, semi-rigid polymers, etc. Additionally,insert1502 may include a plastic backing layer such as a thermoplastic polymer such as oriented polyethylene terephthalate (e.g., a 48 gauge OPET material, etc.) or similar material with an absorbent layer laminated thereon. For example, theinsert1502 may include absorbent layer comprising 60% cellulose and 40% polypropylene laminated on a 48 gauge OPET material. Multiple layers of such plastic backing layers may be used for added rigidity.
• As illustrated inFIG. 47B, theinsert1502, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm1530. Thefilm1530 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert1502 and the food product. That is,film1530 and theinsert1502 may progress through the flow-wrapping apparatus or system in the direction ofarrow1540. In formingfilm1530, an overlapping seal may be created by overlappingseal portions1532 on either side offilm1530, and sealingportions1532 together.Portions1532 can be mated and sealed to form a flat seal by, e.g., pullingfilm1530 and insert1502 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing one or more seal wheels of the flow-wrapping apparatus of system to sealportions1532 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm1530 about theinsert1502 and the food product, two open ends can result, which may be crimped to fully seal the food product withinfilm1530 and supported by theinsert1502, thus allowing theinsert1502 to ultimately sit or rest on a bottom offilm1530. The resulting flat seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. The resulting package could be moisture and/or gas impermeable.
• FIGS. 48A and 48B illustrate aninsert1602 to be contained within afilm1620. Theinsert1602 may include an absorbent layer, a paper layer, or an absorbent layer laminated on a paper backing (or plastic backing). Theinsert1602 may include abase1615 only. Thebase1615 may be designed to support the bottom portion of a food product. Having thebase1615 only without any sides may allow both the food product and theinsert1602 to be easily slid out of an open end of the package, in cases where the food product adheres to thebase1615, to fully remove both theinsert1602 and the food product. Alternatively, having no sides may allow the food product to be easily slid out of an open end of the package to fully remove the food product or, alternatively, may allow the food product to be slid out gradually while one is eating the food product, while the insert remains at least partially in thefilm1620 while still absorbing moisture. In this way, theinsert1602 may also provide additional stability to both the package, while within the package, and to the food product when theinsert1602 and food product are removed from the package.
• Thefilm1620 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film1620 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert1602 may be sufficient to absorb any moisture given off by the food product during heating.
• Theinsert1602 may be made up of a lamination of materials, by laminating an absorbent layer on a paper backing layer, e.g., for absorbing moisture during a food product preparation or cooking process, or for controlling the amount of steam/moisture within the packaging, etc. It should be noted that theinsert1602 may include or be made up of other materials, such as various sealants, polymer films, etc., whereas thefilm1620 itself may be any suitable material, such as flexible film, semi-rigid polymers, etc. Additionally,insert1602 may include a plastic backing layer such as a thermoplastic polymer such as oriented polyethylene terephthalate (e.g., a 48 gauge OPET material, etc.) or similar material with an absorbent layer laminated thereon. For example, theinsert1602 may include an absorbent layer comprising 60% cellulose and 40% polypropylene laminated on a 48 gauge OPET material. Multiple layers of such plastic backing layers may be used for added rigidity.
• As illustrated inFIG. 48B, theinsert1602, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm1620. Thefilm1620 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert1602 and the food product. That is,film1620 and theinsert1602 may progress through the flow-wrapping apparatus or system in the direction ofarrow1630. In formingfilm1620, a fin seal may be created by formingfins1622 on either side offilm1620, and sealingfins1622 together.Fins1622 can be mated and sealed to form a fin seal by, e.g., pullingfilm1620 and insert1602 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins1622 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm1620 about theinsert1602 and the food product, two open ends can result, which may be crimped to fully seal the food product withinfilm1620 and supported by theinsert1602, thus allowing theinsert1602 to ultimately sit or rest on a bottom offilm1620. The resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. The resulting package could be moisture and/or gas impermeable.
• FIG. 49 illustrates an alternative package configuration similar to that shown inFIGS. 46A and 46B. As illustrated inFIG. 49, aninsert1702 is inserted into afilm1720 where thefilm1720 includesfins1722 positioned under theinsert1702 rather than above an insert as shown inFIG. 46B. Thefilm1720 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film1720 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert1702 may be sufficient to absorb any moisture given off by the food product during heating.
• Theinsert1702 may be similar in all or some ways to theinsert1402 shown inFIGS. 46A and 46B. As illustrated inFIG. 49, theinsert1702, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm1720. Thefilm1720 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert1702 and the food product. That is,film1720 and theinsert1702 may progress through the flow-wrapping apparatus or system as discussed above. In formingfilm1720, a fin seal on a bottom of the package below the food product and theinsert1702 may be created by formingfins1722 on either side offilm1720, and sealingfins1722 together.Fins1722 can be mated and sealed to form a fin seal by, e.g., pullingfilm1720 and insert1702 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins1722 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm1720 about theinsert1702 and food product, two open ends can result, which may be crimped to fully seal the food product withinfilm1720 and supported by theinsert1702. It should be noted that the resulting fin seal can be folded down or againstfilm1720, allowing theinsert1702 to ultimately sit or rest on a bottom offilm1720 including the fin seal. The resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. The resulting package could be moisture and/or gas impermeable.
• FIG. 50 illustrates another alternative package configuration combining aninsert1802 similar to those inFIGS. 46A,46B and49, and afilm1820 similar to thefilm1530 ofFIG. 47B. As illustrated inFIG. 50, theinsert1802 is inserted into thefilm1820 where thefilm1820 includesseal portions1832 positioned under theinsert1802 rather than above an insert as shown inFIG. 47B. Thefilm1820 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film1820 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert1802 may be sufficient to absorb any moisture given off by the food product during heating.
• Theinsert1802 may be similar in all or some ways to theinsert1402 shown inFIGS. 46A and 46B. As illustrated inFIG. 50 theinsert1802, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm1820. Thefilm1820 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert1802 and the food product. That is,film1820 and theinsert1802 may progress through the flow-wrapping apparatus or system. In formingfilm1820, an overlapping seal may be created on a bottom of the package under the food product and theinsert1802 by overlappingseal portions1832 on either side offilm1820, and sealingportions1832 together.Portions1832 can be mated and sealed to form a flat seal by, e.g., pullingfilm1820 and insert1802 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing one or more seal wheels of the flow-wrapping apparatus of system to sealportions1832 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm1820 about theinsert1802 and the food product, two open ends can result, which may be crimped to fully seal the food product withinfilm1820 and supported by theinsert1802, thus allowing theinsert1802 to ultimately sit or rest on a bottom offilm1820 that includes theseal portions1832. The resulting flat seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. The resulting package could be moisture and/or gas impermeable.
• FIG. 51 illustrates yet another alternative package configuration. The package ofFIG. 51 includes afin seal film1920 similar to thefilms1420 ofFIG. 46B,1620 of48B and1720 ofFIG. 49. The package ofFIG. 51 also includes a four-sided insert1902 similar to theinsert1502 ofFIGS. 47A and 47B. As illustrated inFIG. 51, theinsert1902 is inserted into thefilm1920 where thefilm1920 includesfins1922 positioned under theinsert1902. Thefilm1920 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film1920 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert1902 may be sufficient to absorb any moisture given off by the food product during heating.
• As illustrated inFIG. 51, thefilm1920 may include asteam valve1940 formed in thefilm1920. Thesteam valve1940 may be a self-venting valve that releases pressure after the package pressure reaches a threshold level during heating. Thesteam valve1940 may be configured to release pressure, but retain moisture in the package, while the cooking continues. This may result in some food products retaining some moisture and remaining soft rather than drying out and becoming hard and/or brittle. For example, a food product such as a tortilla, bread, roll, breading or others, may benefit from such a steam valve. Thesteam valve1940 may be an actual mechanical valve attached to thefilm1920 or, alternatively, may be formed in thefilm1920 using a micro-perforation and/or micro-scoring technique to form a mechanical self-venting aperture in thefilm1920. In this way, thefilm1920 and the package can remain moisture and/or gas impermeable prior to the steam vent releasing. Thesteam valve1940 ofFIG. 51 is circular or elliptical in shape, but other shaped valves may also be utilized. In addition,multiple steam valves1940 may be included in thefilm1920.
• Theinsert1902 may be similar in all or some ways to theinsert1502 shown inFIGS. 47A and 47B. As illustrated inFIG. 51, theinsert1902, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm1920. Thefilm1920 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert1902 and the food product. That is,film1920 and theinsert1902 may progress through the flow-wrapping apparatus or system as discussed above. In formingfilm1920, a fin seal on a bottom of the package below the food product and theinsert1902 may be created by forming thefins1922 on either side offilm1920, and sealing thefins1922 together.Fins1922 can be mated and sealed to form a fin seal by, e.g., pullingfilm1920 and insert1902 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins1922 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm1920 about theinsert1902 and food product, two open ends can result, which may be crimped to fully seal the food product withinfilm1920 and supported by theinsert1902. It should be noted that the resulting fin seal can be folded down or againstfilm1920, allowing theinsert1902 to ultimately sit or rest on a bottom offilm1920 and thefins1922. The resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. However, due to the presence of thesteam valve1940, self-venting seals may not be necessary or desired, depending on the situation.
• FIG. 52 illustrates yet another alternative package configuration. The package ofFIG. 52 includes an overlappingseal film2020 similar to thefilms1530 ofFIG. 47B, and1820 ofFIG. 50. The package ofFIG. 52 also includes a two-sided insert2002 similar to theinserts1402 ofFIGS. 46A and 46B,1702 ofFIG. 49 and 1802 ofFIG. 50. As illustrated inFIG. 52, theinsert2002 is inserted into thefilm2020 where thefilm2020 includesseal portions2032 positioned under theinsert2002. Thefilm2020 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film2020 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert2002 may be sufficient to absorb any moisture given off by the food product during heating.
• As illustrated inFIG. 52, thefilm2020 may include asteam valve strip2040 formed in thefilm2020 generally parallel to a length of the package. Thesteam valve strip2040 may be a self-venting valve that releases pressure after the package pressure reaches a threshold level during heating. Thesteam valve strip2040 may be configured to release pressure, but retain moisture in the package while the cooking continues. This may result in some food products retaining some moisture and remaining soft rather than drying out and becoming hard and/or brittle. For example, a food product such as a tortilla, bread, roll, breading or others, may benefit from such a steam vent. Thesteam valve strip2040 may be an actual mechanical strip valve attached to thefilm2020 or, alternatively, may be formed in thefilm2020 using a micro-perforation and/or micro-scoring technique to form a mechanical self-venting aperture in thefilm2020. In this way, thefilm2020 and the package may remain moisture and/or gas impermeable prior to the steam vent releasing. Thesteam valve strip2040 ofFIG. 52 is straight, but other shaped strip valves may also be utilized. In addition, multiplesteam valve strips2040 may be included in thefilm2020.
• Theinsert2002 may be similar in all or some ways to theinsert1402 shown inFIGS. 46A and 46B. As illustrated inFIG. 52, theinsert2002, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm2020. Thefilm2020 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert2002 and the food product. That is,film2020 and theinsert2002 may progress through the flow-wrapping apparatus or system as discussed above. In formingfilm2020, an overlapping seal may be created on a bottom of the package under the food product and theinsert2002 by overlapping theseal portions2032 on either side offilm2020, and sealingportions2032 together.Portions2032 can be mated and sealed to form a flat seal by, e.g., pullingfilm2020 and insert2002 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing one or more seal wheels of the flow-wrapping apparatus of system to sealportions2032 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm2020 about theinsert2002 and the food product, two open ends can result, which may be crimped to fully seal the food product withinfilm2020 and supported by theinsert2002, thus allowing theinsert2002 to ultimately sit or rest on a bottom offilm2020 that includes theseal portions2032. The resulting flat seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. The resulting package could be moisture and/or gas impermeable. However, due to the presence of thesteam valve2040, self-venting seals may not be necessary or desired, depending on the situation.
• FIG. 53 illustrates yet another alternative package configuration. The package ofFIG. 53 includes afin seal film2120 similar to thefilms1420 ofFIG. 46B,1620 of48B,1720 ofFIG. 49 and 1920 ofFIG. 51. The package ofFIG. 53 also includes asideless insert2102 similar to theinsert1602 ofFIGS. 48A and 48B. As illustrated inFIG. 53, theinsert2102 is inserted into thefilm2120 where thefilm2120 includesfins2122 positioned above theinsert2102. Thefilm2120 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film2120 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert2102 may be sufficient to absorb any moisture given off by the food product during heating.
• As illustrated inFIG. 53, thefilm2120 may include twosteam valve strips2140 formed on opposite sides of thefilm1920 generally parallel to a length of the package. Thesteam valve strips2140 may be a self-venting valve that releases pressure after the package pressure reaches a threshold level during heating. Thesteam valve strips2140 may be configured to release pressure, but retain moisture in the package, while the cooking continues. This may result in some food products retaining some moisture and remaining soft rather than drying out and becoming hard and/or brittle. For example, a food product such as a tortilla, bread, roll, breading or others, may benefit from such a steam valve. Thesteam valve strips2140 may be actual mechanical valves attached to thefilm2120 or, alternatively, may be formed in thefilm2120 using a micro-perforation and/or micro-scoring technique to form a mechanical self-venting aperture in thefilm2120. In this way, thefilm2120 and the package can remain moisture and/or gas impermeable prior to the steam vent releasing. Thesteam valve strips2140 ofFIG. 53 are straight, but other shaped strips valves may also be utilized.
• Theinsert2102 may be similar in all or some ways to theinsert1602 shown inFIGS. 48A and 48B. As illustrated inFIG. 53, theinsert2102, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm2120. Thefilm2120 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert2102 and the food product. That is,film2120 and theinsert2102 may progress through the flow-wrapping apparatus or system as discussed above. In formingfilm2120, a fin seal on a top of the package above the food product and theinsert2102 may be created by forming thefins2122 on either side offilm2120, and sealing thefins2122 together.Fins2122 can be mated and sealed to form a fin seal by, e.g., pullingfilm2120 and insert2102 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing fin seal wheels of the flow-wrapping apparatus of system to sealfins2122 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm2120 about theinsert2102 and food product, two open ends can result, which may be crimped to fully seal the food product withinfilm2120 and supported by theinsert2102. It should be noted that the resulting fin seal can be folded down or againstfilm2120, allowing theinsert2102 to ultimately sit or rest on a bottom offilm2120. The resulting fin seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. However, due to the presence of thesteam valve strips2140, self-venting seals may not be necessary or desired, depending on the situation.
• FIG. 54 illustrates yet another alternative package configuration. The package ofFIG. 54 includes an overlappingseal film2220 similar to thefilms1530 ofFIG. 47B,1820 ofFIG. 50 and 2020 ofFIG. 52. The package ofFIG. 54 also includes a two-sided insert2202 similar to theinserts1402 ofFIGS. 46A and 46B,1702 ofFIG. 49,1802 ofFIG. 50 and 2002 ofFIG. 52. As illustrated inFIG. 54, theinsert2202 is inserted into thefilm2220 where thefilm2220 includesseal portions2232 positioned under theinsert2202. Thefilm2220 may be a section of a film roll that can be fed via a film feed assembly onto a former or forming area in a flow-wrapping apparatus or system.Film2220 may or may not include laminated areas, not shown, such as thelaminated areas1304,1312 or be entirely laminated such as thefilm1318 described above. However, these laminated areas may be omitted since theinsert2202 may be sufficient to absorb any moisture given off by the food product during heating.
• As illustrated inFIG. 54, thefilm2220 may include asteam valve strip2240 formed in thefilm2220 generally perpendicular to a length of the package. Thesteam valve strip2240 may be a self-venting valve that releases pressure after the package pressure reaches a threshold level during heating. Thesteam valve strip2240 may be configured to release pressure, but retain moisture in the package while the cooking continues. This may result in some food products retaining some moisture and remaining soft rather than drying out and becoming hard and/or brittle. For example, a food product such as a tortilla, bread, roll, breading or others, may benefit from such a steam vent. Thesteam valve strip2240 may be an actual mechanical strip valve attached to thefilm2220 or, alternatively, may be formed in thefilm2220 using a micro-perforation and/or micro-scoring technique to form a mechanical self-venting aperture in thefilm2220. In this way, thefilm2220 and the package may remain moisture and/or gas impermeable prior to the steam vent releasing. Thesteam valve strip2240 ofFIG. 54 is straight, but other shaped strip valves may also be utilized. In addition, multiplesteam valve strips2240 may be included in thefilm2220.
• Theinsert2202 may be similar in all or some ways to theinsert1402 shown inFIGS. 46A and 46B. As illustrated inFIG. 54, theinsert2202, and the food product, not shown, may be inserted, e.g., using a horizontal form fill seal apparatus, intofilm2220. Thefilm2220 may be formed into a cylindrical tube or otherwise encompassing shape configured to enclose both theinsert2202 and the food product. That is,film2220 and theinsert2202 may progress through the flow-wrapping apparatus or system as discussed above. In formingfilm2220, an overlapping seal may be created on a bottom of the package under the food product and theinsert2202 by overlapping theseal portions2232 on either side offilm2220, and sealingportions2232 together.Portions2232 can be mated and sealed to form a flat seal by, e.g., pullingfilm2220 and insert2202 (as well as a food product supported and enclosed therein) through the aforementioned former or forming area and allowing one or more seal wheels of the flow-wrapping apparatus of system to sealportions2232 by way of heat and pressure, or a cold seal, etc.
• As discussed above, after formingfilm2220 about theinsert2202 and the food product, two open ends can result, which may be crimped to fully seal the food product withinfilm2220 and supported by theinsert2202, thus allowing theinsert2202 to ultimately sit or rest on a bottom offilm2220 that includes theseal portions2232. The resulting flat seal and/or one or both crimped ends can be created in such a manner that allows for self-venting, as previously described. The resulting package could be moisture and/or gas impermeable. However, due to the presence of thesteam valve strip2240, self-venting seals may not be necessary or desired, depending on the situation.
• It should be noted that the various embodiments of inserts illustrated inFIGS. 46-54, and described herein, may incorporate different shapes and/or include different numbers of sides extending upward from a base of the inserts so as to accommodate differently shaped food products. For example, an insert could be triangular, square, circular, pentagonal, hexagonal, or any other shape. It should be further noted that the various embodiments illustrated inFIGS. 46-54 and described herein, and implemented utilizing an insert within a single, e.g., flow-wrap film, may incorporate one or more features of other embodiments illustrated inFIGS. 1-45 and described above.
• The various embodiments of the packaged food product and packaging disclosed herein provide many benefits to consumers. For example, the packaged food product provides an “on-the-go” food product having user-friendly packaging requiring only a “single step” heating in a microwave oven. Control of steam and moisture content within the packaging during heating decreases preparation time, provides for optimal moisture content of the food product, and ensures an evenly heated food product. Further, the anti-fog treatment of the packaging reduces water droplet formation and maintains an aesthetically pleasing appearance for consumers. Further yet, because the food product may be heated without needing to open the packaging, no additional materials are required (e.g., a napkin, paper towel, etc.), no messes are made within the microwave (e.g., due to spills, splattering, melting, etc. resulting from unpackaged food products or open packagings), and the food product may be eaten right out of the packaging after heating. The creation of a “steam dome” assists in both faster cooking and providing an easy peel feature by weakening the seal through the escape of steam.
• Furthermore, it should be noted that while in various embodiments specific dimensions have been provided, such dimensions are not limiting such that the embodiments disclosed herein may be usable with a variety of dimensions not specified herein (e.g., such as the width of a seal of seal portion, the length and/or width of a vent portion, etc. Further, the number, size, spacing, and shape of various features may also be varied from the specific embodiments shown herein (e.g., the shape of a seal or seal portion, vent, of peelable corner portion, etc.). For example, in some embodiments, one, some, or all corners of a packaging may provide an “easy-peal” feature. Further, reliefs formed into seal bars usable to form vent portions may varying dimensions for length, width, and depth. For example, while the “depth of the relief is shown in some embodiments as being 0.010 inches, according to various other embodiments, the depth of the relief may be more or less than 0.010 inches (e.g., 0.005 inches, 0.003 inches, 0.015 inches, etc.). All such variations in the size shape, number, positioning, etc. of the various components and features disclosed herein are within the scope of the present disclosure.
• It is important to note that the construction and arrangement of the elements of the products and methods as shown in the exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the various embodiments. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and/or omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the spirit of the present disclosure.

Claims (20)

What is claimed is:

1. A package, comprising:

a sheet of film formable about a food product; and

an absorbent material laminated to at least one area of the sheet of film;

wherein a first edge and a second edge of the sheet of film are sealed together via at least one of a self-venting fin seal and an overlapping seal, creating at least a partially absorbent enclosure for the food product.

2. The package ofclaim 1, wherein a third edge and a fourth edge of the sheet of film are each sealed via respective crimped seals.

3. The package ofclaim 2, wherein at least one of the respective crimped seals is configured to be self-venting.

4. The package ofclaim 1, wherein the at least one area of the sheet of film to which the absorbent material is laminated comprises a first laminated area along the first edge of the sheet of film and a second laminated area along the second edge of the sheet of film.

5. The package ofclaim 1, wherein the at least one area of the sheet of film to which the absorbent material is laminated is configured to absorb moisture from within an interior area of the at least partially absorbent enclosure for the food product.

6. The package ofclaim 1, wherein a first interior surface of the at least partially absorbent enclosure for the food product along the self-venting fin seal comprises a base portion upon which the food product rests.

7. The package ofclaim 6, wherein a second interior surface of the at least partially absorbent enclosure for the food product opposite the self-venting fin seal comprises at least one of a non-laminated area and a clear area.

8. The package ofclaim 7, wherein the second interior surface of the at least partially absorbent enclosure for the food product comprises at least one of an anti-fog feature and a steam dome feature.

9. The package ofclaim 1, wherein the at least one area of the sheet of film to which the absorbent material is laminated comprises a laminated area centrally located between the first edge and the second edge of the sheet of film.

10. The package ofclaim 9, wherein the laminated area centrally located between the first edge and the second edge of the sheet of film comprises a base portion upon which the food product rests.

11. The package ofclaim 10, wherein two non-laminated and clear areas located along the first edge and the second edge of the sheet of film, connected via the self-venting fin seal, comprise a viewing area for the food product.

12. The package ofclaim 11, wherein the two non-laminated and clear areas located along the first edge and the second edge of the sheet of film, connected via the self-venting fin seal, further comprise a steam dome.

13. A package, comprising:

a sheet of film formable about a food product; and

an absorbent material laminated to an interior surface of the sheet of film;

wherein a first edge and a second edge of the sheet of film are further formed into at least one of sealable fins or overlapping portions, the sealable fins or the overlapping portions, when sealed together, creating a moisture absorbent enclosure for the food product.

14. The package ofclaim 13, wherein the sealable fins sealed together are configured to self-vent during or subsequent to cooking of the food product.

15. The package ofclaim 13, wherein a third edge and a fourth edge of the sheet of film are each sealed via respective crimped seals.

16. The package ofclaim 15, wherein at least one of the respective crimped seals is configured to be self-venting.

17. A packaged food product, comprising:

a food product;

a package having an interior area containing the food product, the package comprising:

a length of flow-wrap film, at least one portion of which includes a laminated area;

wherein at least two edges of the length of flow-wrap film are sealed together via at least one of a self-venting fin seal or an overlapping seal at least partially forming the interior area, such that the laminated area is configured to absorb moisture within the interior area.

18. The packaged food product ofclaim 17, wherein the laminated area comprises an absorbent material laminated to the at least one portion of the length of flow wrap film.

19. The packaged food product ofclaim 17, wherein at least another portion of the length of flow-wrap film is non-laminated and clear.

20. The packaged food product ofclaim 17, wherein the laminated area provides a base upon which the food product is placed.

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