EP0350660A2 - Composite sheet stock for microwave heating and receptacle - Google Patents

Composite sheet stock for microwave heating and receptacle Download PDF

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Publication number
EP0350660A2
EP0350660A2 EP89111096A EP89111096A EP0350660A2 EP 0350660 A2 EP0350660 A2 EP 0350660A2 EP 89111096 A EP89111096 A EP 89111096A EP 89111096 A EP89111096 A EP 89111096A EP 0350660 A2 EP0350660 A2 EP 0350660A2
Authority
EP
European Patent Office
Prior art keywords
layer
microwave
stock
susceptor
receptacle
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP89111096A
Other languages
German (de)
French (fr)
Other versions
EP0350660A3 (en
Inventor
Kirk A. Jaeger
David R. Popp
Yigal Peleg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Societe des Produits Nestle SA
Nestle SA
Original Assignee
Societe des Produits Nestle SA
Nestle SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US07/218,205 external-priority patent/US4891482A/en
Application filed by Societe des Produits Nestle SA, Nestle SA filed Critical Societe des Produits Nestle SA
Publication of EP0350660A2 publication Critical patent/EP0350660A2/en
Publication of EP0350660A3 publication Critical patent/EP0350660A3/en
Withdrawn legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within the package
    • B65D81/3446Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within the package specially adapted to be heated by microwaves
    • B65D81/3453Rigid containers, e.g. trays, bottles, boxes, cups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3401Cooking or heating method specially adapted to the contents of the package
    • B65D2581/3402Cooking or heating method specially adapted to the contents of the package characterised by the type of product to be heated or cooked
    • B65D2581/3405Cooking bakery products
    • B65D2581/3406Pizza or bread
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3437Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within specially adapted to be heated by microwaves
    • B65D2581/3439Means for affecting the heating or cooking properties
    • B65D2581/3452Packages having a plurality of microwave reactive layers, i.e. multiple or overlapping microwave reactive layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3437Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within specially adapted to be heated by microwaves
    • B65D2581/3471Microwave reactive substances present in the packaging material
    • B65D2581/3472Aluminium or compounds thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3437Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within specially adapted to be heated by microwaves
    • B65D2581/3486Dielectric characteristics of microwave reactive packaging
    • B65D2581/3489Microwave reflector, i.e. microwave shield
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3437Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within specially adapted to be heated by microwaves
    • B65D2581/3486Dielectric characteristics of microwave reactive packaging
    • B65D2581/3494Microwave susceptor

Definitions

  • This invention relates to the microwave heating of food products and more particularly to a sheet stock and a microwave heating receptacle, and a method of using this receptacle for reconstituting frozen food products.
  • reconstituting is used to mean “preparing for consump­tion”.
  • the present invention is particularly applicable for reconstituting frozen pizza, such as elongated, rectan­gular sections of bread topped with pizza constituents and frozen individually.
  • the invention will be described with particular reference to this food product; however, it is appreciated that the invention has substantially broader applications and may be used for heating or re­constituting various food products of the type having a lower, generally flat, farinaceous portion which is to be heated to a crisp condition preparatory to serving.
  • US Patent 4190757 shows a lower sus­ceptor sheet spaced from the bottom wall of the micro­wave oven onto which the lower farinaceous crust portion of the pizza is supported so that the crust portion was heated to a high temperature causing browning and crisp­ness adjacent the lower surface of the crust.
  • This pro­cedure although having some advantages, was not suc­cessful until the development of the susceptor material disclosed generally in US Patent 4641005. Such material was used to construct the plates, boats and/or platforms suggested for reconstitution of frozen pizza.
  • a composite sheet stock comprising a microwave suscep­tor sheet having a dielectric support layer and a heater layer of microwave interactive material allowing passage of microwave energy as it is heated thereby, and a layer of heat-conducting, microwave reflecting material adhered to the heater layer.
  • a receptacle in the form of a self-supporting box or sleeve formed from a highly metal­lized microwave susceptor sheet stock so that the sheet stock has a lower flat portion and an upper flat portion to completely surround the flat pizza to be heated in a microwave oven.
  • the box or sleeve When in its operative assembled condi­tion, the box or sleeve has generally fixed configura­tions with a height substantially greater than the thick­ness of the pizza for which the box or sleeve forms a heating receptacle.
  • This concept uses a susceptor of a generally rigid sheet stock, such as paperboard, which can be bent into a shape that is maintained by the rigi­dity of the support board. This is different from a wrapping stock wherein the shape is dictated generally by the shape of the product.
  • the base of the receptacle may be formed from the com­posite sheet stock in accordance with the invention, with the dielectric layer facing outwardly.
  • the lower portion or base may be made of at least two susceptor layers wherein one of the susceptors may be formed integral with the box or sleeve and the second may be a separate element,optionally secured to the first.
  • the surface resistivity of the second susceptor layer may be different from the surface resis­tivity of the first susceptor layer.
  • the upper portion of the food article is heated by a combination of radia­tion from the surrounding susceptor sheet and microwave energy that passes through the susceptor sheet.
  • the second sheet causes nearly all of the microwave energy to be absorbed so that a substantially greater amount of heat is generated for baking and crisping the crust.
  • the second layer of susceptor material may also extend to areas beyond just the bottom portion for changing the heating character­istics of the sleeve or box.
  • the second layer of susceptor material may extend upwardly along the side walls of the sleeve.
  • the lower portion of the sleeve or box is flat and is desirably elevated a preselected distance from the bottom wall of the microwave oven.
  • the heat absorbed in the first layer of microwave susceptor material is trans­ferred by convection to the second layer of susceptor material.
  • This second layer is also heated by microwave energy and transmits the heat from the first layer and its own heat to the bottom surface of the food article resting upon the two layers of susceptor sheet material.
  • This second susceptor layer or sheet material may be glued or laminated to the first layer in the bottom portion of the box or sleeve or it may bean integral part of the blank which forms the box or sleeve.
  • a highly heat conductive layer such as aluminum foil, may be located between the two microwave susceptor layers. This assists in the transfer by conduction of heat from the lower susceptor sheet to the upper susceptor sheet. When this occurs, the upper susceptor sheet is heated by microwave energy coming through the product itself to create a second heat source in the lower portion of the box or sleeve.
  • the lower portion of the receptacle may be formed from a layer of the compo­site stock described above and a susceptor layer.
  • the feature of increasing the heating effect whilst decrea­sing the amount of microwave energy passing through the bottom of the receptacle may be accomplished by selec­tively increasing the amount of metal in the metallized heating layer of the susceptor sheet in the bottom or lower portion of the receptacle.
  • the receptacle is a sleeve which has side walls that are collapsible so that the sleeve can be flattened and shipped in a position adjacent, preferably under, the pizza segment(s).
  • the flattened sleeve is expanded and used as a self-supporting receptacle for a single pizza segment.
  • This manipulating action may also extend a set of inte­gral legs cut from the rigid paperboard which serve to create the necessary spacing between the bottom wall of the microwave oven and the lower flat portion of the receptacle.
  • the height of the sleeve is preferably greater than the thickness of the pizza segment; howev­er, the width of the sleeve is not substantially greater than the width of the segment, so that there is a space above the pizza, which should not be more than about 25 mm and is preferably less than about 13 mm.
  • FIGURES 1-4 show a package A for shipping and distributing a frozen entree B such as a flat, elongated rectangular segment of pizza formed by placing on the upper surface of a bread layer 10 having a generally cup-shaped crust 10a, a topping layer 12 formed from sauce 14 and miscellaneous food items 16.
  • the bread is baked, sliced and cut to size.
  • items 16 in a frozen condition and sauce 14 are spread on the upper surface of the bread.
  • Package A is formed of paperboard and includes an outer shipping carton 20 of the type which is not microwave compatible and is selected for shipment purposes only.
  • Food article B is wrapped in an air impermeable, plastic wrapper 22 which may be evacuated or filled with an inert gas.
  • Article B is frozen and shipped in carton 20 for display in the freezer section of a retail outlet.
  • a disposable heating or reconstitution receptacle in the preferred form of sleeve C formed from the sheet paperboard blank, such as illustrated in FIGURE 5.
  • Sleeve C is formed from a microwave susceptor sheet 30 of the type disclosed in US Patent 4641005.
  • This sus­ceptor sheet includes a layer of generally continuous microwave interactive material 32 formed by vacuum depo­siting a thin layer of aluminum or similar metal onto a smooth plastic support film 34 which is, in turn, adhered to a flat, generally rigid paperboard 36 forming the support layer for microwave susceptor sheet 30.
  • the interactive material is of the type having a surface resistivity less than about 6 ohms/cm, preferably about 5 to 6 ohms/cm, and is constructed upon a standard weight paper­board and is as rigid as a standard poster stock.
  • Such microwave susceptor sheet stock material but with a higher resistivity, is well known in the art and is widely used for microwave heating of various food prod­ucts.
  • the selection of a low surface resistivity on a firm or generally rigid paperboard for an encircling free standing sleeve C is believed to be novel. This combination of strength and high heating by low resis­tivity is a further advantage of the preferred embodi­ment of the present invention.
  • this sleeve includes two parallel, generally flat portions 50, 52 which are adapted to be located on opposite sides of the food item B during the microwave heating operation.
  • lower or bottom flat portion 50 is formed from two separate layers 50a, 50b of microwave susceptor sheet 30. Consequently, sleeve C comprises parallel flat portions 50, 52 with lower or bottom portion 50 formed by two separate and distinct interactive layers 50a, 50b.
  • sleeve C includes inte­gral side walls 60, 62. Wall 60 includes parallel cut lines or serrated seams 70, 72, and 74.
  • wall 62 includes cut lines or serrated seams 80, 82, and 84.
  • seams sleeve C can be folded into a collapsed condition, as shown in FIGURE 1 or can be manually expanded into the operative, heating confi­guration, as shown in FIGURES 3 and 4.
  • seams 82, 84 are formed into parallel tear lines so that tear strip 90 can be manually removed from side wall 62. This opening feature allows easy removal of the heated food article and as­sures that sleeve C is discarded since it is generally of no use after tear strip 90 has been removed.
  • lower portion 50 To assure that microwave energy enters through lower portion 50, to heat susceptor layers 50a, 50b, lower portion 50 must be spaced from the lower wall D of the microwave oven during the heating process.
  • This spacing can be maintained by a separate element as shown in FIGURE 14 or, as in accordance with the preferred em­bodiment, by a plurality of integrally formed downwardly depending legs 100, 102, 104 and 106 which are folded into a generally flat condition when sleeve C is col­lapsed, as shown in FIGURES 1 and 2, and are moved to downwardly depending positions, as shown in FIGURES 3 and 4, when sleeve C is manually formed into its heating or operative configuration. These legs are cut from mi­crowave susceptor sheet 30, as best illustrated in FIGURE 5.
  • Sleeve C is self-supporting and has the features dis­cussed in the introductory portion of this disclosure. It is collapsed or folded and shipped in a generally flat condition in package A, as shown in FIGURE 1 and FIGURE 2.
  • article B When article B is to be reconstituted, it is removed from wrapper 22, the sleeve is manually assem­bled into the configuration shown in FIGURE 3 and the article is slipped longitudinally into the sleeve, as shown in FIGURE 4.
  • Side walls 60, 62 extend upwardly along the vertical portion of crust 10a.
  • Sleeve C loaded with article B is positioned on lower wall D of the mi­crowave oven and the oven is energized to cook, bake or otherwise reconstitute the frozen food entree or food article B.
  • FIGURES 6, 7A and 7B the operating characteristics of the preferred embodiment of the present invention, as shown in FIGURES 1-5, are illustrated graphically and in a general manner.
  • microwave energy indicated as W
  • W penetrates through upper sleeve portion 52.
  • the inner cham­ber O of self-supporting receptacle C is a small oven chamber wherein heat is radiated from that portion of the susceptor sheet 30 forming upper portion 52.
  • a sub­stantial amount of the microwave energy passes through material 30 and heats the topping 12 which is lossy ma­terial whilst portion 52 radiates heat to the topping surface.
  • the microwaves then pass through the first interactive layer 32 which removes a substantial amount of energy from W1.
  • the amount of absorption is controlled by the amount of metal in layer 32 which is expressed as surface resistivity (R s ).
  • R s surface resistivity
  • This energy absorption by layer 32 of layer 50a produces weaker microwave energy illustrated schemati­cally as W2 shown progressing upwardly through the second layer 50a where it interacts with microwave interactive layer 32 of layer 50b which converts even more of the original microwave energy into heat. Only a minor por­tion, if any, of the original microwave radiation W passes through second layer 50a.
  • the layer 50b is heated by microwave lower interactive layer 32, and heat is convected from this first layer as indicated by the serpentine lines CV upwardly through the layer 50b.
  • This convection heat combines with the further heat generated at the second interactive layer 32 to convert a major portion of the incoming microwave energy into convected heat as indicated by further lines CV above layer 50b.
  • Board 36 of lower layer 50a insulates sleeve C so that the convective energy moves generally upwardly through the upper portion of layer 50b to combine with the heat generated in this layer. There is, thus, a high heat concentration at lower crust 10a.
  • the second layer could be provided in the verti­cal areas of crust 10a adjacent side walls 60, 62.
  • the heating effect is caused by induced flow of current I when microwaves W pass through an interactive layer 32 of susceptor sheet 30; therefore, penetration by radiation is generally required for the purpose of causing heating of the interactive material.
  • sleeve portion 50 is spaced a distance g from lower wall D. This spacing is in the range of 3 to 13 mm and can be provided by legs 100, 102, 104 and 106, as previously described, or by a separate spacer element, such as the corrugated board shown generally in FIGURE 16.
  • the novel sleeve is a receptacle for heating the arti­cle, as opposed to some type of general heat conducting material wrapped around the article and having a shape determined by the article.
  • the lower layer 50a can be pro­vided with a downwardly and transversely extending rib 110, shown in phantom lines in FIGURES 2-4.
  • This rib allows use of a thinner paperboard while maintaining the necessary gap g under lower portion 50.
  • other downwardly depending tabs and ribs could be provided for further enhancing the rigidity of lower portion 50 to prevent undue sagging of this lower support portion of sleeve C.
  • FIGURE 8 shows that the surface resistivity of layer 50a can be different from the surface resistivity of layer 50b.
  • This objective can be accomplished by a separate microwave susceptor sheet forming layer 50b or the layer 50b can be provided with a different thickness of metal constituting interactive material or layer 32 of sheet 30.
  • the higher surface resistivity of lower layer 50a indicates a thinner layer of resistive metal in layer 32 and a correspondingly lesser heating effect at layer 50a.
  • most heating occurs in layer 50b in this par­ticular modification of the present invention.
  • conduction from lower layer 50a is not as impor­tant a component of the total heating effect as when both layers are formed from the same microwave interac­tive material or sheet 30.
  • a third layer 50c of microwave interactive material is incorporated in the lower flat bottom por­tion 120 of a modified sleeve.
  • This separate sheet stock of interactive material can have a distinct surface re­sistivity.
  • the microwave energy is cap­tured at least by the third interactive layer 50c so that only a negligible amount of microwave energy enters into layer 10 from lower flat portion 120.
  • the paperboard support layers 36 of layers 50a, 50b, 50c can be relatively thin since overall support for the product being heated is obtained by the lower layer 50a and at least by lower layer 50a in combination with upper layer 50b.
  • the support paperboard or other dielec­tric material 36 for each layer (50b, 50c) above the bottom structural support layer 50a is relatively thin and may be substantially greater than 16 points.
  • FIGURE 10 shows the composite stock wherein the lower susceptor layer 50a is covered by a heat conduction layer 130 so that heat generated in lower surface 50a is conducted through this heat conductive layer 130 into layer 10 to cause high heat at crust 10a.
  • this conductive layer 130 is aluminum foil that reflects microwave energy.
  • microwave energy passing through reactive layer 32 of lower layer 50a causes heating as the microwaves pass toward and away from the reflective layer 130.
  • This dual action enhances the heating effect of lower layer 50a, which, in turn, causes the temperature at surface 130 to be relatively high.
  • the reflective nature of metal layer 130 shields crust 10a against microwaves from lower portion 50 of sleeve C. Thus, all heat at the surface of crust 10a is by conduction from heated layer 130.
  • FIGURE 11 A further modification of the concept shown in FIGURE 10 is shown in FIGURE 11 wherein the heat conduction layer 130 is located between lower layers 50a, 50b.
  • microwave energy which happens to pass downwardly through topping 12 and bread layer 10 is con­verted into heat by the uppermost layer 50b of lower portion 50.
  • FIGURE 12 A modification of this concept is illustrated in FIGURE 12 wherein layer 50b′ is similar to layer 50b except that the order of lamination is reversed.
  • the interactive material 32 of layer 50b′ is adjacent alumi­num foil 130.
  • the heating cycle for reconstitution of pizza with sleeve C is shown, by way of example, in FIGURE 13.
  • the microwave oven is first energized with a power set­ting of between 25%-50% for approximately 6.0 minutes. This method has been found to be sufficient to reconsti­tute pizza segments sold by Stouffer Foods Corporation under the designation "French Bread Pizza". Should the microwave oven have a low power rating, i.e. in the range of 400-600 watts, then the power setting should be at the higher level, such as approximately 50%. Using a microwave oven having a higher power rating of 600-800 watts, the setting may be reduced to approximately 25% for about 6.0 minutes.
  • the initial heating which causes the starch of the bread layer 10 to swell before water within the starch begins to heat, is followed by heating for approximately 1.0 minute at full power. This allows the microwave energy to fully cook the topping portion of the pizza.
  • FIGURES 14-17 A modification of the preferred embodiment of the inven­tion is illustrated in FIGURES 14-17 wherein the free standing receptacle of the present invention is in the structural form of a box 200 assembled from blank 202 of 16 point, generally self-sustaining paperboard and con­taining, at least, areas of microwave interactive mate­rial.
  • the sheet stock of blank 202 is a microwave susceptor sheet similar to sheet 30 of sleeve C.
  • Blank 202 is illustrated in detail in FIGURE 17 and has a shape to be assembled into a structural configuration which will encircle the pizza segment or other food article B shipped in a wrapper 22 in package A, as shown in FIGURE 14.
  • the pizza segment is shown as being actually shipped in heating receptacle box 200 with a first spacing member 210 under the box.
  • Member 210 has a thickness generally corresponding to the desi­red spacing g.
  • Box 200 includes a separate, second micro­wave susceptor sheet 212 so that the lower flat portion 220 of the box is provided with two susceptor sheets for the reasons explained in connection with the preferred sleeve configuration.
  • the upper por­tion of the encircling microwave susceptor sheet is a self-supporting, flat lid 222 joined with lower flat portion 220 by free standing side walls 224, 226 obtained by folding blank 202 along cut lines or seams 230, 232, 234, as best shown in FIGURE 17.
  • To facilitate folding of tabs 240 there are provided cut lines or seams 241 so that tabs 240 can be interlocked with end flaps 250 de­fined by parallel cut lines or seams 242, 244.
  • Box 200 can be shipped in package A in a flattened con­dition or assembled around the pizza, as shown in FIGURE 14.
  • end flaps 250 are folded upwardly and interlocked with tabs 240.
  • pizza B is placed within the box.
  • Wrapper 22 is removed before actually heating the pizza.
  • spacer member 210 is placed under lower flat portion 220 to raise the box a distance g from lower oven wall D for the purposes of heating in accordance with the method described generally in con­junction with the schematic heating cycle shown in FIGURE 13.
  • Blank 202 can be provided with selective areas of dif­ferent microwave interactive materials.
  • the surface resistivity of the various panels in blank 202 is shown as having a value a, b, or c.
  • the bottom portion 220 has a low surface resistivity which indicates a greater amount of metallization. Consequently, this surface will heat to a greater extent than the side walls and lid which have a higher surface resistivity and, thus, a lower metallization.
  • End tabs 240 and end flaps 250 are not metallized at all, being merely self-sustaining paper­board. In this manner, microwave energy can enter each end of box 200.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Food Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Package Specialized In Special Use (AREA)
  • Cookers (AREA)
  • Electric Ovens (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
  • Wrappers (AREA)
  • Laminated Bodies (AREA)

Abstract

A composite sheet stock for microwave heating comprises a susceptor sheet (30) having a dielectric support layer (36), a heater layer (34) of microwave interactive mater­ial and a heat-conducting microwave reflecting layer (130). A receptacle with a self-supporting configuration for combined microwave baking and cooking of a food ar­ticle, such as pizza, is constructed from susceptor stock and comprises an outwardly exposed, dielectric support layer, such as paperboard, and an inwardly facing heater layer and includes a lower flat portion for supporting the food article during heating. The lower portion may be a layer of composite stock as above or it may be formed from at least two layers of susceptor stock with­out a heat-conducting layer. The lower portion of the food product is, thus, heated primarily by conduction, while the upper portion is heated by combined radiation from the susceptor sheet and absorption of microwaves passing through the susceptor sheet. The receptacle may be collapsible.

Description

  • This invention relates to the microwave heating of food products and more particularly to a sheet stock and a microwave heating receptacle, and a method of using this receptacle for reconstituting frozen food products. Throughout the present specification the expression "reconstituting" is used to mean "preparing for consump­tion".
  • The present invention is particularly applicable for reconstituting frozen pizza, such as elongated, rectan­gular sections of bread topped with pizza constituents and frozen individually. The invention will be described with particular reference to this food product; however, it is appreciated that the invention has substantially broader applications and may be used for heating or re­constituting various food products of the type having a lower, generally flat, farinaceous portion which is to be heated to a crisp condition preparatory to serving.
  • Various approaches have been suggested to the microwave reconstitution of frozen pizza, involving special pack­ages. For example, US Patent 4190757 shows a lower sus­ceptor sheet spaced from the bottom wall of the micro­wave oven onto which the lower farinaceous crust portion of the pizza is supported so that the crust portion was heated to a high temperature causing browning and crisp­ness adjacent the lower surface of the crust. This pro­cedure, although having some advantages, was not suc­cessful until the development of the susceptor material disclosed generally in US Patent 4641005. Such material was used to construct the plates, boats and/or platforms suggested for reconstitution of frozen pizza. By using this new sheet susceptor material, some crispness is obtained at the lower level of the pizza crust; however, the crust remained flaccid and the sauce, forming a constituent of the topping, was overcooked. The remainder of the crust layer was heated in a nonuniform manner to result in a soft crust. Frozen pizza reconstituted by microwave procedures employing a microwave susceptor sheet of the general type disclosed in US Patent No. 4641005 is still substantially unacceptable for quality reconstitution of frozen pizza of the type using stan­dard crust. When using a bread base for the pizza, the bread was flaccid. The lower surface of the crust, in both instances, became brown or crisp; however, the rest of the crust was still extremely crunchy. Thus, even use of the new microwave susceptor sheet material had the disadvantages of prior attempts to reconstitute pizza using standard unbaked crust or a bread base in a micro­wave oven.
  • According to one aspect of the invention, there is provi­ded a composite sheet stock comprising a microwave suscep­tor sheet having a dielectric support layer and a heater layer of microwave interactive material allowing passage of microwave energy as it is heated thereby, and a layer of heat-conducting, microwave reflecting material adhered to the heater layer.
  • In accordance with a another aspect of the present inven­tion, there is provided a receptacle in the form of a self-supporting box or sleeve formed from a highly metal­lized microwave susceptor sheet stock so that the sheet stock has a lower flat portion and an upper flat portion to completely surround the flat pizza to be heated in a microwave oven. When in its operative assembled condi­tion, the box or sleeve has generally fixed configura­tions with a height substantially greater than the thick­ness of the pizza for which the box or sleeve forms a heating receptacle. This concept uses a susceptor of a generally rigid sheet stock, such as paperboard, which can be bent into a shape that is maintained by the rigi­dity of the support board. This is different from a wrapping stock wherein the shape is dictated generally by the shape of the product.
  • The base of the receptacle may be formed from the com­posite sheet stock in accordance with the invention, with the dielectric layer facing outwardly. Alternatively, the lower portion or base may be made of at least two susceptor layers wherein one of the susceptors may be formed integral with the box or sleeve and the second may be a separate element,optionally secured to the first. In addition, the surface resistivity of the second susceptor layer may be different from the surface resis­tivity of the first susceptor layer. The upper portion of the food article is heated by a combination of radia­tion from the surrounding susceptor sheet and microwave energy that passes through the susceptor sheet. In the lower portion of the sleeve, the second sheet causes nearly all of the microwave energy to be absorbed so that a substantially greater amount of heat is generated for baking and crisping the crust. The second layer of susceptor material may also extend to areas beyond just the bottom portion for changing the heating character­istics of the sleeve or box. When the bread crust extends upwardly along the edges of the pizza base, the second layer of susceptor material may extend upwardly along the side walls of the sleeve.
  • The lower portion of the sleeve or box is flat and is desirably elevated a preselected distance from the bottom wall of the microwave oven. The heat absorbed in the first layer of microwave susceptor material is trans­ferred by convection to the second layer of susceptor material. This second layer is also heated by microwave energy and transmits the heat from the first layer and its own heat to the bottom surface of the food article resting upon the two layers of susceptor sheet material. This second susceptor layer or sheet material may be glued or laminated to the first layer in the bottom portion of the box or sleeve or it may bean integral part of the blank which forms the box or sleeve.
  • In accordance with another aspect of the invention, a highly heat conductive layer, such as aluminum foil, may be located between the two microwave susceptor layers. This assists in the transfer by conduction of heat from the lower susceptor sheet to the upper susceptor sheet. When this occurs, the upper susceptor sheet is heated by microwave energy coming through the product itself to create a second heat source in the lower portion of the box or sleeve. In this embodiment, the lower portion of the receptacle may be formed from a layer of the compo­site stock described above and a susceptor layer.
  • In accordance with another aspect of the invention, the feature of increasing the heating effect whilst decrea­sing the amount of microwave energy passing through the bottom of the receptacle, may be accomplished by selec­tively increasing the amount of metal in the metallized heating layer of the susceptor sheet in the bottom or lower portion of the receptacle.
  • In accordance with another aspect of the invention, the receptacle is a sleeve which has side walls that are collapsible so that the sleeve can be flattened and shipped in a position adjacent, preferably under, the pizza segment(s). When a pizza segment is to be recon­stituted, the flattened sleeve is expanded and used as a self-supporting receptacle for a single pizza segment. This manipulating action may also extend a set of inte­gral legs cut from the rigid paperboard which serve to create the necessary spacing between the bottom wall of the microwave oven and the lower flat portion of the receptacle. The height of the sleeve is preferably greater than the thickness of the pizza segment; howev­er, the width of the sleeve is not substantially greater than the width of the segment, so that there is a space above the pizza, which should not be more than about 25 mm and is preferably less than about 13 mm.
  • Brief description of the drawings
    • FIGURE 1 is a partially cross-sectioned, pictorial view of a packaged pizza segment containing a folded recep­tacle constructed in accordance with the preferred em­bodiment of the present invention;
    • FIGURE 2 is a partial, pictorial view of the preferred embodiment of the present invention in the collapsed, shipping configuration, as shown in FIGURE 1, and fur­ther showing an enlarged partial view illustrating fea­tures of the sheet stock of the preferred embodiment of the present invention;
    • FIGURE 3 is a view similar to FIGURE 2 showing the pre­ferred embodiment of the present invention in the manu­ally assembled, free standing heating configuration, together with a modification of the invention shown in phantom lines;
    • FIGURE 4 is a view similar to FIGURE 3 with the pizza inserted into a sleeve constructed in accordance with the preferred embodiment of the present invention and illustrating a tear strip feature of the invention, to­gether with the modification of the preferred embodiment again shown in phantom lines;
    • FIGURE 5 is a construction layout of the sheet stock blank as it is cut and serrated for assembly into the shape illustrated in FIGURES 1-4;
    • FIGURE 6 is a side elevational view showing operating characteristics of the preferred embodiment of the present invention with the modification again shown in phantom lines;
    • FIGURE 7A is an enlarged section illustrating the cir­cular portion 7A of FIGURE 6;
    • FIGURE 7B is an enlarged section illustrating the cir­cular portion 7B of FIGURE 6;
    • FIGURE 8 is an enlarged, cross-sectional view of the lower portion of the receptacle constructed in accord­ance with the invention and illustrating a slight modi­fication of the preferred embodiment of the invention;
    • FIGURES 9-12 are enlarged, cross-sectional views taken generally along the lower portion of the receptacle cons­tructed in accordance with the present invention and illustrating modifications which can be accomplished in the lower portion in accordance with aspects of the pre­sent invention;
    • FIGURE 13 is a time power graph illustrating the heating cycles employed in the preferred method utilizing the disposable, self-supporting receptacle illustrated in FIGURES 1-12;
    • FIGURE 14 is a modification of the preferred embodiment wherein the sleeve illustrated in FIGURES 1-4 is an en­circling box formed from microwave susceptor sheet stock;
    • FIGURE 15 is a multiple plane cross-sectioned view il­lustrating various structural features of the modifica­tion of the invention shown in FIGURE 14, together with an enlarged section illustrating the cross-section of the lower flat wall portion in this modification;
    • FIGURE 16 is a partial pictorial view, in cross-section, illustrating the operating configuration of the modifi­cation of the invention shown in FIGURES 14 and 15; and,
    • FIGURE 17 is a blank cut from a paperboard support stock and including microwave interactive material which can be employed in the modification of the invention shown in FIGURES 14 and 15 and including certain modifications which are applicable to various disposable receptacles constructed in accordance with the present invention.
  • Referring now to the drawings, illustrating the preferred embodiments of the invention, FIGURES 1-4 show a package A for shipping and distributing a frozen entree B such as a flat, elongated rectangular segment of pizza formed by placing on the upper surface of a bread layer 10 having a generally cup-shaped crust 10a, a topping layer 12 formed from sauce 14 and miscellaneous food items 16. The bread is baked, sliced and cut to size. Thereafter items 16 in a frozen condition and sauce 14 are spread on the upper surface of the bread. Package A is formed of paperboard and includes an outer shipping carton 20 of the type which is not microwave compatible and is selected for shipment purposes only. Food article B is wrapped in an air impermeable, plastic wrapper 22 which may be evacuated or filled with an inert gas. Article B is frozen and shipped in carton 20 for display in the freezer section of a retail outlet. Within carton 20 there is provided a disposable heating or reconstitution receptacle in the preferred form of sleeve C formed from the sheet paperboard blank, such as illustrated in FIGURE 5. Sleeve C is formed from a microwave susceptor sheet 30 of the type disclosed in US Patent 4641005. This sus­ceptor sheet includes a layer of generally continuous microwave interactive material 32 formed by vacuum depo­siting a thin layer of aluminum or similar metal onto a smooth plastic support film 34 which is, in turn, adhered to a flat, generally rigid paperboard 36 forming the support layer for microwave susceptor sheet 30. By chan­ging the surface resistivity of microwave interactive material 32 through changing the thickness of this layer, the amount of heating caused at the layer of interactive material 32 can be modulated. In accordance with the preferred embodiment of the invention, the interactive material is of the type having a surface resistivity less than about 6 ohms/cm, preferably about 5 to 6 ohms/cm, and is constructed upon a standard weight paper­board and is as rigid as a standard poster stock. Such microwave susceptor sheet stock material, but with a higher resistivity, is well known in the art and is widely used for microwave heating of various food prod­ucts. The selection of a low surface resistivity on a firm or generally rigid paperboard for an encircling free standing sleeve C is believed to be novel. This combination of strength and high heating by low resis­tivity is a further advantage of the preferred embodi­ment of the present invention.
  • Referring now more particularly to sleeve C, this sleeve includes two parallel, generally flat portions 50, 52 which are adapted to be located on opposite sides of the food item B during the microwave heating operation. In accordance with the present invention, lower or bottom flat portion 50 is formed from two separate layers 50a, 50b of microwave susceptor sheet 30. Consequently, sleeve C comprises parallel flat portions 50, 52 with lower or bottom portion 50 formed by two separate and distinct interactive layers 50a, 50b. To interconnect parallel, flat portions 50, 52, sleeve C includes inte­gral side walls 60, 62. Wall 60 includes parallel cut lines or serrated seams 70, 72, and 74. In a like manner, wall 62 includes cut lines or serrated seams 80, 82, and 84. By incorporating these seams sleeve C can be folded into a collapsed condition, as shown in FIGURE 1 or can be manually expanded into the operative, heating confi­guration, as shown in FIGURES 3 and 4. To allow easy removal of the heated pizza segment or food item B, after the microwave reconstitution, seams 82, 84 are formed into parallel tear lines so that tear strip 90 can be manually removed from side wall 62. This opening feature allows easy removal of the heated food article and as­sures that sleeve C is discarded since it is generally of no use after tear strip 90 has been removed.
  • To assure that microwave energy enters through lower portion 50, to heat susceptor layers 50a, 50b, lower portion 50 must be spaced from the lower wall D of the microwave oven during the heating process. This spacing can be maintained by a separate element as shown in FIGURE 14 or, as in accordance with the preferred em­bodiment, by a plurality of integrally formed downwardly depending legs 100, 102, 104 and 106 which are folded into a generally flat condition when sleeve C is col­lapsed, as shown in FIGURES 1 and 2, and are moved to downwardly depending positions, as shown in FIGURES 3 and 4, when sleeve C is manually formed into its heating or operative configuration. These legs are cut from mi­crowave susceptor sheet 30, as best illustrated in FIGURE 5.
  • Sleeve C is self-supporting and has the features dis­cussed in the introductory portion of this disclosure. It is collapsed or folded and shipped in a generally flat condition in package A, as shown in FIGURE 1 and FIGURE 2. When article B is to be reconstituted, it is removed from wrapper 22, the sleeve is manually assem­bled into the configuration shown in FIGURE 3 and the article is slipped longitudinally into the sleeve, as shown in FIGURE 4. Side walls 60, 62 extend upwardly along the vertical portion of crust 10a. Sleeve C loaded with article B is positioned on lower wall D of the mi­crowave oven and the oven is energized to cook, bake or otherwise reconstitute the frozen food entree or food article B.
  • In FIGURES 6, 7A and 7B, the operating characteristics of the preferred embodiment of the present invention, as shown in FIGURES 1-5, are illustrated graphically and in a general manner. As shown in FIGURE 6, microwave energy, indicated as W, penetrates through upper sleeve portion 52. During this penetration, a certain amount of energy is consumed to heat the layer 32. Thus, the inner cham­ber O of self-supporting receptacle C is a small oven chamber wherein heat is radiated from that portion of the susceptor sheet 30 forming upper portion 52. A sub­stantial amount of the microwave energy passes through material 30 and heats the topping 12 which is lossy ma­terial whilst portion 52 radiates heat to the topping surface. Combined radiation and microwave absorption, together with slight convection, causes oven chamber 0 to heat the topping efficiently, but at a lower temper­ature level than needed to heat bread 10 and make crust 10a crisp. By providing a double layer of susceptor sheet 30 as the bottom flat portion 50 of sleeve C, as shown in FIGURE 7B, the same type of strong microwave heating of bread layer 10 is avoided. As the microwave energy (W) is reflected upwardly toward the vertically elevated, lower flat portion 50, it passes through the two sheets and is reduced in intensity as represented by arrows W3. To show this feature energy W enters paperboard 36 as W1. There is no appreciable energy absorption by the layer 36, which is microwave transparent. The microwaves then pass through the first interactive layer 32 which removes a substantial amount of energy from W1. The amount of absorption is controlled by the amount of metal in layer 32 which is expressed as surface resistivity (Rs). This energy absorption by layer 32 of layer 50a produces weaker microwave energy illustrated schemati­cally as W2 shown progressing upwardly through the second layer 50a where it interacts with microwave interactive layer 32 of layer 50b which converts even more of the original microwave energy into heat. Only a minor por­tion, if any, of the original microwave radiation W passes through second layer 50a. Thus, the layer 50b is heated by microwave lower interactive layer 32, and heat is convected from this first layer as indicated by the serpentine lines CV upwardly through the layer 50b. This convection heat combines with the further heat generated at the second interactive layer 32 to convert a major portion of the incoming microwave energy into convected heat as indicated by further lines CV above layer 50b. Board 36 of lower layer 50a insulates sleeve C so that the convective energy moves generally upwardly through the upper portion of layer 50b to combine with the heat generated in this layer. There is, thus, a high heat concentration at lower crust 10a. To enhance this oper­ation, the second layer could be provided in the verti­cal areas of crust 10a adjacent side walls 60, 62. As indicated in FIGURE 7A, the heating effect is caused by induced flow of current I when microwaves W pass through an interactive layer 32 of susceptor sheet 30; therefore, penetration by radiation is generally required for the purpose of causing heating of the interactive material. To provide reflected radiation, sleeve portion 50 is spaced a distance g from lower wall D. This spacing is in the range of 3 to 13 mm and can be provided by legs 100, 102, 104 and 106, as previously described, or by a separate spacer element, such as the corrugated board shown generally in FIGURE 16.
  • The novel sleeve is a receptacle for heating the arti­cle, as opposed to some type of general heat conducting material wrapped around the article and having a shape determined by the article. To add rigidity to this par­ticular construction, the lower layer 50a can be pro­vided with a downwardly and transversely extending rib 110, shown in phantom lines in FIGURES 2-4. This rib allows use of a thinner paperboard while maintaining the necessary gap g under lower portion 50. Of course, other downwardly depending tabs and ribs could be provided for further enhancing the rigidity of lower portion 50 to prevent undue sagging of this lower support portion of sleeve C.
  • FIGURE 8 shows that the surface resistivity of layer 50a can be different from the surface resistivity of layer 50b. This objective can be accomplished by a separate microwave susceptor sheet forming layer 50b or the layer 50b can be provided with a different thickness of metal constituting interactive material or layer 32 of sheet 30. The higher surface resistivity of lower layer 50a indicates a thinner layer of resistive metal in layer 32 and a correspondingly lesser heating effect at layer 50a. Thus, most heating occurs in layer 50b in this par­ticular modification of the present invention. Conse­quently, conduction from lower layer 50a is not as impor­tant a component of the total heating effect as when both layers are formed from the same microwave interac­tive material or sheet 30.
  • In FIGURE 9, a third layer 50c of microwave interactive material is incorporated in the lower flat bottom por­tion 120 of a modified sleeve. This separate sheet stock of interactive material can have a distinct surface re­sistivity. As can be seen, the microwave energy is cap­tured at least by the third interactive layer 50c so that only a negligible amount of microwave energy enters into layer 10 from lower flat portion 120. In these in­stances, the paperboard support layers 36 of layers 50a, 50b, 50c can be relatively thin since overall support for the product being heated is obtained by the lower layer 50a and at least by lower layer 50a in combination with upper layer 50b. In accordance with another aspect of the invention, the support paperboard or other dielec­tric material 36 for each layer (50b, 50c) above the bottom structural support layer 50a is relatively thin and may be substantially greater than 16 points.
  • FIGURE 10 shows the composite stock wherein the lower susceptor layer 50a is covered by a heat conduction layer 130 so that heat generated in lower surface 50a is conducted through this heat conductive layer 130 into layer 10 to cause high heat at crust 10a. In the prefer­red embodiment of this aspect, this conductive layer 130 is aluminum foil that reflects microwave energy. Thus, microwave energy passing through reactive layer 32 of lower layer 50a causes heating as the microwaves pass toward and away from the reflective layer 130. This dual action enhances the heating effect of lower layer 50a, which, in turn, causes the temperature at surface 130 to be relatively high. Further, the reflective nature of metal layer 130 shields crust 10a against microwaves from lower portion 50 of sleeve C. Thus, all heat at the surface of crust 10a is by conduction from heated layer 130.
  • A further modification of the concept shown in FIGURE 10 is shown in FIGURE 11 wherein the heat conduction layer 130 is located between lower layers 50a, 50b. In this construction, microwave energy which happens to pass downwardly through topping 12 and bread layer 10 is con­verted into heat by the uppermost layer 50b of lower portion 50. A modification of this concept is illustrated in FIGURE 12 wherein layer 50b′ is similar to layer 50b except that the order of lamination is reversed. The interactive material 32 of layer 50b′ is adjacent alumi­num foil 130.
  • In accordance with the cooking method aspect of the in­vention, the heating cycle for reconstitution of pizza with sleeve C is shown, by way of example, in FIGURE 13. The microwave oven is first energized with a power set­ting of between 25%-50% for approximately 6.0 minutes. This method has been found to be sufficient to reconsti­tute pizza segments sold by Stouffer Foods Corporation under the designation "French Bread Pizza". Should the microwave oven have a low power rating, i.e. in the range of 400-600 watts, then the power setting should be at the higher level, such as approximately 50%. Using a microwave oven having a higher power rating of 600-800 watts, the setting may be reduced to approximately 25% for about 6.0 minutes. The initial heating, which causes the starch of the bread layer 10 to swell before water within the starch begins to heat, is followed by heating for approximately 1.0 minute at full power. This allows the microwave energy to fully cook the topping portion of the pizza.
  • A modification of the preferred embodiment of the inven­tion is illustrated in FIGURES 14-17 wherein the free standing receptacle of the present invention is in the structural form of a box 200 assembled from blank 202 of 16 point, generally self-sustaining paperboard and con­taining, at least, areas of microwave interactive mate­rial. Thus, the sheet stock of blank 202 is a microwave susceptor sheet similar to sheet 30 of sleeve C. Blank 202 is illustrated in detail in FIGURE 17 and has a shape to be assembled into a structural configuration which will encircle the pizza segment or other food article B shipped in a wrapper 22 in package A, as shown in FIGURE 14. In this embodiment, the pizza segment is shown as being actually shipped in heating receptacle box 200 with a first spacing member 210 under the box. Member 210 has a thickness generally corresponding to the desi­red spacing g. Box 200 includes a separate, second micro­wave susceptor sheet 212 so that the lower flat portion 220 of the box is provided with two susceptor sheets for the reasons explained in connection with the preferred sleeve configuration. In the box concept, the upper por­tion of the encircling microwave susceptor sheet is a self-supporting, flat lid 222 joined with lower flat portion 220 by free standing side walls 224, 226 obtained by folding blank 202 along cut lines or seams 230, 232, 234, as best shown in FIGURE 17. To facilitate folding of tabs 240 there are provided cut lines or seams 241 so that tabs 240 can be interlocked with end flaps 250 de­fined by parallel cut lines or seams 242, 244.
  • Box 200 can be shipped in package A in a flattened con­dition or assembled around the pizza, as shown in FIGURE 14. To assemble the box before or after shipping, end flaps 250 are folded upwardly and interlocked with tabs 240. After the sheet insert 212 has been placed along bottom portion 220, pizza B is placed within the box. Wrapper 22 is removed before actually heating the pizza. As shown in FIGURE 16, spacer member 210 is placed under lower flat portion 220 to raise the box a distance g from lower oven wall D for the purposes of heating in accordance with the method described generally in con­junction with the schematic heating cycle shown in FIGURE 13.
  • Blank 202 can be provided with selective areas of dif­ferent microwave interactive materials. To illustrate this concept, the surface resistivity of the various panels in blank 202 is shown as having a value a, b, or c. In the illustrated embodiment, the bottom portion 220 has a low surface resistivity which indicates a greater amount of metallization. Consequently, this surface will heat to a greater extent than the side walls and lid which have a higher surface resistivity and, thus, a lower metallization. End tabs 240 and end flaps 250 are not metallized at all, being merely self-sustaining paper­board. In this manner, microwave energy can enter each end of box 200.

Claims (10)

1. A composite sheet stock comprising a microwave suscep­tor sheet (30) having a dielectric support layer (36) and a heater layer (34) of microwave interactive mate­rial allowing passage of microwave energy as it is heated thereby, characterised in that a layer (130) of heat-conducting, microwave reflecting material is ad­hered to the heater layer of the susceptor sheet.
2. A composite stock according to claim 1 comprising a second layer (50b) of susceptor stock adhered to the layer of heat-conducting, microwave reflecting material of the composite stock.
3. A composite stock according to claim 2 in which the heater layer of the second layer (50b′) of susceptor stock faces the layer of reflecting material.
4. A stock according to any preceding claim having a heater layer of which the surface resistivity is less than about 6 ohms/cm.
5. A stock according to claim 4 in which the heater layer has a surface resistivity of 5 to 6 ohms/cm.
6. A receptacle for cooking a food article in a micro­wave oven, comprising:
(a) an upper portion (52) of microwave susceptor stock having an outwardly facing dielectric layer (36) and an inwardly facing heater layer (34) of microwave interac­tive material allowing passage of microwave energy as it is heated thereby;
(b) a lower portion (50) for supporting the food article and having an inwardly-facing heater layer (34) of mi­crowave interactive material;
(c) side walls (60), (62) securing the upper and lower portions in spaced relationship,
characterised in that the lower portion comprises a layer of composite sheet stock according to any one of claims 1 to 5 or at least one additional layer (50b) of micro­wave susceptor stock having a heater layer of microwave interactive material.
7. A receptacle according to claim 6 in which the heater layer of the additional layer(s) of susceptor stock has a surface resistivity lower than the surface resistivity of the inwardly facing heater layer of the lower por­tion.
8. A receptacle according to claim 6 or claim 7 in which the heater layer of the additional layer(s) of susceptor stock is inwardly facing.
9. A receptacle according to any one of claims 6 to 8 comprising two additional layers of microwave susceptor stock adjacent to the lower portion.
10. A receptacle according to any one of claims 6 to 9 including means for holding the lower portion of the receptacle in a position spaced vertically from the floor or lower wall of a microwave oven.
EP19890111096 1988-07-13 1989-06-19 Composite sheet stock for microwave heating and receptacle Withdrawn EP0350660A3 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US218205 1988-07-13
US07/218,205 US4891482A (en) 1988-07-13 1988-07-13 Disposable microwave heating receptacle and method of using same
US23960088A 1988-09-01 1988-09-01
US239600 1988-09-01

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EP0350660A2 true EP0350660A2 (en) 1990-01-17
EP0350660A3 EP0350660A3 (en) 1992-01-02

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AU (1) AU614853B2 (en)
DK (1) DK345389A (en)
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NO (1) NO892832L (en)
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EP0365247A2 (en) * 1988-10-17 1990-04-25 Beckett Industries Inc. Container and blank for, and method of, microwave heating
EP0442333A2 (en) * 1990-02-14 1991-08-21 The Pillsbury Company Reflective temperature compensating microwave susceptors
EP0451530A2 (en) * 1990-04-11 1991-10-16 Societe Des Produits Nestle S.A. Microwave susceptor sheet stock with heat control
EP0471969A1 (en) * 1990-08-13 1992-02-26 Societe Des Produits Nestle S.A. Easy open microwave susceptor sleeve for pizza and the like
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EP0365247A3 (en) * 1988-10-17 1991-05-22 Beckett Industries Inc. Container and blank for, and method of, microwave heating
EP0365247A2 (en) * 1988-10-17 1990-04-25 Beckett Industries Inc. Container and blank for, and method of, microwave heating
EP0442333A2 (en) * 1990-02-14 1991-08-21 The Pillsbury Company Reflective temperature compensating microwave susceptors
EP0442333A3 (en) * 1990-02-14 1992-03-25 The Pillsbury Company Reflective temperature compensating microwave susceptors
AU636465B2 (en) * 1990-04-11 1993-04-29 Societe Des Produits Nestle S.A. Microwave susceptor sheet stock with heat control
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Also Published As

Publication number Publication date
NZ229668A (en) 1991-02-26
DK345389D0 (en) 1989-07-12
FI893014A0 (en) 1989-06-20
PT91134A (en) 1990-02-08
JPH02117823A (en) 1990-05-02
NO892832L (en) 1990-01-15
FI893014A (en) 1990-01-14
AU3672489A (en) 1990-01-18
PT91134B (en) 1994-08-31
DK345389A (en) 1990-01-14
AU614853B2 (en) 1991-09-12
NO892832D0 (en) 1989-07-07
EP0350660A3 (en) 1992-01-02

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