WO2012094291A2

WO2012094291A2 - Microwavable container system

Info

Publication number: WO2012094291A2
Application number: PCT/US2012/020039
Authority: WO
Inventors: Akou Amefia; Kevin Brady; Christopher ROWOTH; Brian Carman
Original assignee: H.J. Heinz Company
Priority date: 2011-01-04
Filing date: 2012-01-03
Publication date: 2012-07-12
Also published as: EP2661402A4; EP2661402A2; WO2012094291A3

Abstract

A microwavable food storage and packaging system includes a first container having a side wall extending from a bottom wall and a second container having a second side wall extending from a second bottom wall. The first container defines a first interior chamber for storing a first food having a first specific heat. A first shielding material is disposed on the bottom and side wall of the first container, and a second shielding material is disposed over and removably coupled to an upper surface of the first container to seal the first interior chamber. The first and second shielding materials together define an opening through which microwave energy may pass. The second container defines a second interior chamber for storing a second food having a second specific heat. A film is disposed over and removably coupled to an upper surface of the second container to seal the second interior chamber.

Description

MICRO WAVABLE CONTAINER SYSTEM

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority of U.S. Provisional patent application no.

61/429,545, filed January 4, 2011, which is hereby incorporated by reference.

FIELD OF DISCLOSURE

[0002] The disclosed system and method relate to food packaging. More specifically, the disclosed system and method relate to food packaging for heating separate food products in a microwave.

BACKGROUND

[0003] With busy schedules, people seldom have time to prepare a home cooked meal from start to finish. Food companies have recognized that many families do not have to prepare a full meal and have attempted to fill this void by offering prepared foods that may be cooked in a microwave and yet still have a home-style taste. These foods are provided in special packaging that may be placed in a microwave.

[0004] Multi-component foods have typically been limited to food items that heat at a similar rate in the microwave so that the entire entree is thoroughly heated in about the same amount of times. Consequently, there is a limited supply of prepackaged microwavable food products that include foods that have uneven cooking times.

SUMMARY

[0005] A microwavable food storage and packaging system includes a first container having a side wall extending from a bottom wall and a second container having a second side wall extending from a second bottom wall. The first container defines a first interior chamber for storing a first food having a first specific heat. A first shielding material is disposed on the bottom and side wall of the first container, and a second shielding material is disposed over and removably coupled to an upper surface of the first container to seal the first interior chamber. The first and second shielding materials together define an opening through which microwave energy may pass. The second container defines a second interior chamber for storing a second food having a second specific heat. A film is disposed over and removably coupled to an upper surface of the second container to seal the second interior chamber.

[0006] A typical bread bowl will be over-cooked, tough and inedible, in the microwave with 120 seconds in a 1200 Watt Microwave. The described packaging system can yield a soft- pliable bread bowl in a 240-300 second cook in a 1200 Watt Microwave without overcooking the bread while fully cooking the accompanying 8oz. soup. The bread bowl is specifically prepared to reduce moisture migration to enhance pliability and shelf life.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:

[0008] FIG. 1 is a perspective view of one example of a microwavable container system;

[0009] FIG. 2 is a partially exploded view of one example of a microwavable container system;

[0010] FIG. 3 is a perspective view of one of the containers of the microwavable container system in accordance with FIG. 1;

[0011] FIG. 4 is a side view of the container illustrated in FIG. 3;

[0012] FIG. 5 is a cross-sectional view of the container illustrated in FIG. 3 taken along line 5-5 in FIG. 4;

[0013] FIG. 6 is a detail view of the detail shown in FIG. 5;

[0014] FIG. 7 is a side view of another one of the containers of the microwavable container system in accordance with FIG. 1;

[0015] FIG. 8 is a cross-sectional view of the container illustrated in FIG. 7 taken along line 8-8 in FIG. 7;

[0016] FIG. 9 is a perspective view of another example of a microwavable container system;

[0017] FIG. 10 is a perspective view of one of the containers of the container system illustrated in FIG. 9 with a lid being pulled back; [0018] FIG. 11 is a side view of another container of the container system illustrated in

FIG. 9; and

[0019] FIG. 12 is a perspective view of the container illustrated in FIG. 11 with the lid on.

DETAILED DESCRIPTION

[0020] This description of preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. The drawing figures are not necessarily to scale and certain features of the invention may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as "horizontal," "vertical," "up," "down," "top," and "bottom" as well as derivatives thereof (e.g., "horizontally," "downwardly,"

"upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including "inwardly" versus "outwardly," "longitudinal" versus "lateral," and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate.

Terms concerning attachments, coupling, and the like, such as "connected" and "interconnected," refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term "operatively connected" is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship.

[0021] A microwavable food storage and packaging system is disclosed that includes a first container having a side wall extending from a bottom wall and a second container having a second side wall extending from a second bottom wall. The first container defines a first interior chamber for storing a first food having a first specific heat. A first shielding material is disposed on the bottom and side wall of the first container, and a second shielding material is disposed over and removably coupled to an upper surface of the first container to seal the first interior chamber. The first and second shielding materials together define an opening through which microwave energy may pass. The second container defines a second interior chamber for storing a second food having a second specific heat. A film is disposed over and removably coupled to an upper surface of the second container to seal the second interior chamber. The first and second containers may be coupled together such that an upper surface of the first container contacts an upper surface of the second container.

[0022] Also disclosed are methods for heating breads in a microwave oven to produce bread having an improved texture compared to conventional methods of heating bread in a microwave. Additionally, methods are disclosed in which bread and soup are simultaneously heated in a microwave oven for the same period of time that produce bread having a fresh-baked taste and texture and soup that is heated to an appropriate temperature.

[0023] FIG. 1 illustrates one example of a multi-component microwavable food package

100. Package 100 includes a shielded bowl or container 102 and an unshielded bowl or container 104 that may be coupled together to form a single package 100 for mass distribution. In one embodiment, bowl 102 stores bread and bowl 104 stores soup. However, one skilled in the art will understand that other foods with uneven cooking requirements (e.g., different specific heats) may be stored within containers 102 and 104.

[0024] As best seen in FIGS. 3-4, bowl 102 has a cylindrical shape including side walls

106 that taper from an open top 108 to a closed bottom 110 such that bowl 102 has a

substantially circular cross-sectional area to promote even heating. However, one skilled in the art will understand that bowl 102 may have other cross-sectional areas such as, for example, rectangular, ovoid, pentagonal, or triangular, to name a few, that may or may not taper along their height. The interface 112 between side walls 106 and bottom wall 110 may be curved as illustrated in FIG. 4. Bowl 102 may be formed from a wide variety of microwavable materials used in the food packaging industry including various polymers, plastics, resins, and the like. In one embodiment, bowl 102 is fabricated from Dylark® FG resins available from NOVA

Chemicals® of Moon Township, Pennsylvania.

[0025] A shield 114 may be disposed around the side walls 106 such that they are substantially, but not completely covered, and disposed on bottom wall 110 such that the side. As best seen in FIGS. 4-6, a small gap or void 116 is defined between the top 108 of bowl 102, which may include an outwardly extending flange 118, and a top 120 of shield 114. In one embodiment, gap 116 is approximately 0.48 cm (approximately 0.1875 inches) in width although one skilled in the art will understand the dimensions of gap 116 may be increased or decreased depending on the heating requirements of the food disposed within bowl 102. In one embodiment, shield 114 may be removably coupled to bowl 102 such that once it may be removed from bowl 102 to increase the recyclability of container 100.

[0026] Flange 118 provides additional surface area for mating of a film 122, such as a polyethylene film, to the top 108 of bowl 102 in order to hermetically seal the internal chamber 124 of bowl 102. A second shield 126 may be disposed over and adhered to film 122 to further insulate the contents of bowl 102, i.e., to prevent or reduce the amount of microwave energy that enters the internal chamber 124 of bowl 102 from the top 108. Shield 126 may be formed from the same material as shield 114. Apertures (not shown) may be defined by shield 114 and/or shield 126 in order to adjust the amount of microwave energy that may enter the internal chamber 124 depending on the contents of bowl 102.

[0027] Turning now to FIGS. 7-8, bowl 104 is shown having side walls 128 that may taper from an open top 130 to a closed bottom 132. Bowl 104 may have a substantially circular cross-sectional area to promote even heating in a microwave; however, one skilled in the art will understand that bowl 104 may have other cross-sectional areas including, but not limited to, rectangular, ovoid, pentagonal, or triangular, to name a few, which may or may not taper along their height. In one embodiment, bowl 104 has a diameter of approximately 14.6 centimeters (approximately 5.75 inches) and a height of approximately 3.8 centimeters (approximately 1.5 inches), although one skilled in the art will understand that bowl 104 may have other dimensions depending on the amount of food to be stored in the internal chamber 134. The interface 136 between side walls 128 and bottom wall 132 may be curved as illustrated in FIGS. 7 and 8. Bowl 104 may be formed from a wide variety of microwavable materials used in the food packaging industry including various polymers, plastics, resins, and the like. In one

embodiment, bowl 102 is fabricated from Dylark® FG resins available from NOVA Chemicals® of Moon Township, Pennsylvania.

[0028] As best seen in FIG. 8, bottom wall 132 of bowl may have a convex protrusion

138, which may extend into internal chamber 134. Convex protrusion 138 separates the contents of bowl 104 from the microwave glass plate in order to prevent the transfer of energy from the heated food into the microwave glass turntable. In other words, as the contents of bowl 104 in the center of the internal chamber 134 heats up, the air inside the convex protrusion insulates the contents from the glass plate. [0029] The top 130 of bowl 104 may include a flange 140 that outwardly extends from an outer surface of bowl 104. Flange 140 provides an increased surface area for a film 142 affixed to bowl 104 in order to hermetically seal the contents of bowl 104. Film 142 helps expedite the heating up time of the contents of bowl 104 by using the high levels of heat calories produced by the steam. Film 142 on bowl 104 allows for a controlled release of steam during cooking so that the steam is contain inside the package throughout the cooking process. The pressure and temperature generated by the steam inside bowl 104 expedites heating of the outer surface of the contents of bowl 104 and slower heating of the interior of the medium.

[0030] Bowls 102 and 104 may be joined together by placing one bowl on top of the other bowl joining them together by a coupling means that extends from, or is disposed on, the top 108 and 130 of the bowls. The coupling means may include a pair of diametrically opposed slots defined by a fiange 118, 140 of one of the bowls 102, 104 and a pair of diametrically opposed projections extending from a fiange 118, 142 of the other one of the bowls that is configured to be received in the slots and may be locked in place by rotating one of the bowls 102, 104 relative to the other. In some embodiments, each bowl 102 and 104 may include both a slot and a projection as will be understood by one skilled in the art.

[0031] To heat the contents of the container 100, shrink wrapping 148 is removed and the bowls 102 and 104 may be separated from one another. For example, if bowls 102 and 104 include a coupling means, then the bowls 102 and 104 may be decoupled from one another by rotating one bowl relative to the other to disengage the projections from the slots or disengaging the snap fit of the detents from the outer surface of a flange depending upon the type of coupling means.

[0032] Once decoupled from one another, the bowls 102 and 104 are placed on the glass plate in the microwave such that their bottom surfaces 110 and 132 contact the glass plate and the films 122 and 146. In one embodiment, the bowls 102 and 104 are spaced apart from each other on the glass plate by approximately 3.8 centimeters (approximately 1.5 inches) and then heated in the microwave for the same amount of time. Once heated, the films 122 and 142 may be removed from their respective bowls 102 and 104 and the contents may be eaten.

[0033] FIGS. 9-12 illustrate another example of a multi-component microwavable food package 200. Package 200 is similar to package 100 described above, and descriptions of like elements, which include the same reference numerals increased by 100, are not repeated. As best seen in FIG. 10, bottom wall 232 of bowl 204 inwardly projects to define a hole 244 such that bowl 202 has a ring shape. Hole 244 defined by bowl 204 increases the external surface area of bowl 204 thereby increasing the amount of microwave energy that may be absorbed by the contents of bowl 204. Flange 240 of bowl 204 is illustrated as including an extension portion 246 that extends from the top 208 of the bowl 202. Extending from the inner surface 248 of extensions portion 246 is one or more detents (not shown) configured to engage an outer edge 250 of flange 240 of bowl 204. To increase enhanced tamper-proof security of the container 200, the two bowls 202 and 204 may be joined together by shrink wrap (not shown) as will be understood by one skilled in the art.

[0034] The inventors have also discovered an improved method of preparing a bread bowl for use with the novel microwavable food packages described above. The method includes preparing a bread dough, sheeting the dough, and placing the dough in a mold having the desired shape, e.g., a concave/convex shape, a triangular shape, a rectangular shape, etc. The dough is allowed to proof in the mold. In some embodiments, the dough may be allowed to age, for example, when the dough is a sourdough or the like. Once proofed, the dough is baked in the mold until a crust is formed over substantially all of the exterior surface of the bread.

Additionally, the bread defines a cavity having a shape that is complementary to the shape of the mold, e.g., concave, with a crust on the inside of the concavity and on the outside of the concavity. The formation of a crust over substantially all of the exterior surface of the bread advantageously reduces the rate at which moisture migrates into the bread. Creating a crust having a different texture and a lower moisture permeability than the inner portion of the bread enables the bread bowl to maintain its structural integrity when stored in microwavable packaging and when the soup is added to the bowl.

[0035] Several different types of breads and soups have been made, stored, and frozen in the microwavable packaging system, and simultaneously heated in the microwavable packaging system. The following examples set forth the measurements and parameters for making a bread bowl in accordance with the present disclosure.

[0036] EXAMPLE 1

[0037] An experiment was performed to produce to test the effectiveness of the novel microwave packaging containers described above. Dough for the bread bowl was created using a the formulation set forth below in Table 1. Table 1

Item Grams Formula Percentage

Sugar 12 1.13

Salt 12 1.13

Vegetable Oil 24 2.25

Water (75°F) 272 25.52

Wheat Flour 635 59.57

Yeast 20 1.88

Water for Yeast Slurry 91 8.54

Total Dough Weight 1066 100

[0038] The dough was made by adding spring wheat flour, having approximately 13 percent protein to a Hobart dough mixer configured with a dough hook. The other dry ingredients, salt and sugar, were added to the mixing bowl in which the flour was added. A yeast slurry was prepared in a separate container by combining the 91 grams of warm water (75°F) with the 20 grams of Red Star yeast. It is more preferable for the dough to be between approximately 80°F and 100°F.

[0039] The mixer was turned on at low speed and the vegetable oil, water, and yeast slurry were added and mixed together for three minutes. The mixer speed was then increased to high for another six minutes until the dough was formed around the dough hook and off of the inner surfaces from the bowl. The dough was let rest for ten minutes. After the ten minutes of rest, the dough was sheeted from 15 mm in thickness to 3 mm in thickness by passing the dough through a dough sheeter three times.

[0040] A bread mold was minimally sprayed with a release agent, which may include vegetable or other cooking oil, and the sheeted dough was then draped over a bread bowl mold that was formed from aluminum and had a three inch upper diameter, a four inch lower diameter, and tapering side walls the extended from the upper diameter to the lower diameter over a distance of approximately two inches. Excess dough was removed from around the bottom of the mold, and the remaining dough on the mold proofed until its volume increased by

approximately 50 percent, which may take approximately 20-30 minutes depending on ambient temperature and humidity. The dough on the bread bowl mold was weighed between 80 and 230 grams.

[0041 ] The dough on the bread molds was placed on perforated pans on a wheeled rack and baked in an industrial oven having an internal temperature of approximately 460°F for approximately 10-11 minutes. The outside surface of the bread after baking was consistently brown in color and weighed between 160 and 190 grams and exhibited a crust over its outer surface. The bread was allowed to cool for approximately ten minutes and then placed in the shielded micro wavable packaging described above. The bread was then sealed with the sealing film as described above. Similarly, a soup was placed into an unshielded microwavable container and sealed within.

[0042] Once the soup and bread were frozen, the microwavable containers housing each were placed into a 1200 Watt microwave oven at the same time and separated by approximately one and a half inches between the two containers. The microwave was then operated on high for four minutes and forty-five seconds after which time the eight ounces of soup was heated to approximately 165 °F.

[0043] The microwave packaging containers described above advantageously enable two foods with different and unequal heating requirements, such as a soup and a bread, to be packaged together and be cooked in the same amount of time in a single microwave oven yielding soup having been heated to an optimal texture and bread heated to an optimal temperature and texture. Additionally, the disclosed method of preparing the bread bowl with a crust developed over the entire outer surface of the bread, including the inner and outer parts of the bowl, advantageously seals the bread and reduces the rate at which moisture migrates into the bread. Reducing the rate at which moisture migrates into the bread enables the structural integrity of the bread bowl to be maintained for longer periods of time compared to breads having a porous outer surface.

[0044] Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.

Claims

What is claimed is:

1. A micro wavable food storage and packaging system, comprising:

a first container having a side wall extending from a bottom wall, the first container defining a first interior chamber for storing a first food having a first specific heat;

a first shielding material disposed on the bottom and side wall of the first container; a second shielding material disposed over and removably coupled to an upper surface of the first container to seal the first interior chamber, the first and second shielding materials together defining an opening through which microwave energy may pass;

a second container having a second side wall extending from a second bottom wall, the second container defining a second interior chamber for storing a second food having a second specific heat; and

a film disposed over and removably coupled to an upper surface of the second container to seal the second interior chamber,

wherein the first and second containers are coupled together such that an upper surfaces of the first and second containers are disposed adjacent to one another.

2. The system of claim 1, wherein the first shielding material defines at least one aperture through which microwave energy may pass.

3. The system of claim 1, wherein the second shielding material defines at least one aperture through which microwave energy may pass.

4. The system of claim 1, wherein the first and second containers include a coupling means for coupling the first and second containers together.

5. The system of claim 1, wherein the first and second shielding materials includes aluminum foil.

6. The system of claim 1, wherein the second bottom wall of the second container includes a convex protrusion that extends into the second interior chamber.

7. The system of claim 1, wherein the second container defines a central aperture.

8. The system of claim 1, wherein the first and second containers are shrink wrapped together.

9. The system of claim 1, wherein the food having a first specific heat is a loaf of bread and the food having a second specific heat is a soup.

10. The system of claim 9, wherein the loaf of bread includes:

a first region having a first texture and a first moisture permeability, and

a second region substantially surrounding the first region, the second region having a second texture and a second moisture permeability, the second moisture permeability being lower than the first moisture permeability,

wherein the loaf of bread defines a cavity for receiving the soup therein.

11. The system of claim 10, wherein the second moisture permeability is approximately one half of the first moisture permeability.

12. The system of claim 10, wherein the cavity has a concave shape.

13. The system of claim 10, wherein the first texture is more pliable than the second texture.

14. The system of claim 10, wherein the second moisture permeability of the loaf of bread is such that the loaf of bread substantially retains its structural integrity for a period of time when a liquid is disposed within the cavity.

15. A loaf of bread, comprising:

a first region having a first texture and a first moisture permeability; and

wherein the loaf of bread defines a cavity for receiving a liquid therein.

16. The loaf of bread of claim 15, wherein the second moisture permeability is approximately one half of the first moisture permeability.

17. The loaf of bread of claim 15, wherein the cavity has a concave shape.

18. The loaf of bread of claim 15, wherein the first texture is more pliable than the second texture.

19. The loaf of bread of claim 15, wherein the second moisture permeability of the loaf of bread is such that the loaf of bread substantially retains its structural integrity for a period of time when a liquid is disposed within the cavity.

20. A method of making bread, comprising:

preparing a bread dough;

sheeting the bread dough;

placing the dough in a mold having a concave shape; and

baking the dough in the mold such that the dough defines a cavity having a convex shape.

21. The method of claim 20, wherein the bread includes:

a first region having a first texture and a first moisture permeability, and

wherein the loaf of bread defines a cavity for receiving a liquid therein.

21. The method of claim 21 , wherein the second moisture permeability is approximately one half of the first moisture permeability.

22. The method of claim 21 , wherein the first texture is more pliable than the second texture.

23. The method of claim 21 , wherein the second moisture permeability of the loaf of bread is such that the loaf of bread substantially retains its structural integrity for a period of time when a liquid is disposed within the cavity.