Food package for segregating ingredients of a multi-component food product

A food package for segregating ingredients of a multi-component food product, such as the multiple components of a sandwich, the package comprising an outer container to house a first food component and at least one flexible envelope or barrier film layer that encloses at least one intermediate food component allowing for separation of the intermediate food component during extended periods of storage and prior to opening the product. A method for opening the package comprises applying a pulling force to an externally located protruding end portion of the envelope, such that the envelope peels apart and separates into ruptured layers that are pulled out of the food product and out of the outer container by the continual pulling force from the protruding end portion.

FIELD

The present disclosure relates generally to a food package, and more specifically to a food package for segregating ingredients of a multi-component food product, such as the multiple components of a sandwich.

BACKGROUND

Multi-component food products, such as sandwich products, are often prepared and eaten the same day or within a few days to avoid storage issues and loss of organoleptic properties of a freshly-made sandwich upon storage. When a sandwich product is prepared and stored for an extended period of time, e.g., more than a few days, there is typically undesirable moisture and flavor migration between the bread of the sandwich and the inner sandwich components, or garnish/toppings, of the sandwich. The inner sandwich components that have higher water activities than adjacent components or the bread components can have moisture that tends to migrate towards the lower water activity food component. During an extended period of storage time, this moisture migration can result in a sandwich that is not as organoleptically pleasing due to issues such as bread becoming soggy, sandwich components losing their texture or crispness, sandwich components losing their flavor, and the like.

As a result, sandwich products that are meant to be stored for an extended period of time have been packaged in ways to try and minimize such moisture and flavor migration between the various components of the sandwich. One such example is to individually and separately package each component of the sandwich, such that the cheese is packaged or wrapped individually and separately from the meat which is also separately packaged, while the bread or bun component is also packaged separately from all of the inner sandwich components. While this may result in preventing the moisture and flavor migration between the components during the extended storage period, it can require the consumer to have to unwrap each component individually and to assemble the sandwich themselves before eating. This can require multiple, time-consuming preparation steps on the part of the consumer, e.g., opening all of the individually wrapped packages and then assembling all of the sandwich components into a sandwich.

Another aspect is described in U.S. Pat. Nos. 5,012,971 and 5,213,256, which consist of a preassembled sandwich or burger that is packaged in a container, such as a Styrofoam hinged container having a top half and a bottom half, where the top half of the bun or top bread component is contained inside the top part of the container, and the bottom bun or bottom bread component is contained inside the bottom part of the container. A card or insert is placed between the top and bottom bread components, such that it separates the top and bottom half of the container, and is positioned such that it can separate two inner sandwich components, such as separating a cheese and a meat component. When the container is in a closed position, the sandwich or burger is in a pre-assembled state therein with the insert or card placed between the two inner sandwich components essentially creating two separate compartments within the container.

Thus, the insert card creates a separately packaged top half of the sandwich, and a separately packaged bottom half of the sandwich. When the consumer is ready to consume the sandwich, they simply grasp the insert or card, preferably it will have a tab for grasping, and pull the insert in a horizontal direction to remove it from the container and from between the sandwich halves. However, the insert only divides the sandwich into two halves, without segregating the inner sandwich components completely. Only one surface or side of an inner sandwich component is segregated from an adjacent surface or side of another sandwich component; the other side of the inner sandwich component is still in contact with the remainder of the sandwich on its half of the container, such that moisture and flavor migration issues can still be prevalent on that half or side of the sandwich. Furthermore, certain food components like cheese, for example, are sticky, i.e., can have a high static coefficient of friction, thus preventing removal of the divider by a simple sliding motion, or causing the food ingredient, such as cheese, to stick to the divider and to be pulled with it.

Still another variation is disclosed in International Publication Number WO 2004/086886, for a package used for retaining the filling of a roll, where the filling can be in a semi-solid state and it can be runny and difficult to maintain in a bread roll. A cavity can be made in the roll into which the packaged filling is placed, where the package can be shaped to compliment the cavity in the roll. Once the consumer is ready to consume the product, pressure is applied to one end of the package (i.e., the end that is visible and extends out from the opening in the roll), such as by squeezing the package, in order to push the filling out through an exit opening or hole in the opposite end. Once the filling has been pushed into the cavity of the roll, then the consumer must pull the remaining package out from the roll. Despite this food product being relatively pre-assembled, the method of removing the package and squeezing the filling into the cavity of the roll as the package is being removed creates an additional step for the consumer in assembling the sandwich, can be difficult to properly execute, and can be messy. Furthermore, the filling is essentially being pushed or squeezed out of the package.

SUMMARY

A package for segregating two or more component parts that are combined to make a product, the components being separated by a barrier material, and in particular, a food package for segregating ingredients of a multi-component food product, such as components of a sandwich, is provided that allows for the sandwich to be relatively pre-assembled yet substantially segregating the inner sandwich components from each other and from the bread components during storage of the sandwich. The inner sandwich components are segregated by a flexible envelope which substantially encloses the sandwich component during storage, while the overall sandwich, including the outer bread components, are stored in a rigid outer container. The flexible envelope encloses the inner sandwich component, which is placed inside of the bread component, where together these components are then packaged in the rigid outer container. Prior to consumption, a consumer can pull on or apply a force to a protruding end portion of the flexible envelope, or pull tab, which peels apart a rupturable seal of the envelope and exposes the sandwich component to the bread component, and any other sandwich components that may be present and removed from their respective envelopes, thus assembling the sandwich due to the force of gravity acting upon it without requiring the consumer to de-assemble or re-assemble the sandwich.

The inner sandwich components are each segregated from each other by their respective flexible envelopes, as well as being segregated from the bread components. As a result, moisture migration and flavor migration can be restricted during storage of the assembled sandwich and the organoleptic properties of the sandwich can be maintained. Additionally, since the overall sandwich is packaged in a rigid outer container, the bread component can be stored without significantly compromising its organoleptic properties, while also packaging the inner sandwich components in their own individual envelopes placed between the bread components. Such packaging technique extends the period of time that the assembled, yet segregated, sandwich can be maintained and stored prior to consumption. Furthermore, a simple, one-step action is required to “open” multiple envelopes, thus exposing the inner sandwich components and creating a sandwich that is ready to be eaten once the rigid outer container is opened. The sandwich is thus fully assembled with minimal preparation steps by the consumer without having significantly compromised organoleptic properties of the sandwich upon storage.

The envelope provided to enclose the sandwich components can be sealed on all or substantially all sides with a rupturable seal. The envelope can conform in shape to the food component and/or to the bread component or can have any other shape. The protruding end portion can be a continuation of the envelope or can be affixed to it, such that the protruding end portion extends from the sandwich and rigid outer container. Upon opening the envelope, the pull tab can be pulled such that the trailing edge of the envelope can begin to separate by partially rolling back upon itself.

Other envelope embodiments are also possible. In one aspect, the envelope can comprise two pull tabs, one on each opposing end, such that the envelope can be pulled away from the food product. In another aspect, the envelope can comprise a middle, or intermediate layer, to which an upper and lower layer of the envelope are attached. In still another aspect, the pull tab can be laminated to a layer of the envelope and defined by a weakened area that can separate the pull tab from the layer of the envelope upon applying a force to its protruding end.

Additionally, the bread component can also have a layer of film that encloses and separates the bread from the other sandwich components. This bread film layer can be attached to flanges of the container. As a result, the envelope layers can either be sealed to the bread film layer itself or at least one layer of the envelope can also be sealed to the flanges. Moreover, the pull tab can be an extension of a film layer attached to the envelope layers and bread layers at a trailing end thereof, such that the pull tab comprises multiple film layers that can be combined to form the pull tab.

In another aspect, the protruding end portion of the envelope can be wound around a roller or spool housing with its end free for grasping, such that as the end of the protruding end portion is pulled the spool is rotated thus activating the protruding end portion and applying a force to the layers of the flexible envelope, which initiates the peeling of the seals of the envelope. The discarded layers of the envelope are subsequently wound around the spool as the protruding end portion is continually pulled, such that the discarded layers can be hidden from view and wrapped around the spool.

In still another aspect, the protruding end portion of the envelope is wrapped around a spool that has a knob for turning, such that the protruding end portion is not visible to the consumer. In order to apply force to the envelope to peel apart the seals, the knob is rotated axially, such that as the knob is turned the seals of the envelope are also pulled apart and peel to expose the inner sandwich components, and the discarded layers of the envelope are wound around the spool and are hidden from view.

In yet another aspect, the protruding end portion of the envelope passes through a secondary compartment within the rigid outer container and an end segment of the protruding end portion extends through an opening in the secondary compartment, where the end segment is to be accessed by the consumer. The end segment of the protruding end portion can be grasped by the consumer and pulled to peel apart the seals of the envelope and expose the inner sandwich components to each other and to the bread. As the envelopes peel, the discarded envelope layers are pulled into the secondary compartment of the outer container and are contained therein and hidden from view.

In another aspect, the food package can comprise a unitary compartment of the container that houses a bread component with the sandwich components suspended inside above the bread component on a barrier film layer. The barrier layer can be configured to rupture upon heating such that the segregated sandwich component can then be combined with the bread component.

A method of opening the package is provided that allows a one-step action for opening the packaged sandwich components and to obtain a completely assembled sandwich. To open the envelope which encloses the sandwich component to result in a completely assembled sandwich, the consumer can apply a force to the protruding end portion either by pulling on the protruding end portion or by rotating a knob axially that has a portion of the protruding end portion thereon. This pulling or rotating action applies a force to the envelopes, thus peeling apart the seals and separating the layers of the envelope from each other and exposing the sandwich components to the inner components of the sandwich. As the protruding end portion is pulled and the layers of the envelopes are separated, the ruptured layers of the envelope are pulled from between layers of the sandwich and rigid container, allowing all of the inner sandwich components to fall into place, thus resulting in the fully assembled sandwich. The rigid container can then be opened to access the sandwich.

DETAILED DESCRIPTION OF THE DRAWINGS

A package for segregating ingredients of a multi-component food product, such as multiple components of a food sandwich, the package having an outer container, that can be rigid, semi-rigid, or flexible, for storing a pair of bread components and one or more flexible envelopes for enclosing a food or sandwich component therebetween, and methods for opening, are disclosed herein and illustrated inFIGS. 1-25. In particular, the outer container has at least one compartment and can have a top compartment and a bottom compartment, where one compartment receives one of the pair of bread components of the sandwich and the other compartment receives the other bread component. At least one flexible envelope can be positioned between the bread components to enclose a sandwich component, where one envelope may be used for each sandwich component contained therebetween. Alternatively, more than one sandwich component can be enclosed within the envelope where migration between the components is not an issue. The flexible envelope substantially completely encloses the sandwich component and can be sealed along a rupturable seal. Aspects of the container and its flexible envelopes will be discussed in terms of a sandwich and sandwich components. However, it will be understood that any multi-component food product can be packaged in this way, or any multi-component non-food product. For instance, the outer container of the package can store a first food component and a second food component having one or more flexible envelopes for enclosing an intermediate food component therebetween.

FIGS. 1-8show a first embodiment of a food package having a rigid outer container for storing food components therebetween and having one or more flexible envelopes for enclosing sandwich components.FIGS. 4-8show a cross-sectional view of the first embodiment, withFIGS. 7-8showing an expanded and more detailed view of the envelope layers.FIGS. 9-10show a first embodiment of a flexible envelope having a tapered end and a protruding end portion or pull tab attached to the envelope at the tapered end. The tapered end, or trailing edge, is pulled against when a force is applied to the pull tab and separation of the envelope layers begins at this point.FIGS. 11-12show a second embodiment of the envelope where the envelope can have a cut out area with a flap attached to cover the cut out area. The envelope can be pulled on two ends, via a pull tab and a pull strip, such that the pull tab removes the flap from the envelope and the pull strip pulls the remaining envelope away from around the sandwich component.

FIGS. 13-14depict a third embodiment where the envelope comprises three layers, the upper and lower layer with an intermediate layer there between. The upper and lower layers seal directly to the intermediate layer. Each end of the envelope can have a pull tab or strip.FIGS. 15-16depict a fourth embodiment of the envelope where the pull tab is laminated to the envelope layers and can be later removed to assist in pulling the layers apart.FIGS. 17A-Ddepict a fifth embodiment of the envelope layers in relation to a compartment layer.

FIGS. 18-19show a second embodiment of the food package where the pull tab is attached to a roller that assists in removing the envelope layers.FIGS. 20-21show a third embodiment of the food package where the pull tab is wound about a knob, such that the turning of the knob initiates the peeling of the envelope layers.FIGS. 22-23show a fourth embodiment of the food package where the food package has a secondary compartment for retaining the ruptured envelope layers.FIG. 24depicts a process line for manufacturing multiple envelopes and enclosing multiple sandwich components in a continuous fashion.FIG. 25depicts a fifth embodiment of a food package where the food package comprises a single compartment container that is separated into additional compartments by a barrier layer of film.FIGS. 26A-Cand27A-B depict a sixth embodiment of a food package where the food package comprises multiple compartments separated by film dividers and assembled by folding. The barrier layer of film supports the sandwich component thereon above the bread component, separating the sandwich component and bread component, and the barrier layer can further be configured to rupture upon heating such that the sandwich component can then be combined with the bread component.

Turning toFIGS. 1-3, a package10for segregating food components22of a sandwich20is shown having a sleeve24, a generally rigid outer container15and at least one generally flexible envelope16therein, and as shown in these figures, at least two generally flexible envelopes16therein. The sandwich20can comprise a pair of bread components20aand20bhaving at least one sandwich component22substantially enclosed in the envelope16and between the bread components20aand20b, where the sandwich component22can comprise any topping, garnish or filling that is typically found in a sandwich. The rigid outer container15can have a top compartment12for receiving one of the pair of bread components20aand a bottom compartment14for receiving the other of the pair of bread components20b. Alternatively, where the sandwich only has one bread component, such as with a pizza or flatbread sandwich, the outer container can have a compartment for receiving the one bread component therein. The term “rigid” is used herein to indicate that the compartments12and14have the ability to retain their respective shapes during normal handling, and preferably, can comprise a rigid plastic material. The term “flexible” is used herein to indicate a pliable and workable material, such as a polymer material. The term “sandwich” is used herein to indicate any assembled multi-component food product such as a sandwich, a flatbread sandwich (i.e., a one-bread sandwich), a burger, a wrap, a pizza, and the like, in which a farinaceous outer food component encloses or contains an inner food component, where the inner food component can include a food used as a topping. The term “bread component” is used herein to indicate any farinaceous food component. Alternatively, a non-food component may also be packaged in such a container where it is desirable to separate the components from each other.

InFIGS. 1 and 4, the package10is depicted during storage of the sandwich20prior to opening. The sandwich can comprise a bun crown or upper bread component20aplaced in the top compartment12of the rigid outer container15and a bun heel or lower bread component20bplaced in the bottom compartment14. As shown in the figures herein, there are at least two sandwich components22between the pair of bread components20aand20b, such as a meat and cheese component, or any other desired sandwich garnishment; alternatively, there can be more or less sandwich components.

The flexible envelope16is positioned between the pair of bread components20aand20band can completely enclose or partially enclose at least one sandwich component22effectively providing a barrier layer between the inner components. Preferably, a single flexible envelope16is used per single sandwich component22. Therefore, if there are multiple sandwich components22then there will equally be a multiple number of flexible envelopes16, one for each component22. Alternatively, it may also be possible for a single flexible envelope16to enclose multiple sandwich components22where the sandwich components are the same or where moisture migration is not an issue, and several such combination envelopes can be provided or may be combined within the sandwich together with one or more single-component envelopes.

The flexible envelope16may be any shape and size such that it adequately conforms to the shape of the sandwich component22, and/or conforms to the shape of the bread components20aand20b, and adequately encloses the sandwich component22. The envelope16can be rectangular and sized as long and as wide as the bread components20aand20b. Preferably, the envelope16will have a point or taper at one end to which a pull tab film layer can be integral or adhered to, as will be discussed herein. The flexible envelope16may be sealed, or closed, on all four sides or peripheral edge portions30of the envelope16, as shown inFIG. 9, such that it completely encloses the sandwich component22. In the envelope16shown inFIGS. 9-10, one side portion or peripheral edge portion30can be folded while the remaining sides can be sealed at their respective peripheral edge portions30by a rupturable seal28. Alternatively, the envelope16can be sealed on all four edge portions30, or can be sealed on at least one edge portion30but less than all side edge portions30.

The rupturable seal28is formed along the edge portions30such that upon applying a force to the envelope16, the seals28separate or peel apart, effectively pulling the layers of the envelope16apart initially at the point or edge31furthest from the pull force such that the layers16aand16bbegin to peel and roll back onto themselves, exposing the sandwich component22to the rest of the sandwich20, as shown inFIG. 10. As the pull tab18is pulled in the direction of arrows A, the upper layer16aand lower layer16bbegin to separate along the trailing edge31at its rupturable seal28thereat. Although the free end of the pull tab18is located adjacent the leading edge32, as the pull tab18is pulled it begins to separate the layers at the trailing edge31first rather than at the leading edge32, as depicted by arrows C. A peeling rather than a sliding motion may take place upon opening the envelope16, i.e., rupturing the seals28, or a combination of a peeling and a sliding motion, which can reduce the forces needed for removal of the layers to a practical level as compared to solely sliding the envelope layers apart from one another. It is believed that the peeling action imparts a force across a line rather than an area, and the separation of the layers is accomplished by tensile failure of the adhesive bond between the sandwich components22(i.e., cheese, meat, etc.) and the packaging film.

The rupturable seal28can be strong enough such that the edges of the envelope16remain sealed while the sandwich is unopened yet the seals28peel apart upon applying a force to the envelope when pulling on a protruding end portion18, or pull tab feature. A protruding end portion18can be positioned at any edge portion30of the envelope16, such that it is anchored and affixed to one end31of the envelope16while its end can extend across the envelope16to extend past an opposite edge32of the envelope16from the anchor point to provide the pull tab end18for pulling. The end31of the envelope16to which the pull tab18is affixed can become the initiating point for the peel or where the seals initially peel. The protruding edge portion18, or tab that extends beyond the edge of the envelope16, can be pulled to apply the force needed to peel apart the envelopes16and peel the respective layers apart in a “rolling” peel motion. Furthermore, the protruding end portion18may be made up of multiple layers that can combine to form a common pull tab, or protruding end portion18.

The flexible envelope16substantially completely encloses the sandwich component22, such that it envelops the sandwich component22on substantially all sides, as shown inFIGS. 9-12. The flexible envelope16can have an upper layer16aand a lower layer16bthat are sealed to each other along their respective peripheral edge portions30by a rupturable seal28, e.g., a heat seal, or have at least one folded edge thereat. The flexible envelope16may comprise a single sheet, or single layer, folded to create an upper layer16aand a lower layer16b, such that the single sheet can be sealed to itself along at least one edge portion30of the upper layer16aand lower layer16b, and preferably along all edge portions30except the folded edge portion32. Alternatively, the flexible envelope16may comprise two individual sheets or layers that are sealed to each other along substantially all peripheral edge portions30, and does not contain a folded edge portion.

In another aspect of the envelope, an upper and lower film layer16a′ and16b′ can be provided with a cutout area34in both layers, as shown inFIGS. 11-12. The cutout area34allows for extracting the sandwich component22therein from the envelope16′ by pulling upon a pull strip64to remove the envelope16′ from around the sandwich component22. The opening34can be formed a number of different ways such as utilizing two separate layers or sheets and leaving one edge portion30substantially unsealed, or by providing a single sheet that is folded and either the folded edge32has a portion cut out of it to create an opening34or the opposite edge from the fold is not sealed, or any other similar embodiment. Additionally, an upper flap36aand lower flap36bcan be attached over the cutout area34, as shown inFIG. 11, and can further comprise narrow peelable seal areas along where the flaps36aand36bintersect the envelope layers16a′ and16b′. A protruding end portion18′, or pull tab, can be affixed to a portion of the flaps36aand36bor can be an extension of the flap36, such that a protruding end portion18can extend from each flap36aand36b, allowing the flaps36aand36bto be peeled off of the envelope16′ using a rolling peel action, when the pull tabs18a′ and18b′ are pulled.

Substantially simultaneously to the pulling of the pull tabs18aand18bto remove the flaps36aand36b, the opposite end31of the envelope16′ can also be pulled. Preferably, the opposite trailing end31can also have a protruding strip64for grasping or a pull strip64. As both ends are pulled, relatively simultaneously, the upper and lower flaps36aand36bcan roll and slide upon themselves to peel off to expose the cutout area34and the sandwich component22therein, while the pull strip64is also pulled to remove the remaining envelope layers16′ from around the sandwich component22, which is extracted through the opening34relatively simultaneously. Where there are multiple sandwich components22, there can also be multiple envelopes16′ used. When multiple envelopes16′ are included, the pull tabs18′ from each flap36can all be grouped together on one side; likewise the pull strips64from the opposite end31of each envelope16′ can also all be grouped together on one-side to be grasped and pulled relatively simultaneously. In yet another aspect, the protruding end portions18′ may be of varying lengths to initiate a substantially sequential peel action, which can minimize the peel force. Once the flaps36are removed from the envelope16′, the envelope16′ can be withdrawn from around the sandwich component22and the sandwich component22can be removed through the opening34.

The protruding end portion18can be an extension of the flexible envelope16, such as an extension of one of the sheets16aor16bof the envelope16, or it can be a separate piece that can be affixed to an edge portion30of the envelope16. The protruding end portion18can further comprise a single layer attached to the end portion30of the envelope16or it can comprise an extension of the multiple layers of the envelopes16sealed together to form a single unit, or any other similar variation of a single or multiple layered end portion18. When there are multiple envelopes16placed in between the sandwich components22, each of the multiple envelopes16can be connected to a single common protruding end portion18, thus applying a pulling force to the protruding end portion18applies a force to all of the envelope seals28, peeling apart the envelopes16substantially simultaneously.

In one aspect, a separate layer of film62that can extend into the protruding end portion18can be attached to at least a layer of the envelope16aor16b, such that a first pull tab film layer62acan be attached to the upper layer16aand a second pull tab film layer62bcan be attached to a lower layer16b. Alternatively, as shown inFIGS. 7 and 8, the pull tab film layers62aand62bcan be extensions of their respective envelope layer. For example, each envelope16that comprises an upper16aand a lower layer16bcan also have two pull tab film layers62aand62b, a first layer62aand a second layer62b, where the first pull tab film layer62ais an extension of the film of the upper layer16aand the second pull tab film layer62bis an extension of the film of the lower layer16b, thus the pull tab film layers62aand62bcan loop back across their respective envelope layer16aor16bat the trailing edge of the envelope16. The free end of the pull tab film layers62aand62bcan protrude out from the sandwich20and container15, and form a part of the protruding end portion18, where the protruding end portion18can essentially be made up of multiple film layers that extend into the pull tab18. Furthermore, it is preferable that the first pull tab film layer62aand second pull tab film layer62boriginate at least at the trailing end31of the envelope16that is farthest, e.g., opposite, from the protruding end portion18, such that when the protruding end portion18is grasped and pulled the rupturable seal28of the envelope16begins to separate and break at the trailing end31opposite the protruding end portion18, where the pull tab film layers62aand62bare affixed to the envelope layer, or originate therefrom. This can create a rolling peel motion, where the envelope16is separated along its seals28in a sequential motion starting at the farthest end31of the envelope16(e.g., where the first pull tab layer62aand second pull tab layer62bof the protruding end18are attached or originate from) and continuing along its side edges30to its end32closest to the protruding end portion18.

In another aspect, the end31of the envelope16furthest from the protruding end portion18can be tapered or pointed, as shown inFIG. 9, such that the area of rupture or peeling for that seal has a small surface area. This aspect allows for a smaller area of resistance when pulling, thus the seal at the tapered end31can peel apart with less force. It is preferable that the seal area at the farthest edge31is not wider than the width of the pull tab layer of film of the protruding end18, to allow for an easier initial peeling of the envelope16. This method of a rolling peel essentially rolls the envelope layers16aand16baway from the sandwich component22inside, rolling the layers of film16aand16bback upon itself. That is, the layers16aand16bare not being pulled out as much as they are being “rolled” away, such that the layers16aand16bare not sliding over the sandwich component22.

When the envelope16is placed in the sandwich20between the bread components20aand20b, the protruding end portion18can extend outwardly from between the bread components20aand20bsuch that the protruding end portion18is external to the sandwich20. As the sandwich20is placed in the rigid container15, where the upper bread component20ais contained in the top compartment12and the lower bread component20bis contained in the bottom compartment14, and the top and bottom compartments12and14are assembled in a closed configuration around the sandwich20, the protruding end portion18can further extend through an opening in the rigid outer container15generally positioned between the top compartment12and the bottom compartment14. The protruding end portion18can be grasped and pulled in an effort to apply a force to the flexible envelopes16to separate the envelopes16along their rupturable seals28about a peripheral edge portion30of the envelopes16. Where the flexible envelope16is sealed on substantially all sides of the envelope16along its peripheral edge portion30, it peels along substantially all peripheral edge portions30. Where the envelope16is of the embodiment shown inFIGS. 11 and 12, upon opening the envelope16′ the sandwich component22can pass through the opening created by the cutout area34upon relatively simultaneously pulling the protruding end portion18′ and the pull strip64extending from the opposite side31, thus extracting the envelope16′ from the sandwich20, rather than requiring separation of the envelope16′ rupturable layers; although the envelope16′ can also peel along its seals28.

Furthermore, as the envelope16peels apart and separates into its layers, e.g., its upper layer16aand lower layer16b, these ruptured layers16aand16bcan be extracted from between the bread components20aand20b, and can further be extracted through the opening between the top compartment12and the bottom compartment14through which a portion of the protruding end portion18already extends. As the ruptured layers16aand16bare separated and removed from around their respective sandwich component22, the sandwich component22therein remains inside the sandwich20between the bread components20aand20b, due to the force of gravity acting upon it. As the ruptured layers16aand16bare rolled away from the sandwich component22, the sandwich component22“drops” into place between the adjacent bread component(s)20aand20band/or adjacent sandwich component22. Due to the rolling and peeling action of the ruptured layers16aand16b, sticking of the layers16aand16bto the sandwich component22and pulling on the sandwich component22can be minimized. This can advantageously reduce buckling or bulging of the sandwich component22during removal of the envelope16, as well as sliding, but rather can remain positioned essentially between the two bread components20aand20b.

In yet another aspect, as shown inFIGS. 7 and 8, an additional film layer60can be positioned adjacent the envelopes16to enclose one or both of the bread components20aand20bin their respective compartment12or14. For instance, a compartment film layer60a, or a bread film layer60a, that encloses the top bread component20awithin the top compartment12can extend across the opening of the top compartment12and can be sealed to the outer flanges121of the top compartment12. In order for the bread film layer60to be removed by peeling the seals between the film layer60and the outer flanges121or141, a protruding end portion film layer or pull tab film layer62ccan also be attached. In this aspect, the pull tab film layer62ccan be an extension of the bread film layer60, such that it loops back across the bread film layer60at an end opposite the protruding end portion18or pull tab, i.e., the trailing end. This arrangement of the pull tab film layer62csimilarly provides for a rolling peel action of the bread film layer60upon opening, i.e., upon applying a force to the protruding end portion pull tab18, such that the bread film layer60rolls or peels away from the bread20aor20bleaving the bread20aor20band adjacent components22relatively undisturbed. Alternatively, the pull tab film layer62ccan be a separate layer attached to the trailing end of the bread film layer60. A bread film layer60bcan similarly be provided to the opposite bread component20band opposite compartment14, such that both bread components20aand20bcan be sealed within their respective compartments12and14.

In still another aspect where at least one envelope16is provided, one of the layers16aor16bof the envelope16can be attached to the flange121or141of one of the compartments12or14as shown inFIG. 7. In one aspect, at least two envelopes16can be provided, where one of the envelopes16can be attached to the flange121of the top compartment12, just beyond the film60that seals to the flange121for enclosing the bread20a, by heat-sealing on the leading edge and sides of that envelope16. Additionally, the other envelope16can be attached to the bottom compartment14in a similar manner. One of the two layers16aand16bof the envelope can extend beyond the perimeter of the other and this longer envelope layer can seal to the flange121or141of the compartment12or14while the other layer seals to the longer layer. For example, where the upper layer16ais adjacent the top compartment12and the lower layer16bis adjacent the inside of the sandwich20, or the bottom compartment14, the lower layer16bcan extend beyond the edges of the upper layer16aand can seal to the flange121of the top compartment12just beyond the sealed edges of the bread film layer60, if used. The upper layer16awould then seal along its edges to the lower layer16bbut within the perimeter of the top compartment12. Similarly, a layer of the second envelope16can be sealed to the flange141of the bottom compartment14, i.e., the upper layer16aof the second envelope16would be sealed to the flange141, with the lower layer16bof the second envelope16being sealed to the upper layer16a.

The attachment of the envelopes16can be in such a way that the envelopes16can be peeled open using a pull tab18that also relatively simultaneously or relatively sequentially peels the bread film layer60from its compartment12or14to expose the bread20aand20b. The envelopes16can also be peeled away from the flanges121or141of the compartments12and14using the pull tabs18, however, the peeling of the film layer from the flanges121or141can lag the other layers slightly. For example, each envelope16or bread film layer60can have its own pull tab film layer62which can be attached to its respective film, or an extension thereof at least at one end, thus extending across the envelope16or bread film layer60to the opposite end to a common protruding tab18, formed of the multiple film layers62. The lower layer16b, which is sealed to the flange121can have a pull tab film layer62baffixed to the lower layer16bor an extension of the lower layer16bas shown inFIG. 7, at least at one end, such as the trailing end, and can extend between the lower layer16band the second envelope, if present. Similarly, the bread film layer60can also have a pull tab film layer62cextending from the bread film layer60at its trailing end and extending across the bread film layer60, between the pull tab film layer62aof the upper layer16aand the bread film layer60. The upper layer16acan have a pull tab film layer62aas in previous embodiments.

The pull tab film layers62a-62ccan be grouped together on the same side, opposite their attachment point, and can be combined into a common protruding end tab18. The lengths of the pull tab film layers62a-62cand their position are such that the initiation of peeling each layer can be slightly staggered. For example, where the lower layer16bis attached to the flange121, upon pulling the pull tab18the upper layer16aand the bread film layer60can begin to peel relatively simultaneously while the lower layer16bcan begin to peel last. This is so the upper layer16ahas a surface against which it can be pulled, in this instance it is the lower layer16b. Therefore, the lower layer16bcan remain intact at least initially to allow the upper layer16ato begin separating from the lower layer16b. Likewise, it can be desirable to also begin peeling away the bread film layer60before the last envelope layer, in this case the lower layer16b, so that the sandwich component22inside the envelope16does not catch or get stuck to the bread film layer60, such that it would peel away with the bread film layer60. Additionally, a portion of the lower layer16bmay not be sealed completely to the flange121at the leading edge, (i.e., edge near protruding ends18) such that the pull tab film layers62aand62cof the upper layer16aand bread film layer60, respectively can pass through an opening in the film layers, such as between the lower layer16band the bread film layer60, to allow the pull tab film layers62aand62cto extend into the common pull tab18, as seen inFIG. 8.

Delaying the peeling of the envelope films from its respective compartment flange121or141can allow the envelopes16to be peeled open without the need of support frames, thus simplifying the design and reducing packaging material. The pull tab18can comprise multiple layers of pull tabs from each layer of film that can be bonded together at their ends to form one common pull tab18to allow opening all component compartments and envelopes16substantially simultaneously or such that the initial peel can be slightly staggered with a simple, single pulling action. Since the film layers are peeled using a rolling action, all the food components22can remain relatively undisturbed from their original position, thus resulting in a neatly stacked assembly within the container15.

In yet another aspect, the envelope16can be sealed to the bread film layer60itself, or rather at least one of the envelope layers16aor16bcan be sealed to a portion of the bread film layer60, as shown inFIGS. 17A-D. For example, an envelope16having its upper layer16aadjacent the bread film layer60, can be sealed to the lower layer16balong its edges to form the envelope16with rupturable seals28therebetween, as in previous embodiments. However, the lower layer16bcan then be sealed to a portion of the bread film layer60at least along a portion of its edges thereof, as shown inFIG. 17A. All layers16a,16band60can have a common protruding end portion18or pull tab formed from multiple pull tab film layers62a-62c, respectively, that originate from a trailing edge131that is opposite the pull direction E, however, each envelope film layer16aor16bor bread layer60in this aspect can peel at different times. This is because of the way the pull tab film layers62a-62care positioned, such that pulling on their common pull tab18will begin a sequential peel.

As shown inFIG. 17A, the bread film layer60is sealed to the flange121of the rigid container15. In this aspect, the top compartment12is illustrated, however, a similar arrangement can be shown with the bottom compartment14and its bottom flange141. The flange121is defined as the area between the outer edge64of the container15and the intersection of an upper extension of the top compartment12with the beginning of a horizontal section of the container15, as designated by a circular edge66.

The lower layer16bis sealed to the bread film layer60at a peripheral edge of the bread film layer60such that a peripheral edge of the lower layer16bextends into the area of the flange121, just beyond the circular edge66. Furthermore, the lower layer16bmay not be completely sealed to the bread film layer60about its perimeter. For instance, as illustrated inFIG. 17B, the lower layer16bcan contain portions along its perimeter that are unsealed to the bread film layer60. In one aspect, a section of an edge68of the lower layer16bthat is adjacent the pull tab film layer62cof the bread film layer60can remain unsealed to the bread film layer60to allow the pull tab film layer62cto loop away from the bread film layer60and extend between the bread film layer60and the upper layer16aof the envelope16through an opening created by the unsealed area68. The unsealed section68can be as wide as the pull tab film layer62csuch that the pull tab film layer62ccan loop through the opening created by the unsealed area68, as shown inFIG. 17B, however, the unsealed area68may also be wider. In another aspect, the lower layer16bcan also remain unsealed to the bread film layer60at the leading edge32of the container15, to allow for the pull tab film layers62aand62cto extend into the space140between the lower layer16band the bread film layer60and past the leading edge32and into the common pull tab18. The remaining perimeter edge portion of the lower layer16bcan be sealed to the periphery of the bread film layer60, as shown inFIGS. 17C and 17D, including a portion of the perimeter of the lower layer16bat the trailing end131that is not immediately adjacent the pull tab film layer62c.FIGS. 17A-Dillustrate only the top half (i.e., top compartment12) of the food package, however a similar arrangement can also be provided on the bottom half (i.e., bottom compartment14) of the food package.

The sequential peel of the film layers16a,16band60can be initiated by pulling on the common pull tab18which can begin peeling the film layers16a,16band60at different times. For example, in the aspect shown inFIGS. 17A-D, the first seal to peel and to begin the rolling peel process can be the upper layer16a. The upper layer16acan begin to peel first, such that it can use the lower layer16bto peel against and away from. This is followed by the lower layer16bbeginning to peel after the upper layer16ahas started to peel. Similarly, this layer16bcan use the bread film layer60as an anchor against which to begin peeling. Lastly the bread film layer60can peel away from the flange121. The bread film layer60can also use the flange121as an anchor against which it can peel away from.

The pull tab film layers62a-62ccan each be attached to their respective layer16a,16bor60, as previously discussed, either as a separate film layer or as an extension of the envelope16or bread layer60that loops away from and across its layer. The pull tab film layers62a,62band62ccan all loop back away from their respective layers and extend adjacent and across their respective layers16a,16band60and into the common pull tab18. Therefore, in one aspect, the pull tab film layer62cof the bread film layer60can also loop away from its respective layer60to extend adjacent and across the bread film layer60, and further extending between the upper layer16aand the bread film layer60to exit at the leading edge32and into the common pull tab18. Likewise, the pull tab film layer62acan also loop away from its respective layer16ato extend adjacent and across the upper layer16a, extending between the upper layer16aand the bread film layer60to exit at the leading edge32of the package and into the common pull tab18. Similarly, the pull tab film layer62bof the lower layer16bcan also loop away from its respective layer16bto extend adjacent to and across the lower layer16band into the common pull tab18.

In still another aspect, a pull tab181can be built into an outer surface of one of the envelope layers1116aor1116b, as shown inFIGS. 15 and 16, such that substantially one contiguous piece can be manufactured having a stub portion66extending past one edge32of the envelope1116. This stub portion66can be a short pull tab or can be a long protruding pull tab. The outline of the pull tab181can be pre-cut into an upper surface of one of the layers1116aor1116bof the envelope1116, such as by pre-scoring the pull tab181into the outer surface of the envelope layer1116aor1116bwith the stub portion66at the end of it. For example, the outer surface of the upper layer1116acan be pre-scored with the shape of the pull tab181, having the stub portion66extend past the edge32of the envelope1116at one end of the pull tab181. The outer surface of the upper layer1116a, or lower layer1116b, can be laminated onto another single layer or another multiple layered film, such that the layer of film with the pre-scored pull tab181can be adhered to the single or multi-layered film using a permanent adhesive along its back surface in all areas except for where the pre-scored pull tab181is located.

The stub portion66can comprise an extension of the layer of film1116awith the pre-scored pull tab181adhered to the single or multi-layered film, and further can also be adhered to the additional layer or layers of film via a permanent adhesive so that when it is pulled it stays together. For example, where the pre-scored pull tab181is on the upper layer1116a, then the upper layer1116acan be adhered with the permanent adhesive along its back surface to another layer, except where the pre-scored pull tab181is located, to collectively make up the final upper layer1116a; the lower layer1116bmay or may not also comprise a multi-layer with a pre-scored pull tab181. Therefore, when the stub portion66is grasped and pulled it peels together all the way to point “X”, which is slightly before the edge32of the envelope1116, at which point only the top layer of film without permanent adhesive, e.g., the pre-scored pull tab181, continues to tear off the upper layer1116a, until it reaches the trailing edge31, where it remains attached, thus forming a longer pull tab portion for pulling apart the envelope1116at its rupturable seals28. Alternatively, the stub portion66can be combined with a common pull tab18such that the pull tab18is pulled to remove the pre-scored pull tab181from its respective film layer as well as peel apart the seals28between the envelope layers. Utilizing the pull tab18in this manner can be effective since it is believed that the pre-scored pull tab181is held in place against its respective film layer by static energy rather than a strong physical bond. If the other layer, e.g., the lower layer1116bin this aspect, does not contain a pre-scored pull tab181, then it would be advantageous for it to at least comprise a pull tab film layer62as previously discussed.

In order to activate the opening of the envelope1116by peeling its seals28, the pre-scored pull tab181needs to be separated from the upper layer1116afirst, as shown inFIG. 16. To remove the pull tab181from the upper layer1116a, its stub portion66can be grasped or its pull tab18attached to the stub portion66pulled. Once the stub portion66or pull tab18is pulled to where it intersects the edge32of the envelope1116, e.g., at point X, the pre-scored pull tab181can begin to tear and to remove the pull tab181from the upper layer1116a, since the pre-scored pull tab181does not contain any permanent adhesive along its backside. Once the pull tab181is pulled across the upper layer1116a, it terminates at an edge31opposite the starting point of the stub portion66, where the pull tab181remains connected to the upper layer1116a. Once the pre-scored pull tab181is freed from its layer1116a, then it can be pulled in direction of arrow A to initiate the peeling of the seals28of the envelope1116along arrows C, as depicted inFIG. 16. The pull tab layer181can comprise an O-polyester (OPET) layer or any other single or multilayer film. The pull tab layer can be adhered to a coextruded ethylene vinyl alcohol (EVOH)/ethylene vinyl acetate (EVA) layer or another polyester layer laminated to a coextruded EVOH/EVA, or any other coextruded or laminated plastic. Alternatively, the lower layer1116bcan include the pre-scored pull tab181of the envelope1116, or still alternatively, both the upper layer1116aand the lower layer1116bcan include the pre-scored pull tab181.

In another aspect of the envelope16, where a large number of envelopes need to be manufactured it may be easier to manufacture multiple, connected envelopes16, rather than individual envelopes16, as shown inFIG. 24. For example, a common web of film can be used for the lower layer166bthat can receive thereon multiple sandwich components22that are then sealed with multiple, narrow upper layers16awhile being advanced in a machine direction, M. For instance, the narrow upper layer16acan be only as wide as the food or other components22that are to be stored therein plus the width of the rupturable seals28. The lower layer166bcan be wide enough to seal a desired number of upper layers16athereto, thus where, for example, it is desired to manufacture three envelopes16at a time, at least three adjacent rows of upper layer films16acan be required, which can be supported by the lower layer166b. The upper layers16acan be sealed to the lower layer166balong rupturable seals28and can then be cut out, or separated, to form a single envelope16enclosing the sandwich component22. When the multiple envelopes16are cut or separated they can be cut such that the lower layer166bis larger or wider than the upper layer16a, at least along side edges thereof. For example, the lower layer166bcan be cut around the sealed upper layer16asuch that the lower layer166bextends beyond the perimeter of the side edges of the upper layer16a. This is so that the larger lower layer166bcan be sealed to the bread film layer60when placed in the sandwich20and container15, or alternatively can be sealed to the flanges of the container15. Protruding end portion layers18similar to earlier aspects can be employed for opening the envelopes16. For instance, the sealed envelopes16can have a pull tab film layer62attached to both the upper layer16aand lower layer16b. Alternatively, a knob or flap can be cut into the film to later attach a pull tab film layer62thereto. Still alternatively, a pre-scored pull tab181could be incorporated.

In another similar aspect, the upper layer166a(not shown) may also comprise a single common layer of film wide enough to cover all of the components22and to cover the lower layer166b. For instance, three separate sandwich components22can be sealed separately using a common upper layer166aas well as a common lower layer166b, where the upper layer166ais a strip long enough to cover and seal all sandwich components22into individual envelopes16, and subsequently multiple sealed pouches or envelopes16can result, which can then be separated into individual envelopes16. Alternatively, the upper layer166acomprises the wide common layer of film to which multiple lower layers16bseal to form multiple envelopes along the upper layer16a.

In another aspect, the upper and lower layers116aand116bcan be laminated, employing narrow seal areas, to an intermediate70, or middle, layer to fully enclose the sandwich component22in a readily peelable envelope116. This three layer envelope116can be referred to as a “framed” envelope, and can be seen inFIGS. 13 and 14. The intermediate layer70can comprise a thin and narrow edge portion, such that the film only partially extends around the perimeter of the sandwich component22having a hole or hollow center therein, such as a U-shape. Having the intermediate layer extend only partially around the sandwich component22allows for at least a portion of the sandwich component22to be unbound by the intermediate layer70, thus making extraction of the sandwich component22easier through this open end in the intermediate layer70. Alternatively, the intermediate layer70can extend all the way around the perimeter of the sandwich component22. At least a portion of the upper and lower layers116aand116bthus can be sealed at their respective edges to the edges of the intermediate layer70, thus forming an envelope116with the intermediate layer70therebetween. Where there is a break in the intermediate layer70, the upper layer16aand lower layer16bcan seal to each other. The upper and lower layers116aand116bcan have pull tabs18(or pull tab film layers62) that are folded over in such a way that those layers116aand116bcan be peeled off of the intermediate layer70, and each other where necessary, by grasping the common pull tab18in one hand and an intermediate pull strip72attached to the intermediate layer70in the other and pulling in opposing directions. The upper and lower layers116aand116broll and slide upon themselves and can peel off to fully expose the sandwich component22contained therein, as the intermediate layer70can be slid away from around the sandwich component22. Where multiple framed envelopes116are used, all pull strips72can be grouped together on one side, and all pull tabs18can be grouped together on the other side into their respective common pull tab18and pull strip72. When the strips72and tabs18are pulled substantially simultaneously all the sandwich components22can be released and stacked neatly upon each other.

Where the container15is additionally packaged inside a sleeve24, as inFIGS. 1-6, the sleeve24can also have a slot or opening to allow passage of a tail or end segment38of the protruding end portion18. Preferably, the slot in the sleeve24would be sized such that only the protruding end portion18can pass through it, while preventing the ruptured layers16aand16bof the envelope16to also pass through. This can be due to the fact that the ruptured layers16aand16bof the envelope16are sized wider than the slot in the sleeve24, while the protruding end portion18is sized narrow enough to pass through the slot. In this aspect, the sleeve24can retain the ruptured layers16aand16binside of the sleeve24and relatively out of view.

In another embodiment of the package100, as shown inFIGS. 18 and 19, the protruding end portion118can be provided with a tab or ring128at an end segment138thereof, that can be grasped by the consumer and pulled in order to apply a force to the protruding end portion118and, resultantly, to the flexible envelopes16attached thereto. The protruding end portion118can be positioned similarly to the previous embodiment, such that a portion of the protruding end portion118passes through an opening in the rigid container115, or preferably between the top compartment12and the bottom compartment14. The protruding end portion118can be a polyester film or string. However, the remaining portion of the protruding end portion118that is external to the rigid container115can be wrapped around a spool or roller130that can be mounted to the container115, and an end segment138of the protruding end portion118can extend from the roller130, unwrapped, and containing the tab128. As the protruding end portion118is pulled in the direction of arrow A, the roller130is activated and rotated, such that the protruding end portion118that is wrapped around the roller130unwinds and extends along the package100, as inFIG. 19.

As the protruding end portion118is pulled, the flexible envelopes16inside the sandwich are separated and peeled along their respective rupturable seals28, thus separating into the layers16aand16bof the envelope16. The flexible envelope layers16aand16bcan then be pulled through the same opening that the protruding end portion118extends through and can further be pulled towards and around the roller130, as the protruding end portion118is continually being pulled. The layers16aand16bcan also be wrapped around the roller130after being pulled through the opening in the rigid container115. As a result, the layers16aand16bof the envelopes16are not left loosely outside of the rigid container115, but rather are collected neatly about the roller130. After the ruptured envelopes16have been separated and removed from the sandwich20and container115, the container115can be opened to remove the ready-to-eat sandwich20. To open the container115, the top compartment12can be separated from the bottom compartment14and preferably the two will be integrally connected along a portion of a side edge, such as by a hinged portion132.

In still another alternate embodiment of the package200, as shown inFIGS. 20 and 21, the protruding end portion218can be substantially completely wrapped around a rotating spool or knob230that is mounted to the container215, such that it does not contain an end segment of the protruding end portion218that extends loosely and visibly from the knob230, e.g., there is no pull tab arrangement. To remove the flexible envelopes16, the consumer only needs to rotate the knob230axially, such that as the knob230rotates, it pulls on the envelopes16applying a force that can peel apart the seals28and separate the layers16aand16bof the envelope16. Thus, the consumer does not need to apply a force directly to the protruding end portion218to separate the envelopes16. As the envelopes16are separated and removed from around the sandwich component22and from the container215, the remainder of the layers16aand16bcan also be wrapped around the knob230, thus being relatively hidden from view. Again, optionally, the rigid container215may contain a hinged portion232along one side edge of the container215, along which the top compartment12and bottom compartment14can be attached.

In yet another alternate embodiment of the package300, as shown inFIGS. 22 and 23, the rigid container315can have a secondary compartment334in either the top or bottom compartment12or14, e.g.,FIG. 23shows a secondary compartment334positioned in the bottom compartment14, which receives a portion of the protruding end portion318during storage and prior to use/opening the package300. The protruding end portion318can extend into the secondary compartment334with an end segment338of the protruding end portion318extending through a slot or opening336in the secondary compartment334, and where the end segment338can be used as a pull tab and can be grasped and pulled by the consumer. The slot336can be provided in the secondary compartment334and/or in one of the top or bottom compartment12or14.

In addition, the secondary compartment334can also house a rotating spool or roller330, about which a portion of the protruding end portion318is wrapped around. The roller330is activated upon pulling the end segment338of the protruding end portion318, and further peels the seals28of the envelopes16as the roller330is continually turned. The ruptured envelope layers16can be rolled up along the roller330as they are removed from the sandwich and container315and pulled into the secondary compartment334as the protruding end portion318is continually pulled, and where the layers16aand16bcan be hidden from view.

In a variation of the envelopes and food package discussed herein, another embodiment of a food package can be provided where the inner sandwich components22are each separated by a barrier layer of heat-shrink film, as shown inFIG. 25. The barrier layer156can be configured to rupture as a result of microwave heating to at least partially combine the sandwich components with each other and with a bread component to form a common food product or sandwich. Once the sandwich is ready to be consumed, the entire package1000can be placed into a microwave and heated such that the heat-shrink film layers156can shrink and at least partially retract toward the point of attachment, thus allowing for the sandwich components22aand22bto combine with the bread component154due to the force of gravity.

A first sandwich component22acan be supported upon a heat-shrink film layer156athat can be affixed relative to the upstanding sidewall of the container151such that the first sandwich component22acan be positioned above the bread component154. The heat-shrink film layer156acan also separate a bottom-facing side of the sandwich component22afrom the bread component154, such that each is housed in a separate compartment152and164. On the opposite side of the sandwich component22a, i.e., the top facing side, the sandwich component22acan be enclosed by either the lid158or another film layer156bforming a separate compartment164for the first sandwich component22a. If a second sandwich component22bis provided, then it too can have a heat-shrink film layer156bpositioned at a bottom-facing side of the sandwich component22b, thus forming a separate compartment166for the second sandwich component22b, where the second sandwich component22bis positioned above the first sandwich component22a. The layers156of the heat-shrink film can provide multiple compartments164and166that support the sandwich components22aand22bthereon and separate the sandwich components22aand22bfrom the bread component154until ready to be heated and combined.

The outer container151can comprise a main inner compartment152that houses the bread component154. The bread component154can comprise a top bun and a bottom bun or a cylinder-shaped bread component that is cut down the middle forming two connected halves, or any other type of bread shape or orientation. The bread component154can be positioned such that it will receive the sandwich component22in an interior section of the bread154, if it is a sandwich, or on an outer surface of the bread154if the final product is a pizza or flatbread type sandwich. Regardless of how the bread component154is shaped or positioned, the entire bread component154can be housed in the same compartment i.e., the main inner compartment152. The outer container151can comprise a base162with an upstanding sidewall168to define an opening160opposite the base162. The food package1000can also include a lid158or other type of closure that covers the opening160. Inside of the container151in an interior section, the sandwich components22can be positioned supported on the layer of film156above the bread component154.

In one aspect upon heating the container1000, the center or middle area of the film layers156can be pre-scored to form a weak spot such that upon heating the film can rupture at this weak spot and can continue to retract toward the sidewall. Alternatively, the film156can be configured to retract from the sidewall first, or some other location than from the center of the film156. Furthermore, the film156can be attached to the sidewall all the way around the perimeter of the film and container interior or only partially attached thereto. Upon heating the container151, the film156can shrink from the area of the pre-score i.e., the center in this aspect, and as the film156shrinks from the center it can continue to retract towards the sidewall, thus releasing the sandwich components22aand22b. Alternatively, a susceptor may be attached or applied to the film156and can be made of sputtered aluminum instead of or in addition to scoring, to aid in creating a break in the film156upon heating. The heat-shrink film layer156can be comprised of a biaxially oriented olefin layer such that it can advantageously partially control the direction of retraction of the film upon heating, although other thermoplastic film materials may also be used, such as polyester.

Yet another embodiment of a food package can be provided where the inner sandwich components22and the bread components20are each separated in individual compartments, as shown inFIGS. 26A-Cand27A-B. The food package400is shown in a pre-assembled state inFIG. 26A, where the package400contains multiple compartments to store the food components. Preferably, each food component will have its own individual food compartment. Where there are four food components, as shown inFIGS. 26A-C, there can also be four compartments, one for each food component. For instance, there can be a top bread component20aand a bottom bread component20bstored in a top bread compartment412and a bottom bread compartment414, respectively. Similarly, there can be two sandwich components22aand22bstored in a first sandwich compartment422and a second sandwich compartment424, however more or less can be provided. In one aspect, the first sandwich component22acan be a cheese product and the second sandwich component22bcan be a meat product, or vice versa. The two bread compartments412and414can be adjacent one another prior to assembly and can be connected via a hinge438. The sandwich component compartments422and424can also be positioned adjacent one another when in the pre-assembled state shown inFIG. 26A, and can contact the bread compartments412and414along a common edge containing a connecting feature, such as a hinge420. Further, the two sandwich compartments422and424can remain unconnected along their common edge.

The bread components20aand20bcan each be stored in their own compartment412and414, respectively, that can also generally conform to the shape of the bread components20aand20b. The bread compartments412and414can each have an open end413and415, respectively, such that the compartments have one end wall with four sidewalls extending therefrom. The sandwich components can likewise each have their own individual compartments. A first sandwich component22acan be stored in the first sandwich compartment422and a second sandwich component22bcan be stored in the second sandwich compartment424. Each sandwich compartment422and424can be open on both ends, such that the compartments422and424comprise only four sidewalls around the sandwich components22aand22b. For instance, the first sandwich compartment422can have a first opening426opposite a second opening432, and similarly the second sandwich compartment424can have a first opening428opposite a second opening430. The openings426and428can each be defined by a flange or peripheral edge portion that connects all of the side wall portions.

Once the compartments are filled with their respective food components, their openings can be sealed with a peelable film layer or divider. Prior to filling, the sandwich compartments422and424can first have their second end openings432and430, respectively, sealed with peelable film layers434and436, respectively, to form a bottom surface onto which the sandwich components22aand22bcan be filled. After filling the sandwich compartments422and424, the first openings426and428, respectively, can be sealed with a peelable film layer to close the compartments422and424. This peelable film layer can comprise a single, common film layer that covers both openings426and428or, alternatively, it can comprise separate film layers416aand416bthat each covers its respective compartment opening426and428, as shown inFIG. 26A. Similarly, the bread compartments412and414can also be sealed with a peelable film layer460aand460b, respectively, which covers the openings413and415, respectively. As shown inFIG. 26A, the bread film layer comprises two separate film layers460aand460b, but can also comprise a single, common layer covering each opening413and415simultaneously.

Additionally, the peelable film layers416a,416b,434,436,460a, and460bcan all contain an extension of film which forms a pull tab that can be pulled to remove its respective film layer. For example, the bread film layer460acan have an extension of film418awhich is positioned at approximately a right angle to the placement of the bread film layer460aplaced over the top bread compartment412before assembling the package400. Likewise for the bottom bread compartment414and its associated film layers. Similarly, the first sandwich compartment film layer416acan have an extension417athat extends at approximately a right angle to its respective film layer416aand further is adjacent the bread film extension418awhen folded. Likewise for the second sandwich compartment424and its associated film layers. Similarly, the second end opening film layers434and436of the sandwich compartments422and424, respectively, can also contain an extension of film419aand419b, respectively, which can also be positioned at approximately a right angle to its respective film layers434and436before assembling the package400. In the embodiment shown inFIGS. 26A-B, the second end opening film layers434and436each have their own individual pull tab extensions419aand419b, respectively, adjacent one another. Alternatively, they may also share a common pull tab extension. As will be explained herein, upon folding the package400into its assembled form the pull tab extensions can also be folded with the package compartments (i.e., can be folded onto or adjacent its respective film layer upper surface) to align and provide a common pull tab or protruding end portion418.

To assemble the food package400, the different compartments can be folded over and onto one another along their hinges to provide the assembled form shown inFIG. 27A. As shown inFIG. 26B, the sandwich compartments422and424can first be folded along hinge420positioned between the sandwich compartments422and424and the bread compartments412and414, as indicated by arrows G so that the sandwich compartments422and424rest above and contact the bread compartments412and414, respectively. For instance, the first sandwich compartment422can fold over and onto the first bread compartment412and the second sandwich compartment424can fold over and onto the second bread compartment414.

Then, as shown inFIG. 26C, after the initial folding step, the two bread compartments412and414can be folded along the hinge438in the direction of arrow H such that the two bread compartments412and414are now located above one another with the sandwich compartments422and424therebetween, and further forming an outer container portion. Upon folding, the film extensions417,418, and419can all line up with one another on the same side of the folded food package400and can be secured together such as by heat-sealing to form a common pull tab440, or protruding end portion, which provides for generally simultaneous opening of all of the film layers. Optionally, a handhold or grasping point can be added at the end of the tab440extending from the package400. Additionally, the remaining free end of the pull tab440can also be folded back towards the underside of the package400(i.e., a bottom surface of the bottom bread compartment414) for attachment to the underside of the package400during storage. As shown inFIG. 27A, once the package400is assembled the four food compartments are stacked on top of each other. The two bread compartments412and414are positioned on the outside with the two sandwich compartments422and424therebetween. Alternatively, there can be more or less sandwich compartments in the package400.

Between adjacent food layers there can be at least one film layer separating the adjacent layers, and as further detailed inFIG. 27B, there are at least four film layers. For instance, a first bread component20athat is positioned in the first bread compartment412can be adjacent a first sandwich compartment422including the first sandwich component22awhen folded into the assembled configuration. Separating the bread component20afrom the first sandwich component22aare two film layers460aand416a, and two extension/pull tab layers418aand417a. The bread film layer460ais closest to the bread component20a, and the sandwich compartment film layer416ais closest to the first sandwich component22a, separated by pull tab extensions417aand418located therebetween. Similarly, the second sandwich component22blocated in the second sandwich compartment424is adjacent the second bread compartment414with four film layers therebetween. The sandwich compartment film layer416bis closest to the sandwich compartment424and the bread film layer460bis closest to the bread compartment414, with these two film layers being separated by two pull tab extension layers417band418b, one for each layer.

Between the two sandwich compartments422and424the second opening film layers434and436are also separated by their associated pull tab film layers419aand419b, such that the first sandwich compartment film layer434is adjacent the second opening432of the first sandwich compartment422and the second sandwich compartment film layer436is adjacent the second opening430of the second sandwich compartment424. Furthermore, the pull tab film extension can be an extension of its associated film layer forming a continuous layer, such that the film layer covering the opening of the compartment is folded back upon itself and extends across its surface to form the pull-tab or, alternatively, the pull-tab may be attached to the film layer as a separate film.

To open the food package400, the common pull tab440can be pulled in the direction of arrow I which begins removal of each film layer. Upon opening, the film layers utilize a rolling peel motion to separate the layers, as described in previous embodiments, thus allowing for release of the film layers from the sandwich components in a peeling motion rather than a sliding motion.

Although the above embodiment was described in terms of bread components and sandwich components, it may be used with any type of food product that contains component parts that need to be segregated inside of packaging. For instance, a first food component and a second food component can be provided, which may comprise bread components or any other food, with at least one intermediate food component therebetween, where the intermediate food component can comprise a sandwich component or any other food. At least three compartments can be provided where there is one intermediate food component.

The material of construction of the outer container15,115,215or315can be any rigid plastic material typically used to package food items and can be a multilayer system to provide a moisture and gas resistant polymer film, such as polyester (PET), EVOH, EVA, high-density polyethylene (HDPE), polyvinyl chloride (PVC), polypropylene, polystyrene, high impact polystyrene, or any combination thereof, but can also be a flexible film material as well which can be opened using a rolling peel action but can also be opened using other techniques. Preferably, PET can be used. The material of construction of the flexible envelopes16can be any flexible plastic or paper material typically used to package food items and can be a single layer or multilayer system to provide a moisture and gas resistant polymer film, such as nylon, EVOH, polyethylene (PE), OPET, EVA, polypropylene, polyvinylidene chloride (PVDC), an ionomer layer, or any combination thereof. Preferably, a multilayer system comprising OPET/PE/EVOH/EVA can be used. Where an outer sleeve24is used to wrap around the outer surface of the rigid container it may comprise paperboard, plastic or other similar package components.

The rupturable seals28of the envelope16can be formed in a variety of manners, such as by applying a food-grade adhesive between or to the layers and/or by heat sealing the layers together. The dimensions of the envelope may range from about 1 inch by about 2 inches to about 8 inches by about 20 inches, and preferably are about 3 inches by about 5.5 inches. The shape of the envelopes16may be any shape that compliments the food and/or the sandwich20such as circular, oval, rectangular, square, and the like. For instance, where the bread component is a round bun, it may be preferable to have a circular envelope. Similarly, where the bread component is a rectangular “sub-style” sandwich it may be preferable to have rectangular-shaped envelopes16. The protruding end portion18,18′,118,218,318, or181can have any thickness that is amenable to withstanding a pulling force necessary to peel the seals28of the envelope16apart. The length of the protruding end portion similarly needs to be long enough to adequately provide the necessary pulling force to peel the envelopes16apart and long enough to pull the ruptured envelopes16out of the sandwich20and out of the container. Typically, the protruding end portion will be at least as long as the length (or diameter, where circular) of the side of the rigid container that contains the opening for the protruding end portion and ruptured layers to pass through.

The dimensions of the outer container can vary due to the many different sized and shaped sandwiches that are possible. Preferably, a rigid outer container will compliment the shape of the bread component. Therefore, dimensions can range from about 2 inches by about 5 inches to about 9 inches by about 21 inches, and preferably may be about 4.5 inches by about 7.5 inches. The bread component of the sandwich may comprise a bread, a roll, a wrap, or any other farinaceous product typically used to make a sandwich. The inner sandwich component, or garnish, may comprise cheese, meat, bacon, lettuce, tomatoes, peppers, pickles, other vegetables, or any other substantially solid food component used as a garnish or topping for a sandwich.

A method is disclosed herein for opening a pre-assembled sandwich, as shown inFIGS. 1-6.FIGS. 1 and 4depict the sandwich20in its packaged state, prior to opening and consuming the sandwich20. The rigid container15can be contained within a sleeve24, as shown inFIGS. 1 and 4, or it may not be contained within a sleeve. The rigid container15can be closed such that the top compartment12is placed in contact with the bottom compartment14, creating an enclosure about the sandwich20. The top compartment12and the bottom compartment14can contact each other at outer peripheral flange portions121and141, respectively. Inside of the closed rigid container15is the sandwich20having the sandwich components22, e.g., garnish or toppings, enveloped inside its respective envelope16. Protruding through an opening or slot between the top compartment12and the bottom compartment14is a portion of the protruding end portion18.

InFIGS. 2 and 5, an end segment38of the protruding end portion18can be grasped and pulled in the direction of arrow A. As the protruding end portion18is being pulled in direction A, the flexible envelope16can begin to separate into two separate layers16aand16bby peeling along its rupturable seals28. As the seals28peel apart, the sandwich component22becomes exposed to the inner surfaces of the sandwich20. Once all of the layers of the flexible envelope16have been removed from the sandwich20and the container15, as inFIGS. 3 and 6, the sandwich components22are exposed to the adjacent component or components, whether it be an adjacent sandwich22or bread component20aand/or20b, or both. As the envelopes16are pulled away and separated, they pull away from their respective sandwich components22and the sandwich components22are relatively automatically assembled into a sandwich20due to the force of gravity acting upon the sandwich components22.

As the sandwich components22are being removed from their respective envelopes16, the rigid container15can be removed relatively simultaneously from the sleeve24by grasping a grip tab26, if one is present, and pulling in the direction of arrow B. The grip tab26can be grasped and pulled at relatively the same time as the protruding end portion18is grasped and pulled, to provide for substantially a “one-step” opening method. Optionally, the grip tab26may also include a finger hole (not shown), for additional support upon pulling. The container15can then be opened and the sandwich eaten. The opened layers16aand16bof the envelope16can remain in the inside of the sleeve24, where they are relatively unseen by the consumer, and do not require any further action by the consumer to collect and/or discard the layers16aand16bof the envelope16.

In the additional embodiments that do not contain a pull tab or visible end segment of the protruding end portion218, such as inFIGS. 20 and 21, the knob or spool230can be rotated to activate the protruding end portion218in order to peel the seals28of the envelope16apart. The knob230can contain the protruding end portion218wrapped around the spool of the knob230such that as the knob230is rotated in an axial direction, the protruding end portion218is further wrapped around the knob230, thus applying a pulling force to the envelope16within the sandwich. The envelope16can be peelable in a similar manner as above, however, the ruptured layers will also wrap about the spool or knob230as the protruding end portion218does once pulled from the sandwich and container215.

From the foregoing, it will be appreciated a food package for segregating ingredients of a multi-component food product is provided such that numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the package set forth in the claims. Therefore, the disclosure is not limited to the aspects and embodiments described hereinabove, or to any particular embodiments. Various modifications to the segregating food package can result in substantially the same container and various other modifications to the method of opening the package could be made.