Raised platform for microwave cooking of a food product

A raised platform for a microwave cooking of a food product that includes a support surface, a pair of generally rectangular legs depending from opposing sides of the support surface, a pair of leg extensions attached to each of the generally rectangular legs, and a susceptor surface disposed on the food product support surface for conducting heat to a food product thereon during microwave cooking. The raised platform can be converted between a collapsed configuration, where the legs are generally parallel to the support surface, and an expanded configuration, where the legs are generally perpendicular to the support surface.

FIELD

This disclosure relates to a raised platform for microwave cooking of a food product, and in particular to a raised platform for microwave cooking of a food product that is convertible between a collapsed configuration and an expanded configuration.

BACKGROUND

Heretofore, considerable effort has been expended to provide food products such as frozen or refrigerated pizzas and sandwiches for preparation by a consumer, utilizing conventional gas or electric heated ovens. More recently, with the increasing popularity of microwave ovens, attention has turned to providing consumers with kits and components for preparing dough-containing products such as frozen or refrigerated pizzas and sandwiches.

As has been detailed in U.S. Pat. No. 5,416,304, microwave ovens exhibit their own unique challenges when preparing frozen food products. For example, microwave ovens exhibit substantial temperature gradients or non-uniform heating. In addition, frozen dough-containing products have been found to exhibit a nonuniform temperature response to microwave radiation throughout their volume, during a typical heating cycle. As a result, portions of the food item melt or thaw before other portions and this results in localized accelerated heating due to the preferential absorption of microwave energy by liquids being irradiated. As a result of these and other conditions, further improvements in the preparation and packaging of dough-containing food products are being sought.

SUMMARY

A raised platform for a microwave cooking of a food product is disclosed. The raised platform includes a support surface, a pair of generally rectangular legs depending from opposing sides of the support surface, a pair of leg extensions attached to each of the generally rectangular legs, and a susceptor surface disposed on the food product support surface for conducting heat to a food product thereon during microwave cooking.

In one aspect, the food product support surface is generally planar and may have an octagonal profile for supporting a food product during microwave cooking thereof. The generally planar support surface has a length and a width, with the length being greater than the width. The food product support surface has a pair of substantially parallel opposing side edges that extend along a portion of the length of the support surface. The pair of generally rectangular legs each depend from one of the parallel opposing sides of the food product support surface for supporting the support surface in a raised position. The leg extensions are attached at opposing ends of the generally rectangular legs for providing additional support for the support surface. The susceptor surface may be disposed on the majority of the support surface.

In accordance with other aspects, the support surface and the susceptor surface may have a plurality of aligned vent holes formed therein for venting moisture and/or heat from a food product during microwave cooking. Each of the legs may have a plurality of vent holes formed therein for venting moisture and/or heat from a food product during microwave cooking. In another aspect, the support surface, the leg extensions, and the braces may be formed from a unitary paperboard material. The leg extensions may generally be right isosceles triangles. Each of the leg extensions may be connected along their hypotenuse to an extension leg brace. Each of the extension leg braces may extend between the extension legs and a side edge of the platform adjacent an end of the parallel opposing sides of the support surface. The extension braces may be generally isosceles right triangles. Each of the legs may be connected to one of the parallel opposing sides of the support surface via a fold. The legs may be pivotable about the fold between a first position generally perpendicular to the support surface and a second position generally parallel to the support surface. Each of the leg extensions may be connected to one of the opposing ends of the legs via a fold. And each of the braces may be connected to one of the leg extensions via a fold. Each of the leg extensions and a portion of the connected brace are generally positioned parallel to and between the leg and the support surface when the legs are in their first position. The raised platform for microwave cooking in a food product may include, in combination, a food product. The food product may have a dough based portion with a footprint about the same size as the support surface.

In another aspect, a raised platform is provided for microwave cooking of a food product, where the raised platform is convertible between a collapsed configuration and an expanded configuration. The raised platform includes a generally planar support surface for supporting a food product during microwave cooking thereof, a pair of generally rectangular legs depending from side edges of the support surface for supporting the support surface in a raised position, and a pair of leg extensions associated with each of the legs at opposing ends thereof for providing additional support for the support surface. In a collapsed configuration of the raised platform, the generally rectangular legs and the leg extensions are parallel to the support surface. In the expanded configuration of the raised platform, each of the legs are generally perpendicular to the support surface and each of the leg extensions is positioned in an acute angle relative to the attached leg.

According to an aspect of the raised platform, the support surface and the susceptor surface have a plurality of aligned vent holes formed therein for venting moisture and/or heat from a food product during microwave cooking. In addition, or alternatively, the legs may each have a plurality of vent holes formed therein for venting moisture and/or heat from a food product during microwave cooking. In one aspect, the support surface is octagonal. The support surface may have a length greater than its width and legs mounted to side edges of the support surface along the entire length thereof. The side edges to which the legs are mounted are longer than other edges of the support surface.

In one aspect, the extension legs are generally right isosceles triangles. Each of the extension legs may be connected along its hypotenuse to an extension leg brace. Each of the extension leg braces may extend between the connected extension leg in a side edge of the support platform adjacent and end of the parallel opposing sides of the support surface. The extension braces may generally be isosceles right triangles.

In an alternative embodiment, the extension legs may comprise supplemental legs that are attached, such as via a fold, to the product support surface. The extension legs may also be generally rectangular, and may have end tabs that are attached, such as with adhesive, to the legs. A fold line, such as a diagonal fold line, may be formed in the legs at each end adjacent the leg extensions to facilitate folding of the legs and leg extensions between the collapsed configuration and the expanded configuration. Alternatively, the legs may have tabs that are attached, such as with adhesive, to the leg extensions and a fold line may be formed in the leg extensions.

Each of the legs may be connected to one of the parallel opposing sides of the support surface via a fold. The legs may be pivotable about the fold between a first position generally perpendicular to the support surface and a second position generally parallel to the support surface. Each of the leg extensions may be connected to one of the opposing ends of the legs via a fold and each of the braces may be connected to one of the leg extensions via a fold as well. Each of the leg extensions and a portion of the connected brace are positioned generally parallel to and between the leg and the support surface when the legs are in their collapsed configuration.

DETAILED DESCRIPTION OF THE DRAWINGS

Various embodiments of raised platforms for microwave cooking in accordance with the above-discussed aspects are illustrated inFIGS. 1-13herein. The raised platforms are convertible between a collapsed configuration and an expanded configuration. In the expanded configuration, legs are extended to elevate the susceptor of the base tray, and thus the food product, above the floor of a microwave during the cooking cycle to promote more even microwave cooking, particularly of the bottom of the food product, as will be explained in greater detail herein.

In use, the product support surface20or120of the raised platform10or110supports a food product12at least partially on a susceptor surface26or126at a position elevated above the bottom floor of a microwave oven. The susceptor surface26or126provides for conductive heating of the portions of the food product in contact herewith. Legs30or130are provided to support the product support surface20or120in the elevated position.

In microwave cooking, polar molecules such as water contained in the food product absorb microwave energy and release heat. Microwave energy typically penetrates further into the food than does heat generated in a conventional oven, such as radiant heat, with the result that water molecules dispersed throughout the food product are selectively heated more rapidly. Ideally, food products such as those in dough-based portions of pizza, sandwiches, pockets and other such food products should properly dissipate the heated moisture in order to avoid the dough-based portion becoming soggy.

The food product being prepared is preferably supported at an elevated position above the bottom surface of a microwave oven to allow a desirable portion of the moisture exiting the food product, such as if vents holes28or128are present in the food product support surface20or120, to become trapped in a determined volume so as to contribute controlled amounts of heat and moisture to the dough-based portion of the food product12and to achieve a desirable brownness or crispness of an adjacent dough-based portion14without becoming dried out, chewy or hard. Thus, it can be preferable to achieve a proper ratio of moisture exiting the food product being prepared between a trapped portion used for heating of the food product and a released portion which is allowed to escape the food product to prevent its becoming soggy or chewy or otherwise undesirably moist.

In addition, supporting the food product12at an elevated position above the bottom surface of a microwave oven allows for cooking energy, such as microwaves, to be deflected on the bottom surface of the microwave oven and redirected to underneath the food product in order to reach the bottom portion of the food product.

Other problems associated with the use of microwave energy for the preparation of food products such as frozen or refrigerated sandwich, pockets and the like are also addressed. In general, certain instances of non-uniform heating can be associated with the preparation of food using microwave energy, such as electromagnetic radiation at a frequency of about 0.3 to 300 GHz. It can be important in order to achieve a cooked food product of pleasing appearance and texture that the dough-based portion of the food product be uniformly heated throughout the cooking. As is now generally accepted, power distribution in a microwave oven cavity can be non-uniform, giving rise to “hot spots” and “cold spots” about the environment of the food product being prepared.

Another problem in many practical applications arises from the fact that a food product such as a frozen sandwich typically does not exhibit desirably uniform temperature response to microwave radiation throughout its volume, during a typical heating cycle. For example, a frozen sandwich when initially subjected to microwave radiation, undergoes local melting or thawing in certain portions of the sandwich, with remaining portions of the sandwich remaining frozen. This problem is accelerated in that thawed portions of a dough-based food product, such as a sandwich, pocket or the like, will preferentially absorb greater amounts of microwave energy than the surrounding frozen portions. A further understanding of difficulties encountered in preparing dough-containing food products such as frozen pizza may be found in U.S. Pat. No. 5,416,304, the disclosure of which is herein incorporated by reference as fully set forth herein. It is important therefore that initial thawing of the food product be made as uniform as possible throughout the food product and that the energy absorption throughout the remainder of the cooking cycle remain uniform. A number of different features of the cooking apparatus disclosed herein provide improved control of microwave cooking of dough-containing food products, throughout the cooking cycle.

In use, the legs30or130elevate the food support surface20or120, and thus the food product12, above the bottom floor of a microwave oven. The food product support surface20or120cooperates with the legs30or130to form a partially enclosed cavity beneath the food product12that is disposed on top of the susceptor surface26or126of the raised platform10or110. Preferably, the legs30or130raise the food product support surface20or120an elevation sufficient to allow for microwaves to reflect off of the sidewalls and bottom wall of a microwave and be redirected to the underside of the food product support surface20or120, i.e., the side opposite the susceptor surface26or126, to provide for heating of the bottom of the food product12. For example, the legs30or130may elevate the food product support surface20or120between about 0.25 and 1.75, and preferably about 1 inch, above the bottom wall of a microwave oven.

A series of aligned apertures28or128may be formed in the food product support surface20or120and susceptor26or126to allow steam vapor exiting the food product12during the cooking cycle to enter the cavity below the food product support surface20or120and between the legs30or130. Excess amounts of steam, or water vapor beyond that desired, can exit the cavity through vents38or138in the legs30or130and other openings. A defined amount of steam can be trapped beneath the food product support surface20or120to provide an amount of additional heating to the food product12as well as maintaining moisture control of the food product environment during the cooking cycle.

In the first embodiment illustrated inFIGS. 1-8, the raised platform10includes a food product support surface20having a susceptor26thereon. The food product support surface20has a pair of parallel, opposing side edges22. A leg30depends from each of these parallel, opposing side edges22in order to elevate the food product support surface20, such as above the bottom of a microwave oven. A pair of leg extensions40, each with a connected brace50relative to an edge24of the product support surface20, are provided on each of the legs30for providing additional stability to the product support platform10in its expanded configuration. The leg extensions40provide the additional stability by assisting in supporting the raised platform20and by, in cooperation with the associated braces50, assisting in maintaining the legs30in a generally perpendicular arrangement with the product support surface20when the raised platform10is in its extended configuration.

Turning now to more of the details of the legs30, leg extensions40and braces50, each of the pair of legs30is rectangular, having a top edge32, an opposite bottom edge34, and a pair of side edges36. The top edge32of each of the legs30is connected to an edge22of the food product support surface20. The side edges36of each of the legs30each have a leg extension40connected thereto. The leg extensions40are generally shaped as right isosceles triangles, connected at one side42to the side end edge of the associated leg. A free side is positioned to be generally in the same plane as the bottom edge of the associated leg to provide additional support for the food product support surface when the raised platform is in its expanded configuration. The hypotenuse side of the leg extension is connected to a brace. The brace extends from the leg extension to an edge of the product support surface, and assists in maintaining the leg extension in its preferred orientation when the raised platform is in its expanded configuration. The braces are generally shaped as right isosceles triangles, with one of the two shorter sides connected to the associated leg extension and the other of the two shorter sides connected to a side edge of the product support platform.

When the raised platform10is in its fully collapsed configuration, as illustrated inFIG. 3c, the legs30, leg extensions40, braces50and food product support surface20are all generally parallel. More specifically, in the fully collapsed configuration the braces50are adjacent the underside of the food product support surface, the leg extensions40are adjacent the braces50, and the legs30are adjacent the leg extensions40. This configuration results in the raised platform10having a minimal thickness, which advantageously can allow the raised platform10to have a slim profile and thereby reduce the size of a packaged raised platform and food product as compared to the raised platform10as compared to the raised platform in its expanded configuration for heating. When the raised platform10of the first embodiment is in its fully expanded configuration, as illustrated inFIGS. 1,3a,4,5,8and8a, the legs30and leg extensions40are orientated generally perpendicular to the product support surface20in order to elevate the product support surface20a predetermined distance.

In the second embodiment illustrated inFIGS. 9-13, the raised platform110includes a generally rectangular food product support surface120having a susceptor126thereon. The food product support surface120has a pair of parallel, opposing side edges122. A primary leg130depends from each of these parallel, opposing side edges122in order to elevate the food product support surface120, such as above the bottom of a microwave oven. Supplemental legs150depend from opposing side edges124of the product support surface120which lack the primary legs130. Each of the pair of legs130has a top edge132, an opposite bottom edge134, and a pair of side edges136. The top edge132of each of the primary legs130is connected to an edge122of the food product support surface120via a fold. Each of the supplemental legs150has a top edge154connected to an edge124of the food product support surface via a fold, an opposite bottom edge162, and a pair of end edges158.

The side edges158of each of the supplemental legs150each have a connecting tab152attached thereto. When fully assembled, the connecting tabs152are adhesively secured to inner surfaces of the adjacent primary legs130to effectively connect the primary and supplemental legs130and150. The connection between the primary and supplemental legs130and150provides additional stability to the product support platform110in its expanded configuration and assists in maintaining the primary and supplemental legs130and150in a generally perpendicular arrangement with the product support surface120when the raised platform110is in its expanded configuration.

When the raised platform110is fully assembled, with the connecting tabs152securing the primary and supplemental legs relative130and150to each other, the raised platform110preferably is predisposed to have the legs130and150in or close to their expanded configuration, where the legs130and150are generally perpendicular to the food product support surface120, as illustrated inFIGS. 9,10a,12aand12b. To assist in shifting the raised platform110from its expanded configuration to its collapsed configuration, the primary legs130have a diagonal fold line160positioned adjacent each of the end edges136. The fold lines160extend from proximate an upper corner of each of the primary legs130, adjacent the upper edges132of the legs130, toward the bottom edges134of the legs130and inwardly from the end edges136. The fold lines160permit the primary and supplemental legs130and150to be shifted from their generally perpendicular orientations relative to the product support surface120to their collapsed orientations where they are generally parallel to the product support surface120, as illustrated inFIGS. 10band l0c. When the raised platform110is in its fully collapsed configuration, as illustrated inFIG. 10c, end regions of the primary legs130are disposed between the supplemental legs150and the inner side of the product support surface120.

The end edges136of the primary legs130do not have to be straight and perpendicular relative to the top and bottom edges132and134of the primary legs130, as illustrated by way of example inFIG. 11. Instead, the end edges136of the primary legs130may include an inclined edge portion164aligned with the portion of the fold line160adjacent the upper edge132and a protruding edge portion166adjacent the bottom edge134. The inclined edge portion164can assist in maintaining the leg extension in its preferred orientation when the raised platform is in its expanded configuration, and can reduce the length of the fold line160and allow for greater flexibility in the preciseness of the placement of the fold line160.

This configuration results in the raised platform110having a minimal thickness, which advantageously can allow the raised platform110to have a slim profile and thereby reduce the size of a packaged raised platform and food product as compared to the raised platform110in its expanded configuration for heating. When the raised platform110of the second embodiment is in its fully expanded configuration, as illustrated inFIGS. 9,12aand12b, the primary legs130and the supplemental legs150are orientated generally perpendicular to the product support surface120in order to elevate the product support surface120a predetermined distance, such as above the floor of a microwave oven.

The raised platform10or110may be packaged in combination with a food product12, and may be packaged in combination with a dough-based food product12that has a dough-based exterior portion14. When provided in combination with a food product12, the raised platform10or110may initially be in its collapsed configuration and the food product12can be disposed on the product support surface20or120. Preferably at least part of the dough-based exterior portion14of the food product12is adjacent the susceptor surface26or126. An outer film60, such as a shrinkable film, surrounds both the food product12and the raised platform10or110in its collapsed configuration to both provide a protective barrier for the food product12and to maintain the raised platform10or110in its collapsed configuration, as illustrated inFIGS. 7a,7b,12aand12b.

When it is desired to heat the food product12, the outer film60can be removed to both expose the food product12and, in the first embodiment of the raised platform10, to release the legs30, leg extensions40and braces50from their collapsed configuration and allow them to be shifted to their expanded configuration, as illustrated inFIGS. 8aand8b. In the second embodiment of the raised platform110, removal of the outer film60both exposes the food product12and releases the primary legs130and supplemental legs150from their collapsed configuration and allows them to be shifted to their expanded configuration, as illustrated inFIGS. 12aand12b. Depending upon the material used for the raised platform10or110, the shifting from the collapsed configuration to the expanded configuration may occur automatically, or may require some manual manipulation of the legs30or130and150by a user. To this end, finger recesses, such as arcuate cut-outs, may be provided in the legs30or130or150for a user to grasp the legs30or130or150and shift them to their expanded configuration. The finger recesses may also be sized to provide a convenient location for a user to remove the raised platform10or110with the food product12thereon after heating.

The raised platforms10and110disclosed herein are particularly suitable for use with food products having an outer dough-based portion. For example, the raised platforms10and110can be used in microwave heating of a food product12that comprises French bread having toppings, such a pizza toppings, and an outer crust14on the bottom. Other examples of food products having dough-based portions include sandwiches, calzones, pitas, pizzas, strombollis and other such dough-enrobed or dough-based food products. The dough-based portions of the food products can be in various forms, such as cooked, par-baked, raw, ready-to-heat, ready-to-eat, proofed or unproofed dough which is suitable for being cooked, browned, and/or crisped.

Preferably, though not necessarily, the raised platforms10and110are formed from a single unitary blank16or116of material, such as paperboard. Forming the raised platforms10or110from a single unitary blank116can eliminate the need for separately attaching any of the legs30or130, leg extensions40or140and braces50, if present, to each other or to the product support surface20or120. With specific respect to the first embodiment of the raised platform10, another advantage of forming the raised platform10from a unitary blank16is that adhesives are not required to join any of the legs30, leg extensions40and braces50to each other or to the product support surface20, thereby eliminating steps in the manufacturing process and providing for simplified construction of the raised platform10.

With respect to the first embodiment, the unitary blank16may be provided with a plurality of fold lines, such as weakened or scored lines, as illustrated inFIG. 6, for assisting in folding of the blank16into the raised platform10. The unitary blank16includes a pair of parallel fold lines between the adjacent edges22and32of the product support surface20and the legs30. The unitary blank16also includes fold lines between the side edges36of the legs30and the adjacent edges42of the leg extensions that perpendicularly intersect the parallel fold lines between the product support surface20and the legs30. Fold lines are also positioned between adjacent edges46and56of the leg extensions40and connected brace50, and between adjacent edges54and24of the braces50and product support surface20.

With respect to the second embodiment, the unitary blank116may be provided with a plurality of fold lines, such as weakened or scored lines, as illustrated inFIG. 11, for assisting in folding of the blank116into the raised platform110. The unitary blank116includes fold lines between the adjacent edges122and132of the product support surface120and the primary legs130. Fold lines are also positioned between adjacent edges124and154of the product support surface120and the supplemental legs150. Fold lines are also positioned between edges158and156of the supplemental legs150and the tab connectors152. Furthermore, the fold lines160at each end of the primary legs130are also positioned on the blank116.

The susceptor26or126can be attached either when the platform10or110has been formed or to the unitary blank16or116prior to its folding into the platform10or116, or at intermediate steps thereof. For example, the susceptor26or126can be attached to the portion of the unitary blank16or116that will become the product support surface20or120prior to folding into the raised platform10or110. However, it is preferable, though not necessary, that the optional vents38or138in the legs30or130and the vents in the product support surface20or120and susceptor26or126are formed prior to folding of the blank16or116into the raised platform10or110and after the susceptor26or126has been attached to the blank16or116. This will permit the simultaneous forming of the aligned vents in the product support surface20or120and the susceptor26or126.

Various types and forms of susceptors26or126can be utilized with the raised platform10or110. For example, the susceptor26or126may be a film having a layer of metal deposited thereon. Alternatively, the susceptor26or126may be printed upon the blank16or116, thereby eliminating the need for separate attachment, such as with adhesives. In addition, the susceptor26or126may have different thickness to assist in concentrating heat energy at select portions of the food product. By graduating the amount of susceptor material or coating, over heating of select portions of the food product can be avoided during cooking. Virtually any pattern of susceptor26or126can be employed. For example, the susceptor26or126can be coated or printed as a series of space-apart diagonal stripes or can comprise an array of dots or other shapes.

The susceptor26or126may be of a type that expands upon heating to better conform to the adjacent portion of a food product, which can be advantageous if the adjacent portion of the food product has surface irregularities or is slightly curved, and thus not entirely planar. To accommodate these irregularities and promote more contact with the adjacent portion of a food product, the susceptor26or126may expand upon heating. One type of expanding susceptor material is made and sold by Graphics Packaging, Inc. under the product name QuiltWave.™. As the susceptor26or126expands, it can at least partially contact some of the non-planar portions of the adjacent portion of a food product.

In accordance with one example of a raised platform10in accordance with the first embodiment, the product support surface20may be about 7 inches long by about 3.5 inches wide, and the legs30may have a height of about 1 inch. A unitary paperboard blank16for forming such a platform10may be about 7 inches by about 5.5 inches. The product support surface20for such a platform10may be generally octagonal, and may have six sides about the same length and two sides that are each longer than any three of the six sides that are about the same length. In accordance with another example of a raised platform, the platform may be about 5 inches long by about 3.5 inches wide, and may have a height of about 1 inch. A unitary paperboard blank for forming such a platform may be about 5 inches by about 5.5 inches.

In order to convert the unitary blank16in this example into the raised platform10, the blank16may be forced into a mold cavity. More specifically, a mold cavity having an opening about the same size as the blank16may be provided with corner portions that are gradually sloped. As a forming tool depresses the blank16into the mold cavity, the corner portions thereof contact the legs30adjacent the fold lines between the legs30and the product support surface20and the braces50adjacent the fold lines between the braces50and the product support surface20to cause the legs30and the braces50to fold about their fold lines relative to the product support surface20, which also causes the leg extensions40to fold about the fold lines between the legs extensions40and the legs30and the braces50. Once removed from the mold cavity, folding bars or other means may be used to fold the legs30, extension legs40and braces50into their fully collapsed configurations.

In one alternative method, folding bars may be used to form the unitary blank16into the raised platform10. For example, a pair of curved folding bars may be positioned parallel to the legs30and in a machine direction. As the blank16is advanced in the machine direction, the folding bars fold the legs30about the fold lines adjacent the product support surface20, thereby causing the leg extensions40and braces50to fold about their respective fold lines.

In accordance with another example of a raised platform110in accordance with the second embodiment, the product support surface120may be about 7 inches long by about 3.5 inches wide, and the legs130may have a height of about 1 inch. A unitary paperboard blank116for forming such a platform110may be about 7 inches by about 5.5 inches. The product support surface120for such a platform110may be generally octagonal, and may have six sides about the same length and two sides that are each longer than any three of the six sides that are about the same length. In accordance with another example of a raised platform, the platform may be about 5 inches long by about 3.5 inches wide, and may have a height of about 1 inch. A unitary paperboard blank for forming such a platform may be about 5 inches by about 5.5 inches.

The drawings and the foregoing descriptions are not intended to represent the only forms of the raised platform in regard to the details of construction and manner of operation. Changes in form and in the proportion of parts, as well as the substitution of equivalents, are contemplated as circumstances may suggest or render expedient; and although specific terms have been employed, they are intended in a generic and descriptive sense only and not for the purposes of limitation.