Abstract:
A microwavable food packaging system includes a tray formed from a base and a sidewall extending from the base which sidewall terminates in a free edge. The base and sidewall define an interior cavity. The free edge defines a tray opening. The base has a raised button extending into the cavity. A sleeve surrounds the tray. The sleeve includes a front panel having a display surface and is disposed adjacent to the tray opening and a rear panel disposed adjacent to the base. The sleeve adjacent to the base extends outwardly to form a leg upon which the sleeve and tray can be upstandingly placed. The tray is adapted to receive food pouches within the cavity. The raised button stabilizes the center of gravity of the food packaging system when the food packaging system is placed in an upstanding position on the leg. Advantageously, at least one food pouch disposed in the cavity. The tray opening may be covered with the polymeric film that is sufficiently self-supporting to serve as a splatter guard by being placed over the tray opening when the tray is placed into a microwave for heating of food in the tray cavity.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-inn-part of application Ser. No. 09/368,893 filed Aug. 5, 1999, the disclosure of which is expressly incorporated herein by reference. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     The present invention relates to shelf-stable food packaging and more particularly to such packaging that is especially adapted for housing microwavable packaged meal kits. 
     Since the development of the microwave oven, there has been a continuing consumer desire for microwave-ready packaged meal kits. However, consumers desire meal kits that are convenient to use, are cooked evenly by the microwave, and taste like homemade food. Consumers additionally desire the meal kits to be efficient and economic in use. If such packaged meal kits are shelf-stable (i.e., can be stored under ambient temperature conditions and do not require refrigeration and/or freezing for storage), then both consumers and retailers are pleased. 
     Retailers prefer packaging that can be placed on existing shelves and do not require special handling from bulk shipping on pallets to final stocking of the items on the store shelf. Too, the packaging must remain intact during handling at the store and at home by the consumer. Storage of the packaging by the consumer is yet another criteria to which the packing designer must respond. The manufacturer desires packaging that attracts consumer attention by readily presenting product information in a relatively large, colorful display area. When the manufacturer is successful in its product packaging design, so too will be the retailers because consumers will purchase the item. Sometimes the packaging designer will be forced to compromise between cost effective packaging and packaging that presents the product in a favorable light, such as by presenting a relatively large label area with interest-provoking impact and insight into the meal contents to stimulate appeal. When the packaging designer has succeeded in his endeavor, the sales will please both the manufacturer and the retailer. 
     In this regard, prior designs include U.S. Pat. No. 5,900,263 which proposes a food package that includes an open-top tray surmounted by a paperboard sleeve wherein a rigid leg extends from the back of the sleeve so that the package stands upright on a store shelf. U.S. Pat. No. 5,743,402 proposes a similarly designed package wherein the sleeve and/or a clear plastic film is adhesively secured to a flange that the tray opening bears. 
     In the field of pasta meals, it would be advantageous to produce a prepackaged pasta meal having the above-described packaging advantages, while offering a convenient pasta meal that has desirable organoleptic properties. In the past, shelf-stable pasta for consumer use has been limited to packaging in glass jars which contain both the sauce and condiments, if any, mixed therewith. This method of storage fails to maintain the organoleptic properties of the pasta over time. The use of glass jars requires extra handling precaution by the retailer as well as the consumer. Typical pasta in a jar also is not meant to be heated by the consumer in a microwave. 
     Accordingly, there are several concomitant challenges to be overcome and benefits to be gained in designing and manufacturing meal kit packaging that is acceptable to both consumers and retailers alike. Such advantages, however, are not limited to the housing of pasta by the meal kits, but extend to a variety of other foods as well. 
     BRIEF SUMMARY OF THE INVENTION 
     A microwavable food packaging system includes a tray formed from a base and a sidewall extending from the base which sidewall terminates in a free edge. The base and sidewall define an interior cavity. The free edge defines a tray opening. The base has a raised button extending into the cavity. A sleeve surrounds the tray. The sleeve includes a front panel having a display surface and is disposed adjacent to the tray opening and a rear panel disposed adjacent to the base. The sleeve adjacent to the base extends outwardly to form a leg upon which the sleeve and tray can be upstandingly placed. The tray is adapted to receive food pouch(es) within the cavity. The raised button stabilizes the center of gravity of the food packaging system when the food packaging system is placed in an upstanding position on the leg. Advantageously, at least one food pouch is disposed in the cavity. Advantageously, the tray opening is covered with a polymeric film that is sufficiently self-supporting to serve as a splatter guard by being placed over the tray opening when the tray is placed into a microwave for heating of food in the tray cavity. 
     A method for making a microwavable food packaging system that is stable when stood in an upright position provides a tray that includes a base and a sidewall extending from the base which sidewall terminates in a free edge. The base and sidewall define an interior cavity. The free edge defines a tray opening and the base has a raised button extending into the cavity. At least one food pouch containing food is placed within the cavity. A sleeve surrounding the tray is provided to include a front panel having a display surface and being located adjacent to the tray opening. The sleeve also includes a rear panel located adjacent to the base. The sleeve adjacent to the base extends outwardly to form a leg upon which the sleeve and tray can be upstandingly placed. The raised button stabilizes the center of gravity of the food packaging system when the food packaging system is placed in an upstanding position on the leg. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a fuller understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: 
     FIG. 1 is a perspective view of the microwavable food packaging system; 
     FIG. 2 is a side elevational view of the food packaging system of FIG. 1; 
     FIG. 3 is a top view of the of the food packaging system of FIG. 1; 
     FIG. 4 is a side view of the food packaging system of FIG. 1; 
     FIG. 5 is a top view of the sleeve of the food packaging system of FIG. 1 shown in an unfolded condition; 
     FIG. 6 is a top view of just the empty tray of the food packaging system of FIG. 1; 
     FIG. 7 is a cross-sectional elevational view of the empty tray of FIG. 7; 
     FIG. 8 is a perspective view of the food packaging system of FIG. 1 showing the sleeve and tray separately; 
     FIG. 9 is a side elevational view of 6 of the food packaging systems of FIG. 1 shown in a display mode as would be encountered in a grocery store; 
     FIG. 10 is a cross-sectional elevational view of the food packaging system of FIG. 1 shown in an upright or standing mode as is depicted in FIG. 9; 
     FIGS. 11-14 sequentially show the steps recommended for consumer to empty the food contents of the food packaging system into the tray and use the polymeric film cover as a splatter guard when microwave heating of the tray food contents; 
     FIG. 15 is a perspective view of an alternative embodiment of the food packaging system of FIG. 1 which is adapted to stand with its longitudinal axis vertical rather than sideways as is the design in FIG. 1; 
     FIG. 16 is a side elevational view of the food packaging system of FIG. 15; 
     FIG. 17 is a side elevational view of 6 of the food packaging systems of FIG. 15 shown in a display mode as would be encountered in a grocery store; 
     FIG. 18 is a perspective view of yet another embodiment of the food packaging system of FIG. ; 
     FIG. 19 is a side elevational view of the food packaging system of FIG. 18; 
     FIG. 20 is a side elevational view of 6 of the food packaging systems of FIG. 18 shown in a display mode as would be encountered in a grocery store; and 
     FIG. 21 is a perspective view of the food packaging system showing a pair of trays being retained by a single sleeve. 
    
    
     The drawings will be described in detail below. 
     DETAILED DESCRIPTION OF THE INVENTION 
     There are many considerations when designing packaging for a microwavable food packaging system. Initially, the packaging must be able to be manufactured in a cost-effective manner. Next, the packaging needs to confirm to current shipping requirements, e.g., carton size, pallet size, etc. Next, the grocer must be able to stock the item on conventional-sized store shelving. Next, the grocer needs to be able to display the packaging so that the consumer can easily see the product and read the label to determine whether or not to purchase the product. Next, the consumer needs to be able to store the item at home in a conventional pantry. Next, the consumer needs to be able to readily gain access to the good item through the packaging. Next, the packaging needs to be compatible with the method of cooking the food, i.e., microwaving the food. Next, the packaging needs to be able to accommodate storing any leftovers in the refrigerator. Finally, the packaging needs to be easily and safety disposed of when the meal has been completely consumed. 
     It, thus, will be observed that the packaging designer is faced with numerous competing demands in designing packaging suitable for microwavable food packaging. The present packaging system responds to such diverse demands in a unique fashion. Referring initially to FIGS. 1-3, one embodiment of the microwavable food packaging system, generally identified as item  10 , is illustrated in perspective view. Food packaging system  10  is seen to be composed of tray  12  and sleeve  14 . For store display purposes, sleeve  14  is folded and sealed together in such a way that leg  16  is created. Leg  16  acting in cooperation with edge  18  forms a base upon which food packaging system  10  can rest in an upright or standing position. As depicted, food packaging system  10  would stand with its longitudinal axis in a horizontal position. 
     Additionally, sleeve  14  has a pair of apertures,  20  and  22  (see FIG.  5 ), which retain ears or dogs  24  and  26 , respectively, for locking sleeve  14  to tray  12 . Apertures  28  and  30  (see FIG. 5) permit the consumer to view the tray&#39;s contents prior to purchase. Polymeric film  32  can be seen beneath apertures  28 / 30  to cover the opening of tray  12  and retain any food items within the cavity of tray  12 . Polymeric film  32  desirably is transparent for enhancing the viewing of the food items by the consumer through apertures  28 / 30 . 
     Referring to FIGS. 4 and 5, it will be observed that sleeve  14  has a pair of free edges that mate to form leg  16 . The formation of leg  16  in this fashion is relatively simple to implement on a commercial scale. That is, edge  34  of sleeve  14  adjacent the bottom of tray  12  protrudes outwardly from the footprint of tray  12  while free edge  36  of sleeve  14  merely is bent outwardly at an angle of around 60° to mate with free edge  34 . Adhesive, e.g., a hot melt adhesive, secures edges  34  and  36  together to form leg  16 . Also, it will be appreciated that the length of sleeve  14  between edges  34  and  36  will be such that sleeve  14  is drawn tightly around tray  12  to assist in it being retained in position during storage and handling of food packaging system  10  in addition to ears  24  and  26  that lock through apertures  20  and  22 , respectively. 
     Top surface  38  and bottom surface  40  of sleeve  14  desirably can be imprinted with a variety of consumer information ranging from word/logotype trademark(s) of the product to a description of the food items to cooking instructions to a list of food ingredients to nutritional information, etc. For that matter, so too can sides  42  and  44  be similarly imprinted. Also seen in FIG. 5 are fold lines  46 ,  48 ,  50 , and  52  that are used to conform sleeve  14  to tray  12 . Of course, printed indicia usually is imprinted on sleeve  14  prior to its being joined to sleeve  12 . Sleeve  14 , then, desirably is manufactured from paperboard stock, although it could be manufactured from polymeric stock. 
     Referring to FIGS. 6 and 7, tray  12  will be seen to have cavity  54  formed by its four sideways and its bottom. Opening or mouth  56  permits foodstuffs to be placed with cavity  54  and removed therefrom. Lip or flange  58  is seen to traverse entirely around and form mouth  56 . Its shape is dictated by strength and handling considerations as those skilled in this art will appreciate. Unique to tray  12  are handles  60  and  62  (see FIG. 8 also) on either longitudinal side of tray  12  for the consumer to easily pick up tray  12 , especially when the food in cavity  54  is hot following the microwave heating operation. Handles  60 / 62  are seen in FIG. 6 to extend into cavity  54 . Also unique to tray  12  is its bottom that has centrally-disposed button  64  that similarly penetrates into cavity  64 . As will be illustrated and described later, handles  60 / 62  and button  64  penetrate into cavity  64  to locate foodstuffs in cavity  64  in a position that alters the center of gravity of food packing system  10  so that it is stable when stood up, e.g., for store display purposes. Internal handles  60 / 62  also reduce the overall width of tray  12 , reduce the amount of material required for manufacturing tray  12 , and provide a more stable product. 
     Tray  12  desirably is manufactured from polymeric stock, such as, for example, polypropylene, preferably pigmented (at least the outside) for consumer aesthetics. The polymeric stock used to manufacture tray  12  preferably also is transparent to microwave radiation. Cavity  54  can be designed to accommodate about a 16 oz. product. Tray  12  desirably measures about 9.6″ in length (10″ maximum) to accommodate store shelves and pallets that typically are 48″ in length (i.e., 5 trays). The depth of tray  12  desirably is no more than 2″ and its width is about 7″. Button  64  also desirably penetrates into cavity  54  to about 0.375″. Again, these measurements may be varied to accommodate different products and or shipping/display criteria. 
     Two different methods for joining sleeve  14  to tray  12  can be envisioned. That is, sleeve  14  can be pre-folded and ends  34 / 36  adhesively joined to form a loop through which tray  12  is inserted into position under ears  24 / 26  lock into position with apertures  20 / 22 . Alternatively, sleeve  14  can be placed around tray  12  and edges  34 / 36  glued in place. This alternative scheme is illustrated in FIG.  8 . It will be observed that pouches  66  and  68  (e.g., aseptically packaged pasta pouch and a sauce pouch, such as shown in U.S. Pat. Nos. 5,057,330, 5,562,938, 5,433,964, and 5,759,607) are placed in cavity  54  of tray  12 . Then, polymeric film  32  is placed over the opening of the cavity and, for example, adhesively joined to the upper side of lip  58 . Sleeve  14  next is placed over tray  12  with ears  24  and  26  placed in apertures  20  and  22 , respectively. Adhesive, e.g., a hot melt adhesive, has been applied to one or both of ends  34  and  36 . Ends  34  and  36  are placed into registration and pressed to ensure their joining. This multi-step process can be simplified, however, if sleeve  14  has its ends  34 / 36  joined together first and then sleeve  14  slipped over tray  12 . Regardless of the technique used to join sleeve  14  to tray  12 , the same food packaging system  10  results. 
     Referring to FIGS. 9 and 10, food packaging systems  70 ,  72 ,  74 ,  76 ,  78 , and  80  are illustrated standing in an upright position on shelf  82 . Such presentation of food packaging systems  70 - 80  will be made at a grocery store, for example, where consumers will browse and select such food items. It will be observed that top surface  40  of one food packaging system abuts against bottom surface  42  of an adjacent food packaging system. Each food packaging system is seen in an upstanding position, e.g., about 85°. 
     With more specific reference to FIG. 10, handles  60 / 62  urge the tray contents towards the center of cavity  54  while button  64  moves the center of gravity opposite the direction of lean of the food packaging system. This center of gravity, arrow  84 , shift makes the food packaging system more stable when placed in the illustrated upright position. 
     Referring to FIGS. 11-14, depicted is the method whereby the foodstuffs housed within food packaging system  10  are removed and prepared for microwave heating. will be observed that sleeve  14  has been removed from tray  12  in these drawings. Thereafter, the consumer peels polymeric film from tray  12  to expose pouches  66  and  68 . If pouch  66  holds aseptically packaged pasta and pouch  68  holds a tomato-based sauce, then the consumer can open pouch  66  and pour pasta  86  into the cavity of tray  12 . Next, the consumer can open pouch  68  and pour tomato sauce  88  around the outside of pasta  86 . Next, the consumer places polymeric film  32  back onto lip  58  to cover opening  56  of tray  12 . In such a position, film  32  serves as a splatter guard when pasta/sauce filled tray  12  is placed in a microwave oven and heated. Simple removal of film  32  following heating permits the consumer to enjoy a pasta meal right from tray  12 . The consumer need not, however, clean up the microwave oven from sauce splatters. Disposal of film  32  is easy also. Of course, the consumer could pour the heated pasta/sauce onto a plate or into a bowl to eat at the expense of extra dishes to clean. 
     It will be appreciated that film  32  needs to manufactured to be more than a simple seal to retain pouches  66 / 68  inside of tray  12 . Rather, film  32  needs to have sufficient rigidity (often, thickness) so that it can be placed on lip  58  to cover opening  56  without moving such as to permit splatters to be released to contact the inside of the microwave oven. Presently, it is preferred that film  32  be manufactured from polyethylene terephthalate (PET), although other materials can be used as is necessary, desirable, or convenient. Pouch sizes of up to about 6″×8″ can easily be accommodated by tray  12  with measurements as given above. 
     FIG. 15 depicts an alternative embodiment where it is desired that food packaging system  90  stand upright with its longitudinal extent vertically oriented, rather than sideways as has been depicted and described above. In this vertical orientation, sleeve  92  has been modified so that one of its ends extends to the end of tray  12 . This end sleeve configuration, then, permits food packaging system  90  to stand with its lengthwise extent vertically, such as is illustrated in FIG.  17 . From FIGS. 15 and 16, it will be observed that sleeve  92  has a pair of apertures through which ears  24 / 26  can lock sleeve  92  with tray  12 . Food packaging systems  94 ,  96 ,  98 ,  100 ,  102 , and  104  stand in the same relationship as do food packaging systems  70 - 80  of FIG.  9 . Button  64  again alters the center of gravity of each food packaging system to ensure stability when arranged as depicted in FIG.  17 . 
     FIGS. 18-20 depict yet another embodiment of the present invention where tray  106  has an elongate flat side and is surmounted by sleeve  108  that has a similar flat side adjacent to said tray flat side. Such flat side permits food packaging system  110  to stand upright, such as is depicted in FIG. 20 for food packaging systems  112 ,  114 ,  116 ,  118 ,  120 , and  122 . Tray  106  has ears  124  and  126  that poke through apertures in sleeve  108  so that tray  106  retains sleeve  108 . Though not evident from the drawings, tray  106  also has a bottom button like button  64  for enhancing the upright stability of food packaging system  110  by altering the center of gravity. Handles also are provided for centering the food pouches therein and for enabling the consumer to carry the tray after foodstuff therein has been heated. Too, polymeric film  130  covers the cavity in tray  106 . 
     FIG. 21 shows an embodiment of the food packaging system like that illustrated in FIG. 1, except that sleeve  132  retains trays  134  and  136 . Trays  134  and  136  are like the trays described above and are stacked one on top of the other. Tabs or ears  138  and  142  are retained in a pair of upper apertures in sleeve  132  while ears  140  and another not seen in FIG. 21 are retained by two lower apertures in sleeve  132 . Its certainly is possible for each tray to utilize only one ear/aperture combination; although, presently a pair of ears is preferred. Also, it also is possible for only one of the trays to use the ears and rely on friction to retain the other tray in the sleeve. Sleeve  132  also has been fitted with foot  144  which with edge  146  of sleeve  132  permits food packaging system  148  shown in FIG. 21 to be stood up as described above. It will appreciated that more than two trays could be retained by a single sleeve and that the tray/sleeve configuration could be like any of the embodiments disclosed herein. 
     It will be appreciated that the foregoing description is illustrative of how the present invention can be practiced, but it should not be construed as limiting the present invention. Finally, all citations referred to herein are expressly incorporated herein by reference.