Abstract:
The present invention relates to a novel package for storing, shipping, preparing and dispensing a meal. In one embodiment the present invention provides for a meal comprising an array of shellfish and vegetables disposed in a tray, which is disposed in a flavor pouch. The package has sufficient structural integrity to withstand shipping and when purchased by the customer, is ready to bake or grill. When prepared by the customer a substantial array of perfectly prepared seafood, steamed in a seasoned butter sauce, is presented. The visual presentation, ease of preparation, uniqueness of combination and high quality ingredients makes a wonderful meal for two or more.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a food packaging. More particularly, the present invention relates to a novel package having sufficient structural integrity for storing, shipping, preparing and dispensing a prepared meal. 
       BACKGROUND OF THE INVENTION 
       [0002]    In the past, prepared meals have commonly been packaged in containers constructed from aluminum foil and/or thin aluminum sheets. One example of such a container is set forth in U.S. Pat. No. 4,785,937, which discloses a package for storing and heating a prepared meal, where the package is constructed from aluminum foil laminated to a polyester film. Another example is illustrated in U.S. Pat. No. 6,896,919, which discloses a pouch constructed from an aluminum/polyester laminate for storing and cooking a meal. Although such packages are simple and suitable for both storing and preparing a meal in a single package, they have several limitations. For example, the materials used in the construction of these packages have poor structural rigidity resulting in a package that is susceptible to ruptures and punctures. Further, the packaging materials&#39; lack of structural integrity limits the total weight of the meal that may be stored, prepared and dispensed. Moreover, the lack of structural integrity renders packaging susceptible to crushing making such packaged meals poorly suited for storage and shipping. 
         [0003]    Attempting to overcome this limitation, and improve the structural integrity of packaged meals and to facilitate the serving of larger portions, several prior art containers have been constructed from multi-layered materials. For example, U.S. Pat. No. 2,951,765 discloses a container formed from a laminate having an inner layer of high wet-strength paper between two layers of aluminum foil. Similarly, U.S. Pat. No. 3,924,013 discloses a food container made from paperboard laminate that may be heated to about 400° F. Although these containers have improved structural integrity as a result of the incorporation of various cellulose based materials they are poorly suited for cooking the contents of the container using a direct flame, such as a barbeque. 
         [0004]    Food packaging materials that can be heated by a direct contact with fire are also known in the art. For example, packaging materials composed of a press-molded aluminum foil container and an aluminum foil lid covering the container have broadly been used as such packaging material that may be heated by direct contact with fire. However, packages of this type are often difficult to seal tightly and are consequently poorly adapted for the storage of prepared foods. 
         [0005]    Several packages having improved sealing characteristics, which may also be exposed to an open flame, have been developed. For example, U.S. Pat. Nos. 3,469,998 and 3,554,770 disclose a food-packaging material comprising a metal foil, the inner surface of which is coated with a polyvinyl chloride resin and the outer surface of which is coated with a heat-resistant resin such as an epoxy resin. Although these packages may be sealed and may be exposed to a flame, such packages are still insufficient because the heat resistant resin tends to impart unwanted flavors to the enclosed meal upon heating. 
         [0006]    Despite the many types of food containers in the prior art there remains a need for a package suitable for storing, shipping, preparing and dispensing a meal, wherein the package has sufficient structural integrity to withstand each of the procedures and particularly sufficient structural integrity for storing, shipping, preparing and dispensing a meal weighing at least about one pound. Further, there is a need in the art for a prepared meal package having the foregoing characteristics as well as the ability to be heated over an open flame, while at the same time comprising a flavoring agent that is released into the meal during preparation, thereby contributing to the taste of the final meal. 
       SUMMARY OF THE INVENTION 
       [0007]    The package of the present invention solves the problems of the prior art by providing a package that is useful for storing, shipping, preparing and dispensing a meal. The package is constructed such that it has structural integrity sufficient to withstand each of these procedures and in particular is constructed to withstand shipping. Moreover, the package of the present invention comprises a flavoring agent that is released into the meal during preparation, thereby contributing to the taste of the final meal. 
         [0008]    In one aspect, the present invention provides a package for storing, shipping, preparing and dispensing a meal comprising an outer flavoring pouch having an inner space, a tray disposed within the inner space of the flavoring pouch and a meal disposed within the tray. In one embodiment the outer flavoring pouch comprises a top, a bottom and at least one sidewall, wherein the bottom wall comprises a first and second layer and a flavoring agent disposed between the first and second layers. In a preferred embodiment the top, bottom and sidewall are constructed from the same material and more preferably are constructed from a heat conductive material selected from the group consisting of aluminum and copper. 
         [0009]    In other embodiments the present invention provides for a pouch formed from two opposed sheets, wherein at least one of the sheets comprises a first and second layer and a flavoring agent disposed between the first and second layers, the pouch being sealed along its outer perimeter to form an inner space. In another embodiment the pouch is formed from a tube having one or more transverse seals to form an inner space. In still other embodiments the pouch may be formed from single sheet of material, by folding a strip of the material in half and sealing the ends to form a tube, and then securing one end of the tube to form a pouch. 
         [0010]    In another aspect the present invention provides a package for storing, shipping, heating and dispensing a meal comprising a pouch comprising at least two opposed sheets, each sheet comprising a first and second layer, and a flavoring agent disposed between the first and second layers, the sheets being sealed together along the outer edges thereof to form a pouch having an inner space, a tray disposed within the inner space, and a meal disposed within the tray. 
         [0011]    In one embodiment the meal, which is disposed within the tray, comprises a protein, a vegetable and a sauce. In a preferred embodiment the protein is selected from the group consisting of a meat, a fish and a shellfish, and more preferably the protein is a shellfish selected from the group consisting of a mollusk, a crustacean, and an echinoderm. In other embodiments the meal may comprise more than one protein and more preferably at least two proteins, wherein one of the proteins is a mollusk selected from the group consisting of a clam, a mussel, an oyster, and a scallop and the other protein is a crustacean selected from the group consisting of a shrimp, a prawn, a lobster, a crayfish, and a crab. In another embodiment the meal comprises more than two proteins, and more preferably at least four proteins, wherein each protein is a shellfish selected from the group consisting of a mollusk, a crustacean, and an echinoderm. 
         [0012]    In still other aspects the present invention provides for a method of shipping a prepared meal, the method comprising the steps of forming a pouch having an inner space, the pouch comprising a first and a second sheet, the first sheet having a first and second layer, and a flavoring agent disposed between the first and second layers, disposing a meal within a tray, disposing the tray containing the meal within the inner space of the pouch, sealing the pouch and shipping the pouch containing the tray and the meal. 
     
    
     
       DESCRIPTION OF THE FIGURES 
         [0013]      FIG. 1  illustrates a package for storing, shipping, preparing and dispensing a meal according to one embodiment of the present invention. 
           [0014]      FIG. 2  illustrates a flavoring pouch according to one aspect of the present invention. 
           [0015]      FIG. 3  illustrates a flavoring pouch according to another aspect of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0016]    Turning to  FIG. 1 , in one embodiment the present invention provides a package  10  for storing, shipping, preparing and dispensing a meal comprising an outer flavoring pouch  15  having an inner space  20 , a tray disposed  25  within the inner space  20  of the flavoring pouch  15  and a meal  30  disposed within the tray  25 . In one embodiment the outer flavoring pouch  15  comprises a top wall  40 , a bottom wall  45 , and an intermediate wall  50  and at least one sidewall  55 , and a flavoring agent  60  disposed between the bottom surface  45  and the intermediate layer  50 . In a preferred embodiment the top wall  40 , bottom wall  45 , intermediate wall  50  and sidewall  55  are constructed from the same material and more preferably are constructed from a heat conductive material. For example, such materials include but are not limited to the group consisting of aluminum, copper, ceramic and other lightweight, readily-heated and burn-resistant materials. 
         [0017]    The flavor pouch, which forms the outermost surface of the package, may be constructed from any material capable of transmitting heat, so long as the material can withstand contact with an open flame. For example, metals such as aluminum and copper may be used to construct the flavor pouch. In a preferred embodiment the flavor pouch is formed from one or more sheets of aluminum foil having a thickness from about 0.0001 to about 0.005 inches, more preferably from about 0.0005 to about 0.002 inches. Suitable aluminum foils are commercially available from a number of suppliers. In other embodiments the flavor pouch may be formed from one or more foil laminates, which are well known in the art and may include, for example, the foil laminates disclosed in U.S. Pat. Nos. 2,711,380, 2,902,396 and 5,098,751. 
         [0018]    The flavor pouch may be formed in any number of ways.  FIG. 2  depicts one embodiment of the present invention wherein the flavor pouch  115  is formed from two opposed sheets,  120   a ,  120   b  wherein at least one of the sheets  120   a ,  120   b  comprises a first layer  140  and second layer  145  and a flavoring agent  150  disposed between the first layer  140  and the second layer  145 , the pouch  115  being sealed along its outer perimeter to form an inner space  120 . In another embodiment, the second sheet, like the first sheet may also comprise a first and second layer, and flavoring agent disposed there between. 
         [0019]    In another embodiment, as illustrated in  FIG. 1  the flavoring pouch  15  comprises a top wall  40 , a bottom wall  45 , an intermediate wall  50 , and at least one sidewall  55 . A flavoring agent is disposed between the bottom wall  45  and the intermediate wall  50 . Each of the walls are joined together to form a pouch  15  having an inner space  20 . The sidewall may be composed of a single continuous piece of material, or may be composed of two or more individual pieces of material. 
         [0020]    In still another embodiment illustrated in  FIG. 3  the flavor pouch  215  may be formed from a single sheet  220  having a first  220   a  and second layer  220   b  and a flavor agent  225  disposed there between, the single sheet folded unto itself and sealed along its outer edge  230  to form a pouch having an inner space  235 . The single sheet may be any shape including, square, rectangular or circular. Alternatively, the single sheet may be formed as a tube and transversely sealed at each of its ends to form a pouch having an inner space. 
         [0021]    In certain embodiments the two sheets between which the flavoring agent is disposed may be constructed from the same or different materials. In a preferred embodiment the first sheet is constructed from a conductive material and the second sheet is constructed from a gas permeable material. The gas permeable material is a material capable of preventing passage of water while allowing passage of air. Suitable gas permeable materials include, but are not limited to polytetrafluoroethylene (PTFE), tetrafluoroethylene (Teflon™, commercially available from E. I. du Pont de Nemours) and poly(p-phenyleneterepthalamide) (commercially available from E. I. du Pont de Nemours as Kevalr®). In other embodiments the first and second layers may be construed from the same heat conductive material, wherein the second layer comprises at least one aperture to allow vapor released from the flavoring agent to enter into the inner space of the pouch. 
         [0022]    The package walls may be sealed together using any one of the methods well known in the art including, for example, heat sealing, mechanical fastening or chemical fastening. In one embodiment the package walls are sealed together by welding or by having a weldable tape attached between the peripheral portions thereof. The tape may be made of PFA. In other embodiments, the package walls could be connected together by a means other than welding, for example by stitching or by a clip or clamp device. 
         [0023]    The flavoring agent of the present invention may be any agent that upon heating generates one or more vapors which include smoke, ambient air, impinged air, steam, gasses, and fumes, as well as aerosol and other suspensions of solid or liquid particles. The vapors generated by the flavoring agent upon heating are introduced to the inner space of the flavor pouch where they come in contact with the meal, thereby imparting flavor to the meal. In one embodiment the flavoring agent is a natural material, such as a wood, an herb, a spice, or natural liquid smoke, which is commercially available from a number of sources including The Colgin Companies, Dallas, Tex. In another embodiment the flavoring agent is a synthetic material or a combination of natural and synthetic materials. 
         [0024]    One preferred flavoring pouch is the Savu™ Smoker Bag, which is commercially available from Sinituote Oy, Hyvinkää, Finland. The Savu™ Smoker Bag is the subject of U.S. Pat. No. 5,520,940 and comprises a bag constructed from aluminum foil having a top wall, a bottom wall comprising a first and second layer and side walls. The bag is sealed along its edges to form an inner space, into which a meal is placed. Between the first and second layers, which form the bottom wall, a flavoring agent consisting of wood chips, sugar and syrup is disposed. The meal is placed on top of the second layer and does not contact the flavoring agents. However, the second layer contains several apertures, which permit vapors released by the flavoring agents during cooking to contact the meal. 
         [0025]    To further enhance the structural integrity of the package and to facilitate the storage and shipping of meals weighing at least about one pound, more preferably at least about two pounds and still more preferably at least about two and half pounds, a tray is placed into the flavoring pouch. The tray, which is received by the inner space of the flavoring pouch, may be formed from any one or more heat resistant materials known in the art. Suitable materials include, but are not limited to a heat conductive metal, such as aluminum or copper, and paperboard, including without limitation the material described in U.S. Pat. No. 4,757,940, or any combination of a heat conductive metal and paperboard. Preferably, the tray is formed from thin sheets of aluminum. The tray may be any size and shape so long as it is capable of receiving the meal, being received by the inner space of the flavoring pouch, and imparts sufficient structurally integrity to the packaged meal so that it may withstanding storage, shipping, heating and serving. In a preferred embodiment the tray is approximately rectangular and has four side walls and a base, the side walls extending from the base about 0.5 inches to form a lip. 
         [0026]    The tray, which is placed inside the flavor pouch, contains the meal. The contents of the meal may include one or more members selected from the group consisting of a protein, a vegetable, and a sauce. The protein may be raw or cooked, frozen or fresh. In one embodiment the protein is preferably one of fish, shellfish, beef, poultry, pork or veal. In one embodiment the meal comprises one or more shellfish selected from the group consisting of a mollusk, a crustacean, and a echinoderm, and still more preferably the meal comprises at least one mollusks selected from the group consisting of a clam, a mussel, an oyster, and a scallop, and at least one crustacean selected from the group consisting of a shrimp, a prawn, a lobster, a crayfish, and a crab. In a preferred embodiment the meal comprises at least one lobster, at least one mussel, at least one shrimp and at least one scallop. The shellfish may be prepared with or without their shells. 
         [0027]    Further, vegetables may be added to the protein. The vegetables may be raw, cooked or partially cooked, and may include for example, corn, peppers, celery, carrots, onions, zucchini or broccoli. In one embodiment the vegetables are partially cooked so that the time remaining to complete cooking of the vegetables is approximately the same as the time required to cook the raw protein. 
         [0028]    In addition to a protein and a vegetable, preferably the meal comprises a sauce. Preferably the sauce comprises at least one lipid and one or more seasoning agents selected from the group consisting of a herb, a spice, a vegetable, a sweetener. Preferred lipids include, butter, olive oil, and vegetable oil. Useful herbs include, but are not limited to, basil, bay leaf, parsley, sage, rosemary, tarragon, and thyme. Useful spices include, but are not limited to, the seeds of dill, fennel, mustard, and pepper, as well as the roots or bulbs of certain plants such as garlic and ginger. Alternatively the sauce may include a mineral product such as salt. In a preferred embodiment the sauce comprises butter, garlic, salt and parsley. 
         [0029]    Preferably the package will have a total weight from about 1 to about 5 pounds, and more preferably from about 1 pound to about 3 pounds and still more preferably from about 2 pounds to 3 pounds. The relative amounts of each of the protein, vegetable and sauce may vary, however, in a preferred embodiment the protein portion weighs from about 1 pound to about 2.5 pounds, the vegetable weights from about 0.25 pounds to about 1 pound and the sauce weighs from about 0.5 ounces to about 4 ounces. 
         [0030]    In one embodiment the packaged is prepared by placing a protein, a vegetable and a sauce in a tray, and the tray containing the meal is placed in the flavoring pouch, excess air is evacuated from the flavoring pouch, which is then sealed to form the package. In one embodiment, after sealing the package is frozen. The package may be stored frozen until the time of consumption, at which the time the package may be thawed or may be heated directly. To cook the meal the package is placed in the proximity of a heat source, such as a barbeque, or an oven. Upon heating of the package the flavoring agent begins to emit vapor, which is transmitted to the meal, thereby imparting flavor to the meal. Further, during heating the meal is cooked and the sauce is liquefied, further flavoring the meal. 
         [0031]    After heating and when the meal has cooked, the package is removed from the heat source. In one embodiment the package is opened using a mechanical device, such as a knife or scissors. Alternatively one sheet of the flavor pouch may include perforations to facilitate the opening of the package without the use of a mechanical device. Once the packaged is opened it may be used to serve the meal contained therein. 
         [0032]    Alternatively, after the meal has been packaged it may be shipped. Surprisingly, the present invention provides a packaged meal having sufficient structural integrity not only to hold meals weighing more than prior art meals, i.e., weighing more than one pound, but also to withstand the rigors of shipping. In a preferred embodiment after the packed meal is prepared it is frozen and then shipped directly to the customer without further processing. 
         [0033]    The following example of a package for storing, preparing and dispensing a meal and methods of making the same are now disclosed. The following example is illustrative in nature of the various aspects of the present invention and is not intended to be limiting in any manner. 
         [0034]    In the present example, the meal was a Maine shore diner, which comprised Maine lobster, sea scallops, shrimp, mussels, corn and a butter sauce. More specifically the meal comprised two Maine lobster tails, which were purchased frozen. The tails weighed from about 5 ounces to about 6 ounces each and include the shell. The meal further comprised approximately 8 sea scallops, the scallops were uncooked and out of the shell and weighed from about 0.9 to about 1.0 ounces; 12 shrimp, tail on and de-veined, weighing from about 0.8 to about 1.0 ounces each; 12 mussels, in the shell, uncooked, weighing from about 0.6 to about 0.8 ounces each; 2 ears of corn on the cob, uncooked, approximately 4 ounces each; and a frozen, spiced, butter sauce. In total the meal weighed approximately 2 lbs, 10 oz. 
         [0035]    The meal was placed on a metal pan, measuring approximately 12.5×8.5 inches and having a 0.5 inch lip. Placing the meal in the pan prior to inserting the pan into the flavoring pouch, protects the pouch, provides structural rigidity to the package allowing for the storing, shipping, preparation and serving of the meal, as well as gathering the drippings from the meal as it cooks, thus contributing to the flavor of the meal. 
         [0036]    The metal pan containing the meal was then placed inside a flavor pouch. The flavor pouch was purchased from Sinituote Oy, Hyvinkää, Finland. The flavor pouch comprised two opposed sheets, wherein each sheet comprised a first and second layer of aluminum foil, and wood chips disposed between the first and second layers. The flavor pouch was then sealed and the package was placed on a charcoal grill to cook for approximately 45 minutes. As the meal cooked, the wood chips impart a mild smoky flavor to the meal. 
         [0037]    Alternatively, rather than being prepared immediately the package may be stored and/or shipped for consumption at a later time. For example if the package is to be shipped a label displaying a photo of the finished product may be affixed to the package. The label may also include descriptive text, such as the phrase “The Maine Shore Dinner is the ultimate lobster bake in a bag.” In one embodiment, the product is shipped frozen and when ready to prepare, is thawed, and then cooked in an oven or on a grill for approximately 45 minutes.