Abstract:
The present description relates to a food container which comprises at least one opening through which food is moved and a humidity source in fluid contact with an air stream providing humidity to the air stream. The air stream is directed across the opening to form a barrier between the interior of the container and the exterior environment.

Description:
BACKGROUND  
       [0001]     The subject matter described herein relates generally to the field of containers. In particular, the subject matter described herein relates to food containers. The food containers may be used for storing food, holding food at temperature, cooling food, humidifying food, rethermalizing food, warming food, and/or cooking food.  
         [0002]     A wide variety and configuration of food containers are used to house and display food in places such as convenience stores, restaurants, etc. Depending on the type of food, these containers may be heated, cooled, and/or humidified to prevent the food from becoming cold and/or hard, thus making the food more appealing to consumers. For example, the containers may be used to house and display donuts, pastries, hot dogs, etc. In other applications, the containers may be used to refrigerate and/or freeze food to prevent it from melting, spoiling, etc. In still other applications, the containers may be used to hold food at elevated temperature or to cook food.  
         [0003]     Typically, a solid barrier such as a door is used to isolate the interior of the container from the exterior environment. The door prevents the transfer of heat and/or humidity between the interior of the container and the exterior environment. The door is usually hinged on one side so that it can be opened and closed to provide access to the interior of the container. Unfortunately continually opening and closing the door may result in a loss of productivity and efficiency on the part of the persons using the containers. Users often desire to quickly remove items from the containers. For example, in a fast food setting, a food preparer may want to be able to quickly access food components (e.g., hot dog buns, hot dogs) to prepare the finished food product (e.g., a hot dog in the bun with desired toppings). In other situations, the container may be provided with an opening that does not include a barrier between the exterior environment and the interior of the container. This arrangement results in a loss of efficiency due to excess heating, cooling, and or humidifying. Accordingly, it would be desirable to provide an improved food container for housing items such as food.  
         [0004]     It should be understood that the claims define the scope of the subject matter for which protection is sought, regardless of whether any of the aforementioned disadvantages are overcome by the subject matter covered by the claims. Also, the terms recited in the claims should be given their ordinary and customary meaning as would be recognized by those of skill in the art, except, to the extent a term is used herein in a manner more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or except if a term has been explicitly defined to have a different meaning by reciting the term followed by the phase “as used herein shall mean” or similar language. Accordingly, the claims are not tied to any particular embodiment, feature, or combination of features other than those explicitly recited in the claims.  
       SUMMARY  
       [0005]     One embodiment relates to a food container which comprises at least one opening through which food is moved and a humidity source in fluid contact with an air stream providing humidity to the air stream. The air stream is directed across the opening to form a barrier between the interior of the container and the exterior environment.  
         [0006]     Another embodiment relates to a food container which defines at least one opening through which food is moved. An air curtain system provides a humidified air curtain over the opening.  
         [0007]     Another embodiment relates to a container comprising a heating element disposed in the container, at least one opening through which food is moved between the interior and exterior of the Container, and at least one duct configured to direct an air stream across the opening to form a barrier between the interior of the container and the exterior environment. The heating element is used to at least one of cook food, rethermalize food, and maintain food at a temperature.  
         [0008]     Another embodiment relates to a container comprising at least one opening through which items are moved between the interior and the exterior of the container, a support surface in the container for supporting the items, and an air curtain system providing an air curtain over the opening. A portion of the air stream flowing over and around the items.  
         [0009]     Another embodiment relates to a container comprising at least one opening through which items are moved between the interior and the exterior of the container and a duct system configured to direct an air stream across the opening, the duct system comprising a plurality of air returns. At least one of the air returns is positioned adjacent to the opening and receives at least a portion of air stream. The portion of the air stream forming a barrier between the interior of the container and the exterior environment. The items are configured to be positioned substantially between at least another one of the air returns and the opening. The another one of the air returns being configured to receive another portion of the air stream.  
         [0010]     Another embodiment relates to a container comprising at least one opening through which items are moved out of the container, an air curtain provided over the opening to form a barrier between an interior environment of the container and an exterior environment, and a first side positioned substantially opposite the opening. The first side comprising at least one air return which is configured to receive a portion of the air from the air curtain.  
         [0011]     Another embodiment relates to a container comprising at least one opening through which items are moved between the interior and exterior of the container and an air curtain provided over the opening to form a barrier between the interior of the container and the exterior environment. The air in the air curtain is used to maintain the temperature and the humidity of the interior of the container at substantially controlled levels.  
         [0012]     Another embodiment relates to a container configured to house food comprising at least one fan configured to output an air stream and a baffle configured to receive the air stream from the fan. The air stream from the baffle passes over a water source to humidify the air stream. The humidified air stream is circulated in the container to maintain the water content of the food at or above a set level. 
     
    
     DRAWINGS  
       [0013]      FIG. 1  is a top perspective view of a container according to one embodiment.  
         [0014]      FIG. 2  is a front elevation view of the container from  FIG. 1 .  
         [0015]      FIG. 3  is a side elevation view of the container from  FIG. 1 .  
         [0016]      FIG. 4  is a cross-sectional side view of the container from  FIG. 2  along line  4 - 4 .  
         [0017]      FIG. 5  is a cross-sectional front view of the container from  FIG. 3  along line  5 - 5 .  
         [0018]      FIG. 6  is a top perspective view of the container from  FIG. 1  with the outside covers removed.  
         [0019]      FIG. 7  is a top perspective view of the container from  FIG. 6  with additional covers removed.  
         [0020]      FIG. 8  is a cross-sectional side view of a container according to another embodiment.  
         [0021]      FIG. 9  is a cross-sectional side view of a container according to another embodiment. 
     
    
     DESCRIPTION  
       [0022]      FIGS. 1, 2 , and  3  show a top perspective, front perspective, and side elevation views, respectively, of a container  50  according to one embodiment. Container  50  comprises an interior chamber  52 , which is configured to house items such as food in a controlled environment. Container  50  shown in  FIGS. 1-9  is shaped similarly to a box with an opening  54  on one side for moving food between the interior and the exterior of container  50 . In other embodiments, container  50  may be any of a number of suitable shapes and configurations. For example, container  50  may be substantially cylindrical, etc. Also, container  50  may be configured to be portable (e.g., moved by hand, rolled on castors, etc.) or fixed in a stationary position using a suitable fastening mechanism (e.g., welding, bolted, glued, etc.). In the embodiment shown in  FIGS. 1-9 , container  50  is configured to be placed on top of a countertop or table. In another embodiment, opening  54  may be located on a top side of container  50 . In still another embodiment, container  50  may comprise two, three, or more openings  54  for moving food between the interior and the exterior of container  50 . In yet another embodiment, container  50  may comprise transparent sides (e.g., glass, plastic, etc.) so that the food is visible.  
         [0023]     In one embodiment, container  50  comprises a control system, which is used to maintain the physical characteristics (e.g., temperature, humidity, etc.) of the air in chamber  52  substantially constant. The control system is typically configured to control both temperature and humidity of the air in chamber  52 . However, in other embodiments, the control system may be configured to control only one of the temperature and humidity of the air in chamber  52  or may be configured to control additional properties of the air in chamber  52  such as the air&#39;s speed. In general, the control system includes any of the components, structure, and matter that is used to control the temperature and humidity of the air in container  50 . In one embodiment, the control system comprises at least a thermometer and/or a hygrometer. In another embodiment, the control system comprises a thermostat and/or a humidistat which are used to control the temperature and/or humidity, respectively, of the air in chamber  52 . In still another embodiment, the control system may comprise infinite controls for controlling the temperature and/or humidity of the air in chamber  52 .  
         [0024]     Control panel  60  may be used to provide input (e.g., set levels for temperature, humidity, etc.) to the control system. In one embodiment, as shown in  FIGS. 1-3 , control panel  60  comprises buttons  62  and display  64 . Buttons  62  may be used to input the desired temperature and/or humidity level. Display  64  is configured to show the user the set and/or actual temperature and/or humidity levels. In addition, container  50  also comprises a power on/off switch  66  and a power cord  68 . In other embodiments, control panel  60  may comprise other input devices and/or displays. For example, control panel  60  may comprise rotary dials instead of buttons  62 . Also, control panel  60  may be distributed on container  50 . For example, display  64  may be located on one side of container  50  and buttons  62  may be located on another side of container  50 . In yet another embodiment, container  50  may be supplied with a computer interface for interfacing with a computerized control system or a computerized information source.  
         [0025]     As mentioned previously, container  50  defines at least one opening  54  through which food may be moved between the interior and the exterior of container  50 . Opening  54  may be any suitable size and shape. In the embodiment shown in  FIGS. 1-3 , opening  54  is quadrilateral and substantially planar. Opening  54  may be positioned in a substantially vertical plane, as shown in  FIGS. 1-3 , or may be positioned in a number of other planes (e.g., a substantially horizontal plane for a container where opening  54  is on a top side or a plane at any degree of inclination between a horizontal plane and a vertical plane).  
         [0026]     In the embodiment shown in  FIGS. 1 and 2 , trays  56  are used to support food (e.g., pastries, brownies, hot dogs, etc.). Trays  56  are of a sufficient size to pass through opening  54  and be received by rails  70  in chamber  52 . In other embodiments, food may be moved between the interior and the exterior of container  50  in a variety of other suitable ways (e.g., individual food items placed in container  50  without using trays  56 , etc.).  
         [0027]     Container  50  uses an air curtain  58  to form a barrier between interior  52  of container  50  and the exterior environment. A user can easily reach through, or otherwise pierce, air current  58  to move food between the interior and the exterior of container  50 . Thus, air curtain  58  provides an effective barrier between chamber  52  and the exterior environment yet eliminates the need for the user to open a door while moving food into and out of container  50 . Air curtain  58  may also provide an effective barrier against insects and other foreign matter that may otherwise enter chamber  52 . Also, a portion of the air from air curtain  58  may be used to humidify, cool, and/or heat the interior of container  50 .  
         [0028]     Referring to  FIG. 4 , a cross-sectional side view of container  50  along line  4 - 4  in  FIG. 2  is shown. Container  50  comprises at least one fan  74  and a duct system  76  which are configured to circulate air stream  72  through container  50 . In general, fans  74  are electrically operated and are configured to provide a constant air flow rate. In another embodiment, fans  74  may be adjustable to provide varying controlled (actively or passively) air flow rates. Fans  74  are provided with outside ventilation using louvers  90 , which allow air to enter a ventilation space  92 . Air that enters louvers  90  may be used to prevent fans  74  from overheating. Ambient air that enters louvers  90  is kept separate from air stream  72 . In another embodiment, air stream  72  may comprise ambient air that is continually being combined with circulated air. In another embodiment, air stream  72  may comprise only ambient air that is brought in through a vent then expelled back into the ambient environment after it has been used to create air curtain  58 .  
         [0029]     In  FIG. 4 , the general flow of an air stream  72  is shown. As shown in  FIGS. 4, 6 , and  7 , fans  74  blow air into a baffle box  78 . Baffle box  78  is a substantially enclosed box comprising a baffle  80  through which air stream  72  is forced to pass. Before passing through baffle  80 , air stream  72  may be heated using heating element  82 . In other embodiments, heating element  82  may be located in any suitable position in duct system  76 . After being heated, air stream  72  passes through baffle  80 . In the embodiment shown in  FIGS. 4, 6 , and  7 , baffle  80  comprises a perforated, substantially planar, plate. Typically, the perforations in baffle  80  are also substantially uniform. As air stream  72  passes through the perforations in baffle  80 , the velocity of air stream  72  increases briefly before slowing down on the other side of baffle  80 . Also, baffle  80  provides a pressure drop.  
         [0030]     After passing through baffle  80 , air stream  72  passes over water source  84  to humidify air stream  72 . Once air stream  72  exits baffle  80  the velocity of air stream  72  decreases substantially. The decrease in velocity of air stream  72  and/or the pressure drop across baffle  80  allows air stream  72  to pick up water from water source  84  better than if baffle  80  was not present. Water source  84  comprises a heating element  86  which can be used to heat the water and provide a controlled amount of water vapor to be picked up by air stream  72 . Water source  84  is filled using water input  86 . Water placed in water input  86  passes through water tube  88  to water source  84 . In another embodiment, water source  84  may be coupled to a continuous water supply that refills water source  84  when it gets low (e.g., a float with a valve that turns on when the water level of water source  84  is low). In other embodiments, container  50  may be configured without a water source  84  or any system for humidifying air stream  72 . This may be desirable in connection with foods that do not need to be humidified.  
         [0031]     After passing over water source  84 , air stream  72  travels through duct  96 , which is a part of duct system  76 . As air stream  72  enters duct  96 , the velocity of air stream  72  increases due to the smaller area through which air stream  72  now passes. Air stream  72  exits duct  96  through nozzles  94 , which are positioned adjacent opening  54  in a downward direction. As air stream  72  passes downward over opening  54 , air curtain  58  is created. Air from air curtain  58  returns back to fans  74  through a plurality of air returns  98  in duct system  76 . At least one of air returns  98  is positioned adjacent to opening  54  opposite nozzles  94 . Air returns  98  positioned opposite nozzles  94  receive a portion of air stream  72  that exits nozzles  94 . This portion typically includes most of air stream  72 . At least one of air returns  98  is positioned on a first side  100  of chamber  52 . Generally, first side  100  is positioned opposite opening  54 . Food placed in trays  56  is positioned substantially between air returns  98  positioned on first side  100  and opening  54 . A portion of air stream  72  passes over and/or around the food before entering air returns  98  positioned on first side  100 . Thus, the water content of the food, temperature and/or humidity of the air in chamber  52  may be controlled using air from air stream  72 . In one embodiment, the air from air stream  72  is used to maintain the temperature and/or humidity of chamber  52  substantially constant without the use of additional temperature and/or humidity control systems.  
         [0032]     As shown in  FIGS. 2 and 5 , first side  100  is perforated according to a substantially uniform pattern to provide a plurality of distributed air returns  98 . In one embodiment, the size of the perforations is between approximately 3 millimeters and approximately 10 millimeters or, desirably, between approximately 5 millimeters and approximately 8 millimeters. In still another embodiment, first side  100  is configured to include a higher density of air returns  98  and/or all of air returns  98  near trays  56 . This allows the portion of air stream  72  that passes through the air returns on first side  100  to be nearer to the food, thus enhancing the heat transfer and/or humidification of the food. In other embodiments, first side  100  may comprise a single air return  98  located in any suitable position. After air stream  72  passes through air returns  98 , air stream  72  travels through duct system  76  back to fans  74  to begin the cycle again.  
         [0033]     Referring to  FIG. 5 , a cross-sectional front view of container  50  along line  5 - 5  in  FIG. 3  is shown. Duct system  76  comprises two separate ducts  102  and  104  through which air is returned from chamber  52  to fans  74 . Also, each fan  74  has separate outlet ducts  106  and  108 . In other embodiments, duct system  76  may comprise a single duct to circulate air stream  72  through container  50 . In still other embodiments, duct system  76  may comprise a filter to capture any particles that may dislodge from the food as it is passed through air curtain  58 .  
         [0034]     Referring to  FIGS. 6 and 7 , a top perspective view of container  50  with the outside covers removed is shown.  FIGS. 6 and 7  provide a top perspective view of fans  74 , baffle box  78 , baffles  80 , ducts  96 , and wiring enclosure  110 . Wiring enclosure  110  houses electrical wires that provide power to heating elements  82  as well as other electrical devices.  FIG. 7  shows container  50  with one of baffle boxes  78  removed. Underneath baffle boxes  78  are covers  112 , which cover water source  84 . Covers  112  help to isolate water source  84  from heating elements  82 . Air stream  72  exits fan outlet ducts  106  and  108 , travels through baffle boxes  78  and into ducts  96 .  
         [0035]     Referring to  FIG. 8 , a cross-sectional side view of container  50  is shown according to another embodiment. In this embodiment, fan  74 , baffle  80 , and water source  84  are located at the bottom of container  50 . Fan  74  is configured to circulate air through container  50  in a manner similar to the previous embodiments. However, in this embodiment, the air in air curtain  58  flows upward from nozzles  94  to air returns  98 .  
         [0036]     In  FIG. 9 , a cross-sectional side view of container  50  is shown according to another embodiment. In this embodiment, a top side  114  of container  50  comprises opening  54 . Accordingly, air curtain  58  is substantially horizontal and provides a barrier between chamber  52  and the exterior environment. The majority of the air from air curtain  58  is received by one or more air returns  98  positioned adjacent to opening  54  and opposite nozzles  94  while the remainder is received by air returns  98  positioned in a bottom side  116  of container  50 . This embodiment may also include any other features described or discussed in relation to other previous embodiments.  
         [0037]     The construction and arrangement of the elements described herein are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those of ordinary skill who review this disclosure will readily appreciate that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter recited in the claims. Accordingly, all such modifications are intended to be included within the scope of the methods and systems described herein. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the embodiments without departing from the spirit and scope of the methods and systems described herein.