Patent Publication Number: US-2019185197-A1

Title: Packages for and methods of packaging food products

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 15/002,504, filed Jan. 21, 2016, which is a continuation-in-part of U.S. patent application Ser. No. 12/704,954, filed Feb. 12, 2010, and entitled PACKAGES AND METHODS OF PACKAGING FOOD PRODUCTS, the contents of which application are incorporated by reference herein in their entirety for all purposes. 
    
    
     FIELD OF THE INVENTION 
     In general, the invention relates to a packaging device for food products. More particularly, the invention relates to expandable packages for food products. 
     BACKGROUND OF THE INVENTION 
     The art of food packaging is well developed. For example, within the art of dough packaging there are multiple ways of packaging proofed and un-proofed dough. Proofing dough is know in the art to mean allowing dough containing a leavening agent to rise for the proper amount of time such that the dough reaches a desired volume. 
     U.S. Pat. No. 6,635,291, Perry, entitled Leavened Dough or Batter Packaging System discloses a package for leavened dough designed to hold a desired internal equilibrium pressure. 
     U.S. Pat. No. 6,733,803, Vidkjaer, entitled Dough Containing, Valved Package discloses a package for dough that does not have to be proofed having a one-way venting valve to allow gas to escape from the package. 
     U.S. Pat. No. 1,861,124, Lorber, entitled Biscuit Package discloses a package for uncooked biscuits having a telescoping cover which provides space for the risen dough. Further, Lorber&#39;s design has a channel for receiving the telescoping cover and requires separation of a number of dough cakes with interposed circular disks which may complicate producing such a design. 
     U.S. Pat. No. 6,240,839, Amato, entitled Device for Proofing Dough discloses a mechanical device having an electronic alarm or electronic visual indicator assembly for signaling when the dough reaches a specific volume. 
     Most of the prior art mentioned above does not provide for packaging of un-proofed dough products. Known packages that do provide for packaging of un-proofed dough do not indicate when the dough is ready or proofed. Letting dough proof for the proper amount of time is an art. The time it takes dough to proof is dependent upon many variables such as temperature, humidity, dough ingredients and the strain of yeast used in the dough. Thus, the proof time of dough is often misjudged and the dough is used either prematurely or after it has proofed. Furthermore, known proofing approaches for dough generally require the consumer to purchase a separate device, apart from the dough packaging, to determine when the dough is ready. Such known prior art devices that indicate when dough is ready tend to be expensive and more suited for commercial operations. 
     Furthermore, recent health concerns around the food packaging of popcorn in microwave ready packages have created a need for an expandable food package for popcorn that is chemical free, made from virgin fiber paperboard, recyclable and compostable. 
     SUMMARY OF THE INVENTION 
     Embodiments of the invention relate to packages for food products. More specifically, embodiments of the invention relate to inexpensive expandable packages in which dough can be sold and in which dough can be proofed to the correct/desired volume by consumers. 
     In one embodiment of the present invention the package has two portions, a first portion and a second portion. The first portion has a first closed end, at least one first side wall surrounding the first closed end, and a first open end opposite the first closed end. The second portion has a second closed end, at least one second side wall surrounding said second closed end, and a second open end opposite the second closed end. The first portion and second portion are movably connected at their respective open ends, such that an enclosed void of variable volume is created between the first closed end and the second closed end. Additionally, at least one indicator is placed in communication with the package such that when the package is expanded to a desired inner volume the indicator is activated. Activation of the indicator may produce, for example, a visual indication, an audio indication, an indication recognizable by touch, or any combination thereof. 
     The packages of the present invention provide for an inexpensive and easily manufacturable package for food products. Furthermore, the packages of the present invention provide for a dough package in which dough can be manufactured, sold, and proofed to the correct or desired volume without the need for separate more expensive devices. 
     In a further illustrative embodiment of the present invention, the packages of the present invention provide for a use as a food package for popcorn allowing for the popping of corn to a desired volume without the need for separate more expensive device. According to the invention, the instant food package can further be used as a serving container for the expanded food product. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention is illustrated in the figures of the accompanying drawings which are meant to be exemplary and not limiting, in which like references are intended to refer to like or corresponding parts, and in which: 
         FIG. 1  illustrates an embodiment of an expandable package wherein the expandable package is expanded to show an indicator; 
         FIG. 2  illustrates an embodiment of an expandable package wherein the expandable package is fully collapsed; 
         FIG. 3  illustrates an embodiment of an expandable package wherein the expandable package portions are separated to show the interface portions; 
         FIG. 4  illustrates an embodiment of a method of making an expandable package; 
         FIG. 5  illustrates an embodiment of a pattern for making the portions of an expandable package; 
         FIG. 6  illustrates another embodiment of a pattern for making the portions of an expandable package; 
         FIG. 7  illustrates an embodiment of a method of packaging a food product in an expandable package; 
         FIG. 8  illustrates an embodiment of a pattern for making the portions of an expandable package; 
         FIG. 9  illustrates another embodiment of a pattern for making the portions of an expandable package; 
         FIG. 10  illustrates an embodiment of an expandable package wherein the expandable package is engaged in a fully expanded packaged where the receiving setting tabs according to the invention are inserted in radial depressions according to the invention hold the expansion of the top and bottom portions in place; 
         FIG. 11  illustrates the receiving setting tabs according to the invention inserted in radial depressions according to the invention; 
         FIG. 12  illustrates an embodiment of an expandable package wherein the expandable package according to the invention is partially expanded packaged; and 
         FIG. 13  illustrates an embodiment of an expandable package wherein the expandable package is fully expanded packaged wherein interlocking tabs according to the invention prevent the overexpansion of the expandable package according to the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Detailed embodiments of the present invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. 
     In general, aspects of the invention relate to packaging, and methods of making a package and packaging a food product. In one aspect, the invention relates to an expandable package for packaging food products. Referring first to  FIGS. 1-3 , wherein  FIG. 1  depicts an expanded package with a square/rectangular cross section,  FIG. 2  depicts a collapsed package with a square/rectangular cross section, and  FIG. 3  depicts a package having a square/rectangular cross section with the package portions separated from one another. One embodiment of the package includes a first portion  100 , a second portion  101 , and at least one indicator  102 . 
     The first portion  100  has a first closed end  103 , at least one first side wall  104  surrounding the first closed end  103 , and a first open end  105  opposite the first closed end  103 . The second portion  101  has a second closed end  106 , at least one second side wall  107  surrounding the second closed end  106 , and a second open end  108  opposite the second closed end  106 . The first portion  100  and second portion  101  are movably connected at their respective open ends  105  and  108  such that an enclosed void of variable volume is created between the first closed end  103  and the second closed end  106 . 
     The at least one indicator  102  is placed in communication with the package such that when the package is expanded to a desired inner volume the indicator  102  is activated. As shown in  FIG. 1 , activation of the indicator  102  produces a visual indication that may read “Half Proofed,” or “Fully Proofed” depending on the inner volume of the package. In a further illustrative embodiment a singular visual indication may read “Pop Corn Done,” or may be just a simple line showing the food package is at full volume. It is contemplated within the scope of the invention that the visual indicator may reflect a variety of food products in various stages of readiness. Although, only printed words are shown in  FIG. 1 , it is contemplated that any number of any words, descriptions, phrases, symbols, pictures, combinations thereof, or other visual indication means may be used. It is further contemplated that activation of the indicator may produce, for example, a visual indication, an audio indication, an indication recognizable by touch, or any combination thereof. 
     In other embodiments, the indicator  102  is activated when the inner volume of the package reaches a volume in the range of about 90 to 94 cubic inches, and/or when the inner volume of the package reaches a volume in the range of about 108 to 112 cubic inches. 
     As shown in  FIGS. 1-3 , the package is depicted as having a square/rectangular cross section. However, in other embodiments of the package any cross sectional shape may be used, for example, a cross section that is circular, square, rectangular, octagonal, triangular, hexagonal, pentagonal, or any combination thereof. 
     Another embodiment of the package, as shown in  FIG. 3 , includes at least one first interface portion  300  at the first open end  105  of the first portion  100 , and at least one second interface portion  301  at the second open end  108  of the second portion  101 . These interface portions  300  and  301  engage with each other when the first and second portions  100  and  101  are connected and allow the package to expand and contract in volume as the first and/or second portion(s)  100  and  101  is moved. The purpose of the interface portions  300  and  301  is to prevent the package from expanding to far and separating the first and second portions  100  and  101  apart. As shown in  FIG. 3 , the interface portions are depicted as tabs folded inward on the first portion  100  and outward on the second portion  101 . However, it is contemplated that any means of preventing the two portions  100  and  101  from separating apart when the package is expanded may be used. 
     Further embodiments of the package may include one or more of the following features. The first portion  100  wherein the first closed end  103  is capable of being opened such that the food product packed within can be removed. As shown in  FIGS. 1-3 , the package is shown as expanding vertically. However, in other embodiments of the package any configuration may be used, for example, the package may expand vertically, horizontally, or on an angle. Furthermore,  FIGS. 1 and 2  depict the package as having a second portion  101  which is smaller that the first portion  100  such that the second portion  101  fits within the first portion  100 . However, in other embodiments of the package the first portion  100  is smaller than the second portion  101  and is placed within the second portion  101 . 
     In another aspect, the invention relates to a method of making an expandable package. Referring to  FIG. 4 , one embodiment of the method for making a package includes providing a first portion pattern  400 , providing a second portion pattern  401 , bending or folding the first portion pattern  402 , bending or folding the second portion pattern  403 , fastening the first portion such that the first portion retains the folded configuration  404  and fastening the second portion such that the second portion retains the folded configuration  404 , and assembling the first portion and the second portion  405 . 
     More specifically, bending or folding the first portion  402  includes folding the first portion pattern to form a first portion having a first closed end, at least one first side wall surrounding the first closed end, a first open end opposite the first closed end, and at least one first interface portion at the first open end. Bending or folding the second portion  403  includes folding the second portion pattern to form a second portion having a second closed end, at least one second side wall surrounding the second closed end, a second open end opposite the second closed end, and at least one second interface portion at the second open end. 
     The fastening step  404  includes securing the bended or folded patterns with any adhesive material to maintain their bended or folded configurations of the first and second portions. Furthermore, assembling the first portion and the second portion  405  includes assembling the first and second portions such that the first interface portion of the first portion engages with the second interface portion of the second portion, and thus producing a package in which the first and second portions are movably attached to each other at their respective open ends. 
     Other embodiments of the method for making a package, may include one or more of the following steps: providing sheet stock for printing onto  406 ; printing graphics or other designs onto a sheet stock  407 ; and die cutting or laser cutting the patterns for the first and second portions out of a printed or un-printed sheet stock  408 . 
     One example of a pattern for producing the first and/or second portions is shown in  FIG. 5 , wherein the dashed lines represent folds or bends. Bending/folding and fastening the pattern depicted in  FIG. 5  into a first and/or second portion includes the following, not necessarily in the following order: fastening tab  500  to edge  501 , folding the two tabs  502  toward the center, folding end  503  over the two tabs  502 , inserting tab  504  into the enclosure, and folding the interface tabs  505  in the desired direction depending on which portion is being folded, as mentioned above. 
     Another example of a pattern for producing the first and/or second portions is shown in  FIG. 6 , wherein the dashed lines represent folds or bends. Bending/folding and fastening the pattern depicted in  FIG. 6  into a first and/or second portion includes the following, not necessarily in the following order: fastening tab  600  to edge  601 , folding the two tabs  602  toward the center, folding and interlocking the two end tabs  603  together over the two tabs  602  and fastening, and folding the interface tabs  604  in the desired direction depending on which portion is being folded, as mentioned above. 
       FIGS. 5 and 6  depict the pattern as producing a first and/or second portion having a square/rectangular cross section. However, in other embodiments of the pattern may produce a first and/or second portion having any cross sectional shape may be used, for example, a cross section that is circular, square, rectangular, octagonal, triangular, hexagonal, pentagonal, or any combination thereof. Although  FIGS. 5 and 6  only provide two examples it is contemplated that other patterns could be used to create embodiments of the invention. 
     In another aspect, the invention relates to a method for packaging a food product. Referring to  FIG. 7 , one embodiment of the method of packaging includes providing a food product  700 , providing a package  701 , and enclosing the food product within the package  702 . Providing a food product  700  may further include providing a food product such as dough or popcorn. Enclosing the food product within the package  702  may further include placing the food product inside the package and closing the package. 
     Furthermore, providing a package  701  includes providing a package, having a first portion, a second portion, and at least one indicator. The first portion has a first closed end, at least one first side wall surrounding the first closed end, and a first open end opposite the first closed end. The second portion has a second closed end, at least one second side wall surrounding said second closed end, and a second open end opposite the second closed end. The first portion and second portion are movably connected at their respective open ends. The at least one indicator is placed in communication with the package such that when the package is expanded to a desired inner volume the indicator is activated. 
     A further example of a pattern for producing the first and/or second portions according to the invention is shown in  FIG. 8 , wherein the dashed lines represent folds or bends. Bending/folding and fastening the pattern depicted in  FIG. 8  into a first and/or second portion includes the following, not necessarily in the following order: fastening tab  800  to edge  801 , folding the two tabs  802  toward the center, folding end  803  over the two tabs  802 , inserting tab  804  into the enclosure, and folding the interface tabs  805  in the desired direction depending on which portion is being folded, as mentioned above. The folded pattern as depicted in  FIG. 8  creates a bottom portion  810  of a food packaging according to the invention. This assembled bottom portion  810  is shown in  FIGS. 10, 11, 12 and 13 . According to the invention, as shown in  FIGS. 8, 10, 11, 12 and 13  this pattern and resulting bottom portion  810  has side panels  806  each having a radial depressions  807  for receiving setting tabs  906  (shown in  FIG. 9 ). 
     Another example of a pattern for producing the first and/or second portions according to the invention is shown in  FIG. 9 , wherein the dashed lines represent folds or bends. Bending/folding and fastening the pattern depicted in  FIG. 9  into a first and/or second portion includes the following, not necessarily in the following order: fastening tab  900  to edge  901 , folding the two tabs  902  toward the center, folding and interlocking the two end tabs  903  together over the two tabs  902  and fastening with the interlocking tabs  905  contained with the two end tabs  903 , and folding the interface tabs  904  in the desired direction depending on which portion is being folded, as mentioned above. The folded pattern as depicted in  FIG. 9  creates a top portion  910  of the food packaging according to the invention. This assembled top portion  910  is shown in  FIGS. 10, 11, 12 and 13 . As shown in  FIGS. 9, 10, 11 and 12 , this illustrative pattern has setting tabs  906  that interface with the radial depressions  807  of the bottom portion  810  (shown in shown in  FIGS. 8, 10, 11 and 12 ). The setting tabs  906  allow the top portion of  910  and bottom portion  810  to remain in an expanded volume after the expansion of a food product within the first and second portion allowing one to use the food package according to the invention as a serving container. The interlocking tabs  905  allow for the top end of the top portion to be opened after the expanded food product is in its ready to consume state allowing access to expanded volume of a food product that is ready to consume. It is contemplated within the scope of the invention that the top portion  910  and bottom portion  810  in  FIGS. 8, 9, 10, 11 and 12  can be utilized for expandable food products such as popcorn. It is further contemplated within the scope of the invention that any expandable food product may be packaged within the top portion  910  and bottom portion  810  depicted in  FIGS. 8, 9, 10, 11 and 12 . 
     According to the invention,  FIGS. 8 and 9  provides a food package  701  having a first portion, a second portion, and at least one indicator. The first portion has a first closed end, at least one first side wall surrounding the first closed end, and a first open end opposite the first closed end. The second portion has a second closed end, at least one second side wall surrounding said second closed end, and a second open end opposite the second closed end. The first portion and second portion are movably connected at their respective open ends. The at least one indicator is placed in communication with the package such that when the package is expanded to a desired inner volume the indicator is activated. The first or second portion that is a top portion of the food package has a closed end that can be opened with the package is expanded to a desired inner volume allowing access to the expanded food product. 
       FIGS. 8 and 9  depict the pattern as producing a first and/or second portion having a square/rectangular cross section. However, in other embodiments of the pattern may produce a first and/or second portion having any cross sectional shape may be used, for example, a cross section that is circular, square, rectangular, octagonal, triangular, hexagonal, pentagonal, or any combination thereof. 
     Another embodiment of the method of packaging further includes providing a package having interface portions, which prevent the package from expanding to far and separating the first and second portions apart. Providing a package with interface portions includes providing a first portion with at least one first interface portion at the first open end of the first portion and a second portion with at least one second interface portion at the second open end of the second portion. 
     Another embodiment of the method of packaging includes the step of sealing the food product in a bag  703 . Sealing the food product in bag, within the package, prevents the food product from becoming contaminated during the storage, transportation, and manufacturing of the packaged food product. Furthermore, the food product can be sealed in a plastic bag, a thermoplastic bag, a foil or metallic bag, a paper bag, a bag having the desired barrier properties such as moisture or gas barrier properties, any other contamination preventing covering, or any combination thereof. Optionally, the step of sealing the food product in a bag  703  may further include sealing the food product in a bag having a large enough volume to expand the packaging enough to activate an indicator, allowing the food product to expand within the bag and reach the desired volume. 
     According to the invention, the patterns forming the food package are made from standard virgin fiber paperboard that is food grade. It is contemplated within the scope of the invention that the patterns may be made from card stock, paperboard, polymers and combinations thereof. It is further contemplated within the scope of the invention that layered materials containing layers of paper and polymeric films may form the material that the patterns are made from. 
     While the invention has been described and illustrated in connection with preferred embodiments, many variations and modifications will be evident to those skilled in the art and may be made without departing from the spirit and scope of the invention. The invention is thus not to be limited to the precise details of methodology or construction set forth above as such variations and modification are intended to be included within the scope of the invention.