Patent Publication Number: US-10314429-B2

Title: Embossed paper-based bakeable tray

Description:
BACKGROUND 
     Paper-based, oven-ready or bakeable trays are well known in the art for baking, heating, or reheating foods. Such paper-based bakeable trays are commonly used by “take-and-bake” pizza companies. Paper-based bakeable trays are also used by makers of frozen pizza, partial baked “par-bake” and raw pizza dough. These paper-based bakeable trays include barrier coatings such that they are impermeable to liquids and can withstand typical oven temperatures. While these trays may serve their intended purpose, it has been found that when foods are baked in these conventional trays, the food may not cook uniformly. For example, when pizza is cooked on these conventional trays, that the pizza crust in the middle of the tray is often soft and doughy. Accordingly there is a need for a paper-based bakeable tray that promotes uniform cooking. 
     Additionally, conventional paper-based bakeable trays have a flat or substantially flat bottom. When the cooked food is allowed to sit in these flat bottom trays, the food often becomes soggy from condensation or from grease or other juices dripping from the food. Accordingly there is a need for a paper-based bakeable tray that minimizes or prevents the food baked within the tray from becoming soggy due to condensation or from sitting in its own juices while cooking or after cooking. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of one type of conventional paper-based bakeable tray with a flat bottom surface. 
         FIG. 2  is a perspective view of another type of conventional paper-based bakeable tray with raised contour surfaces in the form of a pinwheel pattern on the bottom surface of the tray. 
         FIG. 3  is a perspective view of yet another type of conventional paper-based bakeable with raised contour surfaces in the form of an octagonal pattern on the bottom surface of the tray. 
         FIG. 4  is a plan view of one embodiment of a paper-based bakeable tray similar to the conventional paper-based bakeable tray of  FIG. 1 , but with an embossing pattern comprising upward projections on the bottom surface of the tray. 
         FIG. 5  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 4  as viewed along lines  5 - 5  of  FIG. 4 . 
         FIG. 6  is a plan view of one embodiment of a paper-based bakeable tray similar to the conventional paper-based bakeable tray of  FIG. 1 , but with an embossing pattern comprising upward projections and downward depressions on the bottom surface of the tray. 
         FIG. 7  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 6  as viewed along lines  7 - 7  of  FIG. 6 . 
         FIG. 8  is a plan view of one embodiment of a paper-based bakeable tray with raised contour surfaces in the form of a pinwheel as in  FIG. 2 , but with an embossing pattern on one side of the bottom of the tray. 
         FIG. 9  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 8  as viewed along lines  9 - 9  of  FIG. 8 . 
         FIG. 10  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 8  as viewed along lines  10 - 10  of  FIG. 8 . 
         FIG. 11  is a plan view of one embodiment of a paper-based bakeable tray with raised contour surfaces in the form of a pinwheel as in  FIG. 2 , but with an embossing pattern comprising upward projections and downward depressions on the bottom surface of the tray. 
         FIG. 12  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 11  as viewed along lines  12 - 12  of  FIG. 11 . 
         FIG. 13  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 11  as viewed along lines  13 - 13  of  FIG. 11 . 
         FIG. 14  is a plan view of one embodiment of a paper-based bakeable tray with raised contour surfaces in the form of an octagonal pattern as in  FIG. 3 , but with an embossing pattern on one side of the bottom of the tray. 
         FIG. 15  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 14  as viewed along lines  15 - 15  of  FIG. 14 . 
         FIG. 16  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 14  as viewed along lines  16 - 16  of  FIG. 14 . 
         FIG. 17  is a plan view of one embodiment of a paper-based bakeable tray with raised contour surfaces in the form of an octagonal pattern as in  FIG. 3 , but with an embossing pattern comprising upward projections and downward depressions on the bottom surface of the tray. 
         FIG. 18  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 17  as viewed along lines  18 - 18  of  FIG. 17 . 
         FIG. 19  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 17  as viewed along lines  19 - 19  of  FIG. 17 . 
         FIG. 20  is a plan view of one embodiment of a paper-based bakeable tray with raised contour surfaces in the form of a pinwheel as in  FIG. 8 , but with an embossing pattern on one side of the bottom of the tray and located only between the contour surfaces. 
         FIG. 21  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 20  as viewed along lines  21 - 21  of  FIG. 20   
         FIG. 22  is a partial cross-sectional view of the embossed paper-based bakeable tray of  FIG. 20  as viewed along lines  22 - 22  of  FIG. 20 . 
     
    
    
     DESCRIPTION 
     Referring to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views,  FIG. 1  illustrates a conventional paper-based bakeable tray  10  having a bottom surface  12  and sidewalls  14 . The sidewalls may include a peripheral lip  16 .  FIG. 2  illustrates a conventional paper-based bakeable tray  10  having raised contour surfaces  20  formed in the bottom surface  12  in the form of a pinwheel pattern.  FIG. 3  illustrates a conventional paper-based bakeable tray  10  having raised contour surfaces  20  formed in the bottom surface  12  in the form of a an octagonal pattern. The conventional paper-based trays  10  are typically formed using a thermoforming process. As recognized and understood by those of skill in the art, barrier coatings or barrier materials may be applied to the paper-based material, before, during or after the thermoforming process or otherwise incorporated into the paper-based material such that the trays are impermeable to liquids and/or to withstand typical oven temperatures. 
       FIG. 4  illustrates an embossed paper-based bakeable tray  100  similar to the conventional paper-based bakeable tray  10  of  FIG. 1 . The embossed paper-based bakeable tray  100  has a bottom surface  112  and sidewalls  114 . The sidewalls  114  may include a peripheral lip  116 . However, unlike the conventional tray  10 , the embossed tray  100  includes an embossed pattern  102  formed in the bottom surface  112  of the tray.  FIG. 5  is a partial cross-sectional view of the tray  100  as viewed along lines  5 - 5  of  FIG. 4 . As used herein, the term “embossed pattern” should be understood to include any type of stamping, imprinting, pressing or forming process that creates a series of closely spaced intermittent projections as opposed to raised contour surfaces  20  as depicted in  FIGS. 2 and 3 . 
       FIG. 6  illustrates an alternative embodiment of an embossed paper-based bakeable tray  200  similar to the conventional paper-based tray  10  of  FIG. 1 , but with an embossed pattern  202  formed in the bottom surface  212  of the tray and wherein the embossed pattern  202  comprises both upward and downward projections  204 . The embossed paper-based bakeable tray  200  has sidewalls  214  which may include a peripheral lip  216 .  FIG. 7  is a partial cross-sectional view of the embossed tray  200  as viewed along lines  7 - 7  of  FIG. 6  showing the embossing pattern  202  comprising both the upward and downward projections  204 . 
       FIG. 8  illustrates an alternative embodiment of an embossed paper-based bakeable tray  300  similar to the conventional paper-based tray  10  of  FIG. 2  having raised contour surfaces  20  in the form of a pinwheel, but with an embossed pattern  302  formed in the bottom surface  312  of the tray and wherein the embossed pattern  302  comprises upward projections  304 . The embossed paper-based bakeable tray  300  has sidewalls  314  which may include a peripheral lip  316 .  FIG. 9  is a partial cross-sectional view of the embossed tray  300  as viewed along lines  9 - 9  of  FIG. 8 .  FIG. 10  is a partial cross-sectional view of the embossed tray  300  as viewed along lines  10 - 10  of  FIG. 8  illustrating the cross-sectional view of one of the raised contour surfaces  20  of the pinwheel pattern. As illustrated, the raised contour surfaces  20  of the pinwheel pattern include the embossed pattern  302 , but it should be appreciated that, if desired, the embossed pattern  302  may only be provided between the raised contour surfaces  20 . An embodiment of this configuration with the embossed pattern  302  existing only between the raised contour surfaces  20  is illustrated in  FIG. 20 . Similarly, a cross-sectional view is illustrated in  FIG. 21 , as viewed along lines  21 - 21  of  FIG. 20 . 
       FIG. 11  illustrates an alternative embodiment of an embossed paper-based bakeable tray  400  similar to the conventional paper-based tray  10  of  FIG. 2  having raised contour surfaces  20  in the form of a pinwheel, but with an embossed pattern  402  formed in the bottom surface  412  of the tray and wherein the embossed pattern  402  comprises both upward and downward projections  404 . The embossed paper-based bakeable tray  400  has sidewalls  414  which may include a peripheral lip  416 .  FIG. 12  is a partial cross-sectional view of the embossed tray  400  as viewed along lines  12 - 12  of  FIG. 11 .  FIG. 13  is a partial cross-sectional view of the embossed tray  400  as viewed along lines  13 - 13  of  FIG. 11  illustrating the cross-sectional view of one of the raised contour surfaces  20  of the pinwheel pattern. As illustrated, the raised contour surfaces  20  of the pinwheel pattern include the embossed pattern  402 , but it should be appreciated that, if desired, the embossed pattern  402  may only be provided between the raised contour surfaces  20 . 
       FIG. 14  illustrates an alternative embodiment of an embossed paper-based bakeable tray  500  similar to the conventional paper-based tray  10  of  FIG. 3  having raised contour surfaces  20  in the form of an octagonal pattern, but with an embossed pattern  502  formed in the bottom surface  512  of the tray and wherein the embossed pattern  502  comprises upward projections  504 . The embossed paper-based bakeable tray  500  has sidewalls  514  which may include a peripheral lip  516 .  FIG. 15  is a partial cross-sectional view of the embossed tray  500  as viewed along lines  15 - 15  of  FIG. 14 .  FIG. 16  is a partial cross-sectional view of the embossed tray  500  as viewed along lines  16 - 16  of  FIG. 14  illustrating the cross-sectional view of one of the raised contour surfaces  20  of the octagonal pattern. As illustrated, the raised contour surface  20  of the octagonal pattern includes the embossed pattern  502 , but it should be appreciated that, if desired, the embossed pattern  502  may only be provided between the raised contour surfaces  20 . 
       FIG. 17  illustrates a an alternative embodiment of an embossed paper-based bakeable tray  600  similar to the conventional paper-based tray  10  of  FIG. 3  having raised contour surfaces  20  in the form of an octagonal pattern, but with an embossed pattern  602  formed in the bottom surface  612  of the tray and wherein the embossing pattern  602  comprises both upward and downward projections  604 . The embossed paper-based bakeable tray  600  has sidewalls  614  which may include a peripheral lip  616 .  FIG. 18  is a partial cross-sectional view of the embossed tray  600  as viewed along lines  18 - 18  of  FIG. 17 .  FIG. 19  is a partial cross-sectional view of the embossed tray  600  as viewed along lines  19 - 19  of  FIG. 17  illustrating the cross-sectional view of one of the raised contour surfaces  20  of the octagonal pattern. As illustrated, the raised contour surface  20  of the octagonal pattern includes the embossed pattern  602 , but it should be appreciated that, if desired, the embossed pattern  602  may only be provided between the raised contour surfaces  20 . 
     Each of the embossed paper-based bakeable trays  100 ,  200 ,  300 ,  400 ,  500 ,  600  may be formed in the same manner using the same type of thermoforming press used to produce conventional paperboard trays  10  but with the desired embossing pattern formed in the face of the male and/or female dies used in the thermoforming press. The embossed trays may be used for a number of purposes and may take any desired shape. For example, rather than being a circular tray as shown, the tray may be rectangular or triangular or it may take the shape of the food product. 
     The embossing patterns  102 ,  202 ,  302 ,  402 ,  502 ,  602  comprises a series of closely spaced projections  104 ,  204 ,  304 ,  404 ,  504 ,  604  formed into the bottom surface  112 ,  212 ,  312 ,  412 ,  512 ,  612  of the paper-based embossed trays  100 ,  200 ,  300 ,  400 ,  500 ,  600 . The projections may be any suitable configuration, size and spacing. As an example, the projections may have a diameter of about 3/16 inch, and a height range between about 0.010 to about 0.040 inches, with a center-to-center spacing of about ½ inch. It should be appreciated, however, that the projections need not be round or circular and may have any desired size or shape, including any polygonal shape with widths and lengths or diameters between about ⅛ inch to about 1 inch, and may be spaced at distances ranging from about ⅜ inch to about 2 inches depending on the size of the projections. 
     The projections  104 ,  204 ,  304 ,  404 ,  504 ,  604  serve to intermittently support the food product thereby allowing air circulation below the food product so the food does not become soggy due to the collection of condensation, drippings or juices from the food as it is being cooked or after cooking. The projections also provide an air space which minimizes heat transfer via conduction thereby keeping the food warmer for a longer period of time. With the embossed trays having both upward and downward projections, the downward projections or depressions may permit additional air circulation and serve as small wells in which condensation, food juices or drippings are collected. 
     It has been found that paper-based bakeable trays having an embossing patterns as described herein improves the quality of certain foods when reheating or baking, due to the projections creating an air space and allowing more air circulation below the food. For example it has been found that if a conventional flat (non-embossed) paper-based bakeable tray having a flat bottom surface as in  FIG. 1  is formed with an embossing pattern as described herein, and if this embossed trays are then used to bake pizza, the resulting crust is more uniformly cooked, is crispier and has a more uniform golden-brown crust. It was also found that if a black colored, conventional flat (non-embossed) paper based bakeable tray such as illustrated in  FIG. 1  is formed with an embossing pattern as described herein so as to create a black embossed paperboard tray, the resulting crust is even crispier and more golden-brown. 
     The embossed trays  100 ,  200 ,  300 ,  400 ,  500 ,  600  may be made of premium grade solid bleached sulfate (SBS) or any other suitable type of paper, paperboard, cardstock or cardboard material or any other type of pulp-based, fiber-based or cellulose-based material, whether from wood, other plant or natural material or from synthetic material. 
     Depending on the application and intended use of the embossed trays  100 ,  200 ,  300 ,  400 ,  500 ,  600  and the type of food it is intended to contact, the embossed trays may include appropriate barrier coatings as well known to those of skill in the art such that the embossed trays are suitable for baking, heating, or reheating foods. Additionally, or in the alternative, the embossed trays may include barrier coatings such that the embossed trays are freezer-to-oven ready and/or impermeable to liquids. 
     The foregoing description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the embodiments of the apparatus and the general principles and features described herein will be readily apparent to those of skill in the art. Thus, the present invention is not to be limited to the embodiments described above and illustrated in the drawing figures, but is to be accorded the widest scope consistent with the spirit and scope of the appended claims.