Abstract:
A food container and its method of use are disclosed. The food container includes a top panel, bottom panel and plurality of sidewalls. A movable panel is hingedly connected to one of the sidewalls, allowing a consumer to open the container. Attached to the lower edge of the movable panel is a shelf supporting a food item. A consumer can access the food item by opening the movable panel, which causes the shelf to carry the food item outside the container into a position that permits the consumer to easily manipulate it. The food item or a portion thereof can then be replaced in the container by simply closing the movable panel. The shelf may engage one or more sidewalls of the bottom panel to assist in maintaining the container in a closed position after initial opening and reclosing. The container is suitable for packaging food items that include both microwaveable and non-microwaveable ingredients. A foldable blank for manufacturing the container is also disclosed.

Description:
This is a division of prior application Ser. No. 09/234,686, filed Jan. 21, 1999, now U.S. Pat. No. 6,063,415, which is hereby incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The present invention relates generally to food containers, and more particularly, to a microwaveable food container. 
     BACKGROUND OF THE INVENTION 
     In providing a container for commercial packaging of food products, among the considerations that must be addressed are the ability of the container to receive the product in packaging operations, the degree of difficulty that will be encountered by the consumer in removing the product from the container, and the ability of the container to withstand various loads during filling, sealing, shipping, display and consumer use, without being damaged or unduly distorted or disfigured. Containers for food products must be capable of maintaining a closed, sealed configuration and an undamaged appearance until opened by the consumer. Even if the container is functionally intact, an appearance that the container is damaged or that it is not properly closed and sealed may make the product unacceptable to consumers. 
     Containers for consumer food products must also be capable of being opened without undue difficulty. Packaging which does not require the use of a knife, scissors, or other sharp implements can provide a significant advantage in the marketplace. 
     Microwaveable packaging must satisfy additional criteria. Packaging that is required to hold food products during microwave cooking may need to withstand short term exposure to microwave radiation, heat, steam, and/or hot water while maintaining a required degree of strength and rigidity, and without being subject to arcing, delamination, loss of integrity, or melting. In addition, microwaveable packaging may be required to contain one or more reflectors, shields, susceptors, or other elements intended to affect the cooking process. 
     Another significant consideration is that, in some cases, the food product is to be removed from the packaging prior to cooking, then replaced after removing a portion of the food product or the packaging. Thus, in some cases, the packaging must be capable of initial opening, reclosing, and reopening. Ease of use with respect to each of these steps can provide a package with a significant advantage. 
     It is a general advantage of the invention to provide a microwaveable container for consumer packaging of microwaveable food products which satisfies the above discussed criteria, and which offers enhanced capabilities with respect to initial opening, reclosing and reopening. 
     SUMMARY OF THE INVENTION 
     The invention provides a novel and improved microwaveable container for microwaveable food products having a movable support to facilitate handling of food products by the consumer. In particular, the container facilitates initial opening of the container, removal and replacement of one or more food items, and employment of the container as a holder for the food product(s) during cooking in a microwave oven, and removal of the food product(s) after cooking. The container may be particularly useful in the context of multiple-component food products, wherein one or more components is intended to be cooked, and one or more other components is not intended to be cooked, by facilitating selective removal and/or replacement of individual components. 
     The movable support may be a shelf which overlies the bottom panel of the container in frictional engagement therewith so that, after initial opening and reclosing, the weight of the food product on the shelf maintains the container in a closed position. Also, the shelf may have an edge portion which engages one or more sidewalls to aid in maintaining the container in a closed configuration after reclosing. 
     In the preferred embodiment of the invention, the food container includes a top panel, a bottom panel, and a plurality of sidewalls. A movable panel is hingedly connected to one of the sidewalls, allowing a consumer to open the container. 
     In the preferred embodiment of the invention, the food container includes a top panel, a bottom panel, and a plurality of sidewalls. A movable panel is hingedly connected to one of the sidewalls, allowing a consumer to open the container. Attached to the lower edge of the movable panel is a movable support for supporting a food item. A consumer can access the food item by opening the movable panel, which in turn causes the movable support to carry the food item outside the container into a position that permits the consumer to easily separate any non-microwaveable ingredients. The microwaveable portion can then be replaced in the container by simply closing the movable panel. After heating the enclosed food, the consumer can easily withdraw the heated microwaveable portion by again manipulating the movable panel. 
     The present invention also provides a foldable blank for inexpensively constructing a container as described above, and a unique method of preparing a food item packaged in the container. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a food container in accordance with a first embodiment of the present invention; 
     FIG. 2 is a perspective view of the food container of FIG. 1 shown in an open position; 
     FIG. 3 is a top plan view of the blank from which the container of FIGS. 1-2 is constructed; 
     FIG. 4 is perspective view of a food container in accordance with a second embodiment of the present invention; 
     FIG. 5 is a perspective view of the container of FIG. 4 shown in an open position; and 
     FIG. 6 is a top plan view of the blank from which the container of FIGS. 4-5 is constructed. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention is generally embodied in a food container and in a method of preparing a food product packaged in the container. 
     Referring now to the drawings, and more particularly, to FIGS. 1 and 2, there is illustrated a food container  10  that conforms to a first embodiment of the present invention. The container  10  is preferably made of paperboard material or another material having sufficient strength, stiffness and durability to withstand loads associated with shipping, handling, etc., in commercial use. The container is also preferably capable of withstanding exposure to microwave radiation, heat, steam, and hot water during microwave cooking of a food product contained therein. In FIG. 1, the food container  10  is shown in the closed position; while in FIG. 2 it is shown in an open position. The food container  10  includes an octagonal top panel  12  and a generally polygonal bottom panel  14 , which is substantially parallel to the top panel  12 . The container  10  also includes a plurality of sidewalls  16   a-e  attached between the top and bottom panels  12 - 14 . A movable panel  18  is hingedly connected to an end  20  of one of the side panels  16   a.  Projecting from the lower edge of the movable panel  18  toward the interior of the container  10  is a movable support which may be a shelf  22  for supporting a food item  19 . The shelf  22  is slidable over the upper surface of the bottom panel  14  as the movable panel  18  is moved between the open and closed positions. 
     The movable panel  18  is retained in the closed position by two tear strips  32 ,  44 . The tear strips are included in two adhering flaps  23 ,  34 . The first adhering flap  23  is joined to the top panel  12  at fold line  24 . The flap  23  includes a pair of weakening lines  25 ,  26  which divide the flap  23  into an upper panel portion  29  and a lower panel portion  30  with the area between the weakening lines  25 ,  26  being the tear strip  32 . An adhesive can be disposed upon the lower portion  30  for adhering the same to the lower exterior surface of the movable panel  18 . 
     The second adhering flap  34  is located at the unhinged end of the movable panel  18 . The flap  34  includes a pair of vertical weakening lines  36 ,  38  that divide the flap  34  into an adhering portion  40  and an inner portion  42  with a vertical tear strip  44  between the weakening lines  36 ,  38 . An adhesive disposed upon the interior surface of the adhering portion  40  can be used to secure the same to the exterior surface of the sidewall  16   e.    
     To remove the food item  23  from the interior of the container  10 , the horizontal tear strip  32  is grasped at its end  45 , and a pulling force applied thereto severs the same along the weakening lines  25 ,  26  in a manner as shown in FIG.  1 . The vertical tear strip  44  is removed in a similar manner. The tear strip  44  is grasped by its upper end  46  and a pulling force is applied to sever the strip  44  along the weakening lines  38 ,  36 . Upon removal of the tear strips  32 ,  44  the movable panel  18  is free to hinge or pivot laterally as viewed in FIG. 2, about the sidewall end  20 . 
     Once the container  10  is opened, the food item  19  can be manipulated by the consumer. For instance, with the panel  18  in the open position as shown in FIG. 2, the consumer can easily separate microwaveable and non-microwaveable portions of the food item  19 . After separating the ingredients, the microwaveable portion can be conveniently enclosed in the container  10  by simply closing the movable panel  18 . Replacing the food in the container  10  prior to heating greatly reduces the cooking time, as well as the possibility of mess caused by spattering. 
     The shelf  22  can overlie the bottom panel  14  of the container  10  in frictional engagement therewith so that, after initial opening and reclosing, the weight of the food product on the shelf  22  maintains the container  10  in a closed position. Also, the shelf  22  may have an edge portion which engages one or more sidewalls to aid in maintaining the container in a closed configuration after reclosing. 
     Referring now to FIG. 3, a blank  50  is shown which can be used to form the container  10  of FIGS. 1 and 2. The blank  50  is illustrated as a sheet of material, such as cardboard, defining the top panel  12 , which is set off by fold lines  52 ,  54 ,  56 ,  58 , and  60  to impart an octagonal shape thereto. Four flanges  62 ,  64 ,  68 , and  70  are joined to the top panel  12  by the respective fold lines  52 - 60 . In constructing the container, adhesive is disposed upon the flanges  62 - 70  to attach them to the upper interior surfaces of the respective sidewalls  16   a-b,    16   d-e.    
     The bottom panel  14  is set off by fold lines  72 ,  74 ,  76 ,  78 , and  80 , which impart a generally polygonal shape thereto. The bottom panel  14  includes a curved edge  82  that extends toward the opening of the container  10 . Four flanges  84 ,  86 ,  88 , and  90  are joined to the bottom panel  14  by the respective fold lines  72 - 80 . In constructing the container  10 , the bottom flanges  84 - 90  are attached to the lower interior surfaces of the side panels  16   a-b,    16   d-e  using an adhesive disposed thereupon. 
     The middle sidewall  16   c  is joined to the top and bottom panels  12 ,  14  at fold lines  56 ,  76 . The sidewalls  16   a-e  are set off from each other by fold lines  92   a-d.    
     The movable panel  18  is joined to the sidewall  16   a  by the fold line  20 . The fold line  20  can be formed in a manner to produce a living hinge, which allows the movable panel  18  to axially pivot about the fold line  20 . The movable panel  18  includes a plurality of vertical panels  94   a-c  being set off by fold lines  96   a-c.  To permit a flush fit with the container body when the movable panel  18  is in the closed position, the vertical panels  94   a-c  have a vertical height that is slightly less than that of the sidewalls  16   a-e.    
     The slidable shelf  22  has a generally polygonal shape that is set off by fold lines  98 ,  100 ,  102 . Flanges  104  and  106  are joined to the slidable shelf  22  at the respective fold lines  98 ,  102 . The slidable shelf is joined to the middle vertical panel  94   b  at fold line.  100 . An adhesive can be disposed on the flanges  104 ,  106  permitting them to be attached to the lower inner surface of the vertical panels  94   a, c.  This allows the slidable shelf  22  to maintain a substantially normal relationship to the vertical panels  94   a-c  of the movable panel  18 . 
     FIGS. 4 and 5 show a food container  120  that is in accordance with a second embodiment of the present invention. In FIG. 4, the container  120  is shown in the closed position; while in FIG. 5, it is shown in the open position. Food container  120  includes a generally square top panel  122  and a generally square bottom panel  124  that is substantially parallel to the top panel  122 . The container  120  also includes a plurality of sidewalls  126   a-c  attached between the top and bottom panels  122 ,  124 . A movable panel  128  is hingedly connected at an end  130  of one of the side panels. Projecting from the lower edge  132  of the movable panel  128  is a shelf  134  supporting a food item  136 . The shelf  134  is slidable over the upper surface of the bottom panel  124  as the panel  128  is moved between the open and closed positions. 
     Joined to the bottom panel  124  is an adhering flap  138  for retaining the movable panel  128  in the closed position. The adhering flap  138  includes a pair of horizontal weakening lines  140 ,  142  that divide the flap  138  into an upper panel portion  144  and a lower panel portion  146  with the area between the weakening lines  140 ,  142  defining a horizontal tear strip  148 . In constructing the container  120 , adhesive is disposed upon the interior surface of the upper portion  144  to attach it to the upper exterior surface of the movable panel  128 . 
     The sidewall  126   a  includes a finger insert  166  at its end adjoining the movable panel  128 . The finger insert  166  is defined by a generally vertical weakening line  168  formed in the sidewall  126   a  between the top and bottom panels  122 ,  124 . The weakening line  168  also defines a flange  170  having a tab  172 . The flange  170  is attached to the exterior surface of the movable panel  128  using an adhesive. In constructing the container  120 , the flange  170  is sandwiched between the adhering flap  138  and the movable panel  128 . 
     The shelf  134  includes a retaining tab  160  projecting from its outer curved edge  162 . As the shelf  134  is moved from the closed position into the open position, the retaining tab  160  is received by a slot  164  formed at the lower edge of the sidewall  126   a.  This arrangement prevents the shelf  134  from being easily moved beyond a position that is supported by the bottom panel  124  and lower portion  146  of the adhering flap  138 . 
     FIG. 6 is a top plan view of a blank sheet of material, such as cardboard, that can be folded into the container  120  shown in FIGS. 4 and 5. The top panel  122  is set off by fold lines  182 ,  184 ,  186  and a weakening line  188 , imparting a generally square shape thereto. An interior sidewall  190  is joined to the top panel  122  at fold line  184 . An adhesive can be disposed on the underside of the interior sidewall  190 , permitting attachment to the interior surface of the back sidewall  126   b.    
     The sidewall  120  is joined to the top panel  122  at fold line  186 . Two flanges  192  and  194  are joined at the ends of the side panel  126  by fold lines  196 ,  198 . Fold line  196  can be used to form a living hinge connecting the movable panel  128  to the side panel  126   c.  In constructing the container  120 , adhesive is disposed on the upper surface of the flange  192  to attach it to the exterior surface of the movable panel  128 , while adhesive can be used to attach the under surface of the flange  194  to the interior side of sidewall  190 . 
     The side panel  126   a  is joined between the top panel  122  and the bottom panel  124  by fold lines  182 ,  200 . The tabbed flange  170  is detachably joined to the side panel  126   a  by the weakening line  168 . The flange  202  is joined to the opposite end of the side panel  126   a  by fold line  204 . Adhesive can be disposed upon the under surfaces of the flanges  170 ,  202  so that they can be respectively attached to the exterior surface of the movable panel  128  and interior surface of the interior side panel  190 . 
     The bottom panel  124  is set off by fold lines  200 ,  204 ,  206  and  208 , imparting a generally square shape thereto. The side panels  126   a-b  are joined to the bottom panel  124  at fold lines  200 ,  208 ; while the adhering flap  138  is joined to the bottom panel  124  at fold line  204 . A flange  210  is joined to the bottom panel  124  at fold line  206 . Adhesive can be disposed on the under surface of the flange  210  so that it can be attached to the interior surface of the side panel  126   c.    
     The slidable shelf  134  is joined to the movable panel  128  by perforated fold line  212 . The fold line  212  includes a series of slits for weakening the fold. This reduces the tendency of the movable panel  128  to pivot downwardly about the fold line  212  when the panel  128  is released from the closed position. In turn, this allows the movable panel  128  to maintain a relatively perpendicular relationship to the shelf  134  in the open position. 
     The movable panel  128  is detachably joined to the top panel  122  by the weakening line  188 . Accordingly, the movable panel must be detached from the top panel  122  to access the contents of the container  120 . 
     To remove the food item  136  from the container  120 , the tear strip  148  is grasped by its end  158  and a pulling force is applied to sever the strip  148  along the weakening lines  140 ,  142  in the manner shown in FIG.  4 . Once the tear strip  148  has been removed, the lower portion  146  of the adhering flap  138  pivots downwardly as shown in FIG.  5 . The lower portion  146  provides additional support under the shelf  134  as it is moved into the open position. After removing the tear strip  148 , the movable panel  128  can be separated from the top panel  122 . This is accomplished by rupturing the sidewall  126   a  along the weakening line  168  to define the finger insert  166 . A finger is then inserted into the insert  166  to apply force against the interior surface of the movable panel  128 , thereby separating the movable panel  128  from the top panel  122 . The movable panel  128  axially pivots about fold line  196  to expose the food item  136  carried by the shelf  134 . Similarly to the container  10  shown in FIGS. 1 and 2, the exposed food item  136  can be manipulated and then conveniently re-enclosed in the container  120 . 
     While specific embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that the disclosed invention may be modified in numerous ways and assume many embodiments other than the preferred forms specifically set out and described above. Accordingly, it is intended by the appended claims to cover all modifications of the invention which fall within the true spirit and scope of the invention.