Patent Description:
Frozen foods are easy to store, transport, and serve. Other types of foods are also sold in stores as pre-prepared and ready for immediate cooking or microwaving. The packaging of these foods typically uses a clear plastic film that covers the food product inside the food container or bowl, as well as an outer package or box in which the food container is housed. In use, the consumer must open the box, cut or remove the plastic film in order to vent the food during cooking, cook/microwave the food, then discard the box and film. There are, however, instances when the film is not properly vented or when the user does not have the proper tool (e.g., knife or scissors) to vent the film, causing undesirable mistakes in the food cooking process. Providing both a plastic film and a packaging box also creates undesirable waste. Accordingly, improvements in the packaging of pre-prepared food products are desirable. For example, in <CIT> to a predecessor of the present applicant, there is disclosed a three-panel lidding device used to seal a food container which eliminates the need for any clear film membrane that traditionally covers a food container. The conventional techniques have been considered satisfactory for their intended purpose. The devices of US '<NUM> are also considered satisfactory for their intended purpose. However, there is an ever present need for improved systems and methods for packaging food such as pre-prepared food products. This invention provides a solution for this need, by providing systems and methods as described herein to seal containers, such as for frozen food products, and to provide for handling the containers when open with hot food products therein.

According to a first aspect of the invention for which protection is sought, there is provided a food package suitable for heating in a microwave as defined in claim <NUM>. The food package comprising a food container and a lidding device. The lidding device includes a first panel comprising a lid covering and sealing the food container. At least the first panel comprising a thermoplastic or heat sealable coating applied to a food-facing side thereof and being, at least in part, heat-sealingly bonded to the food container. A second panel is foldably connected to the first panel. A third panel includes a bottom panel opposite the lid. The second panel is foldably connected to the first panel and the third panel. A fourth panel is foldably connected to at least one of the first panel and the third panel, whereby the food container is at least partially enclosed between the second and fourth panels. An insulation space is defined between the food container and at least one of the first, second, third, and fourth panels. The insulation space provides a convenient means of handling the food package after heating in a microwave.

Optionally, side flaps may be foldably connected to at least one of the first and third panels configured for adhering the first panel to the third panel. The first panel, second panel, third panel, fourth panel, and side flaps can completely enclose the food container.

It is also contemplated that two opposed panels can be foldably connected to the first panel, wherein each of the two opposed panels includes a cutout which receives a respective edge of the food container.

The first panel can include a venting system including one or more lines of weakness along an edge of the first panel for venting the first panel. The first panel can include a pull tab for peeling back the first panel along one or more lines of weakness along the first panel edges. The second panel can be configured for use as a foot that allows the lidding device to stand upright on the second panel. At least one of the panels can be configured to be printable for printing product identifying material or instructions thereon. The first panel comprises a thermoplastic or heat sealable coating applied to a tood-facing side thereof. The thermoplastic coating can comprise a polyolefin dispersion or a polymeric-based film.

The panels of the lidding device may be formed from paperboard material having one or more coatings thereon, which one or more coatings can comprise a clay coating. The paperboard material can be pre-printed with marketing graphics with heat resistant microwaveable inks and/or overprint.

These and other features of the food package of the present invention will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the food package of the present invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:.

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an embodiment of a lidding device, known from the Prior Art, is shown in <FIG> and is designated generally by reference character <NUM>. Other embodiments of systems, known from the Prior Art, are described below and illustrated in the associated <FIG>. Then, embodiments of the present invention are described with reference to the drawings provided in <FIG>. The systems and methods described herein can be used to seal containers, such as for frozen food products, and to provide for handling the containers when open with hot food products therein.

The figures illustrate various embodiments of a lidding device <NUM>. As shown in the <FIG>, the lidding device <NUM>, known from the Prior Art, comprises three panels: a first panel <NUM> separated from a third panel <NUM> by a second panel <NUM>. Any of the panels may include marketing materials, product identifiers and information, or graphics. The first panel <NUM> forms a lid that covers and seals the contents of a food container <NUM>. The second panel forms a foot <NUM> that is useful for display purposes. The third panel <NUM> provides a base panel.

A thermoplastic or heat seal coating is applied to the food-facing side of the first panel <NUM>, which is the side that interacts with the container <NUM> to seal the contents of the container. The heat-seal coating is applied at suitable places around the panel. This coating also acts as a barrier to protect the lid from water/oils in the product(s) stored in the container <NUM>. In some embodiments, the thermoplastic coating is a polyolefin dispersion, although other water or solvent-based coatings that provide a suitable seal between the device and the container may be used. For example, polymeric based films, which may be adhesively laminated to the paperboard blank or directly extrusion coated to the blank, may be used. In some embodiments, the heat sealable coating is applied to the underside of substantially the entirety of the first panel <NUM> so that it faces and covers/seals the contents of the container. In some cases, the coating consists of a heat sealable adhesive that is applied to the paperboard blank as part of production before the blank is cut, and in other cases is applied afterwards. The coated paperboard is configured to withstand a range of environmental conditions relating to manufacture, transportation, storage (which may include freezing), sale, and use of the product, which may include defrosting and/or heating (such as by microwave oven, conventional oven, convection oven, and/or toaster oven) of the product stored within the food container. The coated paperboard is also configured to be safe for contact with food products in compliance with <NUM> CFR <NUM>.

One specific embodiment of a lidding device <NUM>, known from the Prior Art, that is useful for covering and sealing a food product container <NUM> is illustrated by <FIG>. Appropriate food product containers <NUM> are typically made of plastic, but may be made of any appropriate material that can house and store food, and that also allow the food to be cooked therein. Such containers are commonly recognizable as the type of containers that are used for microwavable food products, but they may also be used in conventional ovens, toaster ovens, or convection ovens.

The lidding device <NUM> that is used to cover and protect the food contained in the container <NUM> is typically made of paperboard, but may be made of any printable, foldable, fiber-based substrate. In a particular embodiment, the lidding device <NUM> is made of a two-sided clay coated SBS (Solid Bleached Sulfate) having an appropriate coating as described above applied thereto, although it should be understood that any food-safe lidding material may be used.

The lidding device <NUM> provides a three-panel system that covers the top and bottom of the food container <NUM>, as well as provides a side panel that functions as a connecting panel, which also provides a display function. As shown in <FIG>, a first panel <NUM> is provided to form the cover or lid panel of the lidding device. The first panel may have an opening feature that allows for venting during the heating process. For example, first panel may have a venting system <NUM>, as will be described in more detail with respect to further figures, and venting system <NUM> maybe provided in a number of ways. For example, the venting and/or opening feature may include lines of weakness that are configured to be broken and/or removed or displaced to provide ventilation. Optionally, a pull-tab or tear strip adjacent the opening feature may be used to move the opening feature into its vent position.

Specifically, as shown in <FIG>, first panel <NUM> has one or more lines of weakness <NUM> provided along its edge areas <NUM>, which allows the first panel <NUM> to be removed before, during and/or after the cooking process. Lines of weakness <NUM> may be provided as perforations, score lines, partial cuts, reverse partial cuts, or any other feature that allows the first panel <NUM> to be broken, removed or displaced upon application of the appropriate amount of pressure. These lines <NUM> may assist with the venting, but they may also be used to remove the entire lid panel <NUM> from the container <NUM>, as shown in <FIG>.

<FIG> also shows an embodiment of a venting system <NUM> that is created via cooperation between a pull tab <NUM> and a score line <NUM>. In use, the user grasps pull tab <NUM> and pulls a portion of the panel lid <NUM> back to the area where the score line <NUM> is located in order to create an opening in the panel lid <NUM>. The pull tab <NUM> is generally located near the side of the panel where the venting score line <NUM> is located. The pull tab <NUM>/score line <NUM> system may be provided near the right side of the panel <NUM> (<FIG>), along the left side of the panel <NUM> (<FIG>) or along the top (or bottom) of the panel <NUM> (<FIG>). Pull tab <NUM> may be any appropriate shape, such as a rectangular tab (<FIG> and <FIG>) or a rounded protrusion (<FIG>). As the edge portion of the panel lid is pulled back, the lines of weakness <NUM> that secured the lid in place are disrupted, and they allow a peeling back of the lid portion to the score line <NUM>. It is also possible to create further lines of weakness <NUM> that extend between the tab <NUM> and the score line <NUM>, in order to further ease the peeling back of the lid, if desired or necessary.

In an alternate embodiment, no tab is required, but a line of weakness <NUM> is provided as the venting system <NUM>, as shown in <FIG>. In use, finger pressure may be used along the venting line of weakness <NUM> to create the desired opening. This line of weakness <NUM> may be formed as a shape <NUM> that could be peeled back or punched out/removed completely, as shown in <FIG>. Alternatively, this portion may be provided as a single perforated line <NUM> that is punctured to create a venting slit or hole, as shown in <FIG>.

In a further embodiment of the prior art, a pull open tear strip <NUM> may be provided, as shown in <FIG>. The pull open tear strip <NUM> features a thumb tab <NUM> connected to a tear strip feature <NUM> that travels along an edge of the panel lid <NUM>. In an alternate embodiment, known from the Prior Art, as shown in <FIG>, instead of a thumb tab, there is a puncturable/covered opening <NUM> provided in the lid where a thumb may punch out the removable portion, insert a thumb, and grasp the tear strip feature <NUM>.

In a further embodiment, there may be provided a push to vent feature in the lid. One embodiment of a simple push to vent feature, known from the Prior Art, is shown in <FIG>, where the opening <NUM> is created by thumb pressure along the perforated line. More fully developed embodiments of push to vent features are shown in <FIG>. For example, <FIG> shows a push to vent feature <NUM> which is adjacent to a pull to open feature <NUM>. The user may press at the push to vent <NUM> portion in order to create a venting area. Once the cooking/heating process has been completed, the user may then grasp the pull to open portion <NUM> to remove the lid from the food container.

An alternate embodiment of a push to vent feature, known from the Prior Art, is shown in <FIG>. This figure illustrates back-to-back push to vent <NUM> and pull to open <NUM> areas. A further embodiment, known from the Prior Art, provides a pinch to open feature <NUM>, as shown in <FIG>. In this embodiment, two push to vent features are provided as semi-circles <NUM> formed as perforations in the lid. After the semi-circles <NUM> are pressed in for venting during cooking/heating, they may be used to pinch the lid to open. The space <NUM> between the semi-circles creates somewhat of a handle for the user to raise the lid.

Although a number of alternate embodiments for venting system are shown and described, it should be understood that any configuration that provides a venting system may be used in connection with the three-panel lid disclosed herein. Regardless of the embodiment provided, upon appropriate pressure or pulling at the venting system <NUM>, the first panel <NUM> opens or separates from the container <NUM>, allowing air to vent into and from the food container during cooking. In some embodiments, the first panel is removed before serving and consumption. Once the food has cooked completely, the entire panel lid <NUM> may be removed, as shown in <FIG>. The edge lines of weakness <NUM> may assist with this removal.

<FIG> illustrates that alternate shapes and sizes for the panels may be provided, depending upon the shape and size of the container to be lidded. In general, however, the first panel <NUM> is generally shaped to cover a food product container <NUM>, albeit slightly larger than the opening of the container so that the entire opening of the container <NUM> is covered. The tabs may be positioned at any appropriate location, the score lines may be interchanged for perforations and vice versa, and alternate venting systems may be provided.

Reference is now made back to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, which show embodiments, known from the Prior Art, of the lidded device blank prior to its being folded, shaped, and enclosing a container <NUM>. A second panel <NUM> is connected to the first panel <NUM>. As shown in <FIG>, second panel <NUM> is positioned between and separates the first panel <NUM> and the third panel <NUM>. The connection areas are generally via either score lines <NUM> or small cuts or perforations <NUM> in the blank that allow easy removal of the second panel <NUM> from the first and third panels <NUM>, <NUM> in use. Although score lines <NUM> are shown in some figures are perforations <NUM> in others, it should be understood that these features may be interchangeable and/or used collectively.

The second panel <NUM> generally forms a side or bottom panel (depending upon how the device <NUM> is positioned). In some embodiments, the second panel is configured to serve as a foot <NUM> that keeps the bowl upright, as shown in <FIG>. Once the lidded device <NUM> is folded and positioned with respect to a food container <NUM>, the foot <NUM> can be used to allow the device <NUM> to stand thereon, such that the device can be easily stacked in a freezer, refrigerator, or shelf section, while still displaying the package printing and taking up less space than if the containers were stacked vertically.

Any or all of the panels have at least one (or both) side(s) that are configured to be printable for printing product identifying material and/or instructions thereon. For example, the non-food facing side of the first panel <NUM> generally contains brand and product messaging or images, while additional information, such as a list of ingredients and cooking and/or opening instructions, may be included on another panel, such as the second and/or or third panels.

Also disclosed is a method of forming a lidding device. The device may be formed using standard paperboard forming machinery to form a die-cut blank, having various lines of weakness, such as score lines and/or perforations, positioned thereon. A clay coating is then applied to the blank. Next, the suitable thermoplastic heat seal coating is applied to one side of the blank, which will generally be the food-facing side of at least the first panel <NUM>. Alternatively, the thermoplastic heat seal coating may be applied during manufacture of the paperboard out of which the blank is cut. The paperboard may be printed with heat resistant microwaveable inks and/or overprint. Moreover, the blank used to form the lidding device may be die cut to a customer's specifications, depending upon the shape of the food container to be covered and sealed.

In use, the container <NUM> is filled with food (or other product) and the lidding device <NUM> is folded and formed from the blank and wrapped around the container <NUM>. Heat sealing equipment may then be used to activate the heat sealable coating to bind the paperboard to the container. In other embodiments, ultrasonic or radio frequency sealing technology may be used to activate the heat sealable coating. This may be done using any suitable machinery or method.

Referring to <FIG>, <FIG> and <FIG>, an embodiment according to the present invention is illustrated. The blank <NUM> for a lidding device <NUM> (shown in <FIG>, erected from the blank <NUM> of <FIG>) includes a first panel <NUM> comprising a lid <NUM> configured to cover and seal a food container <NUM>. A second panel <NUM> is foldably connected to the first panel <NUM>. A third panel <NUM> includes a bottom panel opposite the lid <NUM> when the blank is erected as shown in <FIG>. The second panel <NUM> is foldably connected between the first panel <NUM> and the third panel <NUM>. A fourth panel <NUM> is foldably connected the third panel <NUM>, and a fifth panel <NUM> is foldably connected to the first panel <NUM>. When the blank <NUM> is erected as shown in <FIG>, the fourth and fifth panels <NUM> and <NUM> are adhered together to form a single panel that is opposite the second panel <NUM> for at least partially enclosing the food container <NUM> between the second and fourth panels <NUM>, <NUM>.

With continued reference to <FIG> and <FIG>, the food container <NUM> is sealed to the first panel <NUM> around a sealing perimeter <NUM> around the lid <NUM>. The food container <NUM> enclosed between first panel <NUM> and the third panel <NUM>, as well as between the second panel <NUM> and the fourth panel <NUM>. An insulation space <NUM> (identified in <FIG> and <FIG>) is defined between the food container <NUM> and each of the first, second, third, and fourth panels <NUM>, <NUM>, <NUM>, <NUM>. Side flaps <NUM>, <NUM> are foldably connected to at least one of the first and third panels <NUM>, <NUM> configured for adhering the first panel <NUM> to the third panel <NUM> (e.g. by adhering the flaps <NUM>, <NUM> to the respective sections <NUM>, <NUM> of the third panel <NUM>. The corner sub-panels <NUM> of the first, second, third, fourth, and fifth panels <NUM>, <NUM>, <NUM>, <NUM>, <NUM> are used to form the recessed corners <NUM> when the blank <NUM> is erected as shown in <FIG>. The first panel <NUM>, second panel <NUM>, third panel <NUM>, fourth panel <NUM>, and side flaps <NUM> completely enclose the food container <NUM>. The blank <NUM> thus forms a paper container in a lidding device that includes the food container <NUM>. The paper container surrounds the food container <NUM> on at least four sides of the food container, and there is an insulation space <NUM> is defined between the food container <NUM> and the paper container.

With reference now to <FIG>, another embodiment of a blank <NUM> and lidding device <NUM> according to the present invention is shown. A first panel <NUM> defining a lid <NUM> is foldably connected to a second panel <NUM>, which is foldably connected to a bottom or fourth third panel <NUM>. A fourth panel <NUM> is foldably connected to the first panel <NUM> and can be connected to the third panel <NUM> adhering the adhesive flap <NUM> (that is foldably connected to the fourth panel <NUM>) to the third panel <NUM> to erect the blank <NUM> into the lidding device <NUM> of <FIG>. The reinforcement flap <NUM> is foldably connected to the third panel <NUM> to form a foot <NUM> that can be used to stand the lidding device <NUM> upright relative to the position shown in <FIG>. Two opposed panels <NUM>, <NUM> are each connected to the second, third, and fourth panels <NUM>, <NUM>, <NUM> in the assembled lidding device; and the two opposed panels <NUM>, <NUM> are foldably connected directly to the first panel <NUM>. Each of the two opposed panels <NUM>, <NUM> includes a respective cutout <NUM>, which receives a respective protruding corner or edge <NUM> of the food container <NUM> extending therethrough. The insulation space <NUM> is provided in the corners of the lidding device. The insulation spaces <NUM>, <NUM> allow for handling the lidding devices <NUM>, <NUM> when hot, e.g., after microwaving the food contents, a user can handle the lidding devices <NUM>, <NUM> by grabbing the lidding device <NUM>, <NUM> proximate the insulation space <NUM>, <NUM>.

With reference now to <FIG>, another blank <NUM> according to the invention is shown, including first, second, third, and fourth panels <NUM>, <NUM>, <NUM>, <NUM> similar to those described above with respect to blank <NUM>. The lid <NUM> can be adhered to a food container (such as food containers <NUM>, <NUM>) and the blank <NUM> can be erected around the food container, adhering the adhesive flap <NUM> to the third panel <NUM> much as described above with reference to <FIG>. Flaps <NUM> can be overlapped and adhered together to partially enclose opposed ends of the food container (e.g. food container <NUM> and <NUM>). Corner regions <NUM> are left open, not fully enclosing the food container, and corners <NUM> provide the insulation space <NUM> much as described above with respect to blanks <NUM>, <NUM>. The first panel <NUM> includes a venting system including one or more lines of weakness <NUM> along an edge of the first panel <NUM> for venting the food container, e.g. during cooking. The first panel <NUM> includes a pull tab <NUM> for a user to use in peeling back the lid <NUM> of the first panel <NUM> along one or more lines of weakness along the first panel edges. Blanks <NUM>, <NUM> described above can have similar venting systems and pull tabs.

In any of the blanks <NUM>, <NUM>, <NUM>, at least one of the panels can be configured to be printable for printing product identifying material or instructions thereon. At least the first panel of the blanks <NUM>, <NUM>, <NUM> comprises a thermoplastic or heat sealable coating applied to food-facing side of the panel, and the thermoplastic coating can comprise a polyolefin dispersion or a polymeric-based film.

An example of a method of forming a lidding device (e.g. lidding device <NUM>, <NUM>, <NUM>) includes providing a printable or pre-printed paperboard material, forming a multi-panel blank (e.g. blanks <NUM>, <NUM>, <NUM>) from the paperboard material, wherein the panels (e.g. panels <NUM>, <NUM>, <NUM>, <NUM>) are separated via lines of weakness (e.g. fold lines <NUM> shown in <FIG>), and applying a thermoplastic heat seal coating to at least a portion of one side of the blank. The method includes fitting the blank around a container (e.g. food container <NUM>, <NUM>) to surround the container between at least a top panel and an opposed bottom panel and between a first side panel and an opposed second side pane and heat sealing the thermoplastic heat seal coating to the container. Three-sided embodiments, e.g., as in <FIG>, are wrapped around the respective tray, and the four-sided embodiments, e.g. <FIG>, can have the tray inserted in a form/fill/seal operation.

The method can include applying one or more coatings to the paperboard material. The one or more coatings can comprise a clay coating. The applying the one or more coatings can comprise applying a thermoplastic heat seal coating to at least a portion of one side of the blank. The paperboard material can be pre-printed with marketing graphics with heat resistant microwaveable inks and/or overprint. Fitting the blank around the container can include completely surrounding the container inside the blank (e.g. as shown in <FIG>). Fitting the blank around the container can include protruding two edges of the container through cutouts in opposed flaps of the blank (e.g. as shown in <FIG>). Fitting the blank around the container can include forming at least one insulation space (e.g. insulation spaces <NUM>, <NUM>, <NUM>) between the container and the panels of the blank.

Systems and methods disclosed herein provide consumer features such as the following. The plastic tray does not have to be removed from the carton for cooking. The carton can provide a convenient means of handling the food tray for placement in the oven and removal of the hot tray after cooking, by virtue of the insulation spaces which serve as carrying handles. The integrated food tray and carton can potentially create a more aesthetically pleasing food vessel. The option of a hinged lid can allow for convenient venting but can also serve as a splatter guard inside the oven. A lid can also provide a means of protecting food and keeping it warm as it is transported from oven to table or desk. The lid can also be used to cover food discreetly when others are near. Also, paperboard and plastic components can be separated for recycling.

Claim 1:
A food package suitable for heating in a microwave, the food package comprising a food container (<NUM>; <NUM>) and a lidding device (<NUM>; <NUM>), the lidding device (<NUM>; <NUM>) comprising:
a first panel (<NUM>; <NUM>; <NUM>) comprising a lid covering and sealing the food container (<NUM>; <NUM>), at least the first panel comprising a thermoplastic or heat sealable coating applied to a food-facing side thereof and being, at least in part, heat-sealingly bonded to the food container (<NUM>; <NUM>);
a second panel (<NUM>; <NUM>; <NUM>) foldably connected to the first panel (<NUM>; <NUM>; <NUM>); and
a third panel (<NUM>; <NUM>; <NUM>) comprising a bottom panel opposite the lid, the second panel (<NUM>; <NUM>; <NUM>) being foldably connected to the third panel (<NUM>; <NUM>; <NUM>);
the food package characterised by:
the lidding device (<NUM>; <NUM>) further comprising a fourth panel (<NUM>; <NUM>; <NUM>) foldably connected to at least one of the first panel (<NUM>; <NUM>; <NUM>) and the third panel (<NUM>; <NUM>; <NUM>), whereby the food container is at least partially enclosed between said first and third panels (<NUM>, <NUM>; <NUM>, <NUM>; <NUM>, <NUM>) and between said second and fourth panels (<NUM>, <NUM>; <NUM>, <NUM>; <NUM>, <NUM>); and
an insulation space (<NUM>; <NUM>; <NUM>) being defined between the food container (<NUM>; <NUM>) and at least one of the first, second, third, and fourth panels, the insulation space providing a convenient means of handling the food package after heating in a microwave.