Background and Summary of the Invention
The present invention generally relates to the
combination of an upstanding pouch and a food entree
sealed therewithin, as well as a method of providing a hot
food entree. More particularly, the invention relates to
the combination of an upstanding flexible pouch and a food
entree contained therein, which flexible pouch is able to
stand upright on its own during microwave heating and the
like, the food entree being of the type which is
pasteurized within the pouch and which is then
refrigerated until same is heated, opened and served.
Packages having food components sealed
therewithin until subjected to microwave heating are
generally known. Typically, these products are not
refrigerated types of products. Examples in this regard
include popcorn or other food items which do not exhibit
qualities requiring or permitting refrigeration. Such
products can tend to be more in the nature of shelf-stable
items or frozen items. Generally, foods which are
subjected to retort conditions or the freezing process do
not maintain taste, texture and appearance qualities when
compared with products which are not subjected to harsher
conditions such as high temperature processing or
freezing. Accordingly, there is a need for a combination
wherein a refrigerated food entree can be packaged and
distributed as a refrigerated product which is
microwaveable for heating to a serving temperature.
One difficulty that is often encountered with
packaged microwaveable products is a concern over burning
or making uncomfortably hot the fingers of the person
opening the packaging. This is due to the relative
simplicity of microwaveable packages which are typically
disposable and thus not readily amenable to extra
packaging details that would add to the expense,
complexity and wastefulness of the packaging.
Accordingly, there is a need for food entree microwaveable
packaging which can go from refrigeration to microwave
heating without requiring sophisticated, multi-component
packages to help alleviate concerns of high temperatures
contacting the fingers or digits of the user during
opening of the packaging.
In summary, the present invention provides a
refrigerated food entree sealed within an upstanding pouch
which has features that allow the user to open the pouch
and pour the heated food entree out of the pouch after
suitable microwave warming by providing areas of the
sealed pouch surfaces that serve as handle areas spaced
adequately from the heated entree so as to reduce heat
transfer to acceptable levels at the areas at which the
pouch is grasped during opening and pouring. The food
entree is of the type that is pasteurized within the
sealed pouch and then refrigerated until desired microwave
warming. The invention also encompasses a method for
providing a hot food entree by sealing same in a flexible
pouch, pasteurizing same, refrigerating during storage,
distribution, in-store display and home storage, heating
same within a microwave oven and emptying the contents in
a safe and efficient manner.
It is accordingly a general object of the
present invention to provide an improved refrigerated,
microwaveable food entree sealed within a disposable
pouch.
Another object of the present invention is to
provide an improved refrigerated, microwaveable food
entree and pouch which will stand erect on its own during
microwaving, along with an accompanying method.
Another object of the present invention is to
provide an improved food entree and pouch combination and
method intended for use within a microwave oven while
providing non-wasteful packaging that provides safe
grasping locations for opening the heated pouch and for
emptying the heated food entree from the pouch.
These and other objects, features and advantages
of the invention will become apparent from and clearly
understood through the further and more detailed
description of the invention which follows.
Brief Description of the Drawings
In the course of the description, reference will
be made to the attached drawings providing further details
of a preferred and exemplified embodiment of the
present invention.
FIG. 1 is a perspective view of a preferred
embodiment of a pouch and food entree combination in
accordance with the invention, shown in an expanded and
upstanding orientation; FIG. 2 is an illustration of a typical procedure
for opening a pouch of the type illustrated in FIG. 1; FIG. 3 illustrates the opened pouch of FIG. 2
from which the heated food entree is being poured; FIG. 4 is a vertical cross-sectional view along
the line 4-4 of FIG. 1; FIG. 5 is a horizontal cross-sectional view
along the line 5-5 of FIG. 1; FIG. 6 is a partial cross-sectional view similar
to that of FIG. 4 but at an off-center location; and FIG. 7 is a partial cross-sectional view similar
to that of FIG. 4 but with the pouch bottom in an
unexpanded orientation.
Detailed Description of the Invention
A fully closed pouch is generally designated at
11 in FIG. 1. A food entree 12 is sealed therewithin, and
the pouch bottom is expanded. It will be noted that, in
this preferred embodiment, the pouch 11 is of the stand-up
or upstanding type wherein the pouch is in a vertical
orientation and remains so oriented by virtue of the
structure of the pouch and its combination with the food
entree sealed therewithin when the bottom portion of the
pouch is expanded as shown.
Pouch 11 includes two side panels 13 and 14
(FIG. 4) sealed together along top and side edge portions.
More particularly, top edge portion 15 of side panel 13 is
fused or sealed to top edge portion 16 of side panel 14 in
order to form a top seal 17, typically by heat sealing
together the entirety of the top edge portions 15 and 16.
A so-called chisel seal 20 is also included so as to form
a "seal within a seal" or a double seal of the pouch.
More specifically, the chisel seal 20 is usually
first made and is spaced from the top edge of the package
as shown, this seal being relatively narrow, for example
about 1/8 inch or 3 mm. Then the top seal 17 is made over
the chisel seal so as to generally enclose the chisel seal
within the top seal as can be seen in FIG. 1. This
combination of seals has been found to be important in
withstanding heating during pasteurization of the pouch
and its contents. Otherwise, leaking of some pouches can
develop during pasteurization.
Side panels 13 and 14 are also fusion sealed
together along both side edge areas of both panels in
order to form side seals 21 and 22. Preferably, side
seals 21 and 22 include one or more areas 18, 19 which are
especially suitable for grasping the pouch. These areas
provide a preferred location at which to grasp the pouch
top area with one hand, while the other hand grasps an
area of the pouch immediately therebelow, as generally
shown in FIG. 2. As is evident from FIG. 2, it is one of
these side seals which is grasped, together with one of
the grasping areas 18, 19 during the course of opening the
pouch 11. It is preferred to provide a slit or notch 23
in order to facilitate initiation of the opening
procedure. A line of weakening 24 may also be provided in
order to ensure even and effective opening to a condition
such as that illustrated in FIG. 2.
Once thus opened, the food entree 12 is readily
poured out of the mouth 25 which is defined between
severed edges of the respective side panels 13 and 14. It
will be noted from FIG. 3 that the user is able to grasp a
bottom portion of the opened pouch 11 without requiring
contact of the fingers or digits with the area of the
pouch within which the heated food entree is contained.
Instead, the fingers or digits grasp an end of a handle
projection 26 which is defined in greater detail herein.
With more particular reference to the handle
projection 26, it typically will be composed of at least
four layers of the polymer sheeting used in making the
pouch. Each polymer sheeting may be itself a laminate or
coextrusion of from two to several layers. These four
polymer sheetings are the bottom portion 31 of the side
panel 13, the bottom portion 32 of the side panel 14, and
two portions of a bottom panel 33.
When the package is in its upstanding and
bottom-expanded configuration as illustrated in FIG. 1 and
FIG. 4, the wall of the handle projection 26 will vary in
depth, as can be generally seen in FIGS. 1, 2 and 3. The
central cross-section of FIG. 4 illustrates the shortest
depth of this handle projection at the stand-up
orientation. This depth should be at least 1/8 inch
(about 0.3 cm) to achieve a good stand-up function. At
this shortest-depth location along the handle projection
26, bottom portion 31 is sealed to a central portion 34 of
the bottom panel 33, while bottom portion 32 is sealed to
another central portion 35 of the bottom panel 33. This
forms a lip 51 on both sides of the pouch along a portion
of its bottom edge. It will be appreciated that, with the
illustrated configuration of the handle projection 26, the
seal area between the side panels and the bottom panel
increases in depth along diagonal seal interfaces 52.
Diagonals 52 are in opposing directions away from the lips
51 and the central portions 34, 35 of the bottom panel 33.
This is generally illustrated in FIG. 6, which is a cross-section
taken between the central portions 34, 35 and the
side seals 21, 22.
As thus illustrated, the seal area between the
side panels 13, 14 and the bottom panel 33 is deeper in
FIG. 6 than in FIG. 4. This seal area is between side
panel bottom portion 31 and an intermediate portion 36 of
the shaped sealed area. This sealed area is also between
side panel bottom portion 32 and an intermediate portion
37 of the bottom panel 33. It will thus be appreciated
that, as one moves outwardly, the depth of the seal area
and thus of the handle projection 26 increases, with the
maximum grasping area being at corner portions 38 and 39.
Accordingly, the handle projection 26 is defined by a seal
which has narrowed seal lips 51 that are flanked by and
joined at much deeper sealed corner portions 38 and 39.
In addition, these corners portions are also
insulated from the hot food entree 12 by virtue of the
insulative air space which is present between the opposing
walls of the bottom panel 33. More particularly, this
insulated area is located between the central portions 34
and 35 and between the intermediate portions 36 and 37,
which area continues through to the fully sealed corner
portions 38, 39 at which the package is most conveniently
grasped in order to pour out the contents as illustrated
in FIG. 3.
In order to better understand the construction
of the bottom portion of the pouch 11, reference is made
to FIG. 7, which shows the pouch in a configuration at
which the air space between the opposing portions of the
bottom panel is reduced to the extent that same can be in
contact with each other when all of the food entree has
been squeezed out of the unsealed portion 41 of the bottom
of the pouch, the uppermost portion of which is designated
by phantom line 42 in FIG. 3 and FIG. 7. This shows the
collapsed orientation of the bottom portion of the
flexible pouch. Phantom line 43 in FIG. 7 illustrates the
sealed area which is below unsealed portion 41 in this
central portion of the pouch. In this drawing, the lips
51 contact each other because the gusset of the pouch is
collapsed.
When the pouch is in its stand-up or upstanding
configuration and expanded-bottom orientation as shown in
FIG. 4, the sealed handle projection 26 defines a
peripheral skirt 44. More specifically, the peripheral
skirt 44 is defined by the seal between the side panels 13
and 14 and a portion of the bottom panel 33. This
peripheral skirt portion defines a bottom panel peripheral
edge 45, which is the portion of the pouch that engages
the support surface, such as a horizontal surface within a
microwave oven (not shown). Thus, the flexible pouch 11
will stand up when this skirt bottom edge 45 engages the
support surface. The result is an upstanding flexible
pouch having a vertical cross-section which is
substantially triangular as generally shown in FIG. 4.
It will be noted that, in the preferred gusset
arrangement which is shown, the lips 51 and diagonal seal
interfaces 52 meet at generally angular seal intersections
53 and 54. This facilitates a positive and distinct
opening of the bottom gusset, such as when the pouch is
filled. The relatively sharp intersections 53 and 54
focus the energy of gusset opening action at four point-like
locations so that the energy concentrates toward
those locations to more rapidly "pop" open the four gusset
corners. This energy focus is also believed to help to
more fully open these corners of the gusset which provide
an open gusset that has the structurally supportive
advantage of sharp corners that tend to keep the gusset
open, and the pouch erect, once the gusset has been
opened.
With further reference to the food entree 12, a
premeasured quantity of food entree is hermetically sealed
within the flexible pouch in order to provide a
combination sealed flexible pouch and food entree. The
food entree is of a type which is refrigerated until
heated for use and serving. Because they are pasteurized
and refrigerated, rather than retorted for example, the
entrees not only have a longer shelf life, they are also
of high product quality because they are not subjected to
elevated temperatures in excess of pasteurization
temperatures, which are relatively mild.
Preferred entrees are those which include
substantial quantities of protein material such as
vegetables, meat, poultry, fish and the like. Protein
sources 46 are illustrated in the drawings. It is
generally preferred that a sauce 47 is combined with the
protein source 46 in order to provide a seasoned meal
component or entree which is suitable for combining with
desired materials (not shown), such as baked dough
materials including breads, buns, bagels, chips,
tortillas, and the like. Exemplary meal entrees are
barbecue beef, barbecue chicken, southwestern chicken,
sloppy joe, ham and cheese, turkey and gravy, lemon herb
chicken, and the like. It is preferred that the meat
component be low in fat so as to provide a food entree
which is not a substantial source of fat.
It is typically preferred that the pouch contain
printed indicia which will provide the required packaging
and labeling information, instructions for use,
promotional material, and the like. In this instance, it
is preferred that the pouch include a transparent area or
window through which the consumer can view the food entree
prior to, during and after heating. An exemplary window
in this regard is designated at 48 in FIG. 1. Printed
indicia can be printed onto the remainder of the flexible
pouch.
It will be appreciated that the fully sealed
grasping areas 18 and 19 and the fully sealed grasping
corner portions 38 and 39 each have a surface area size
which is adequate for digital or finger grasping to
facilitate opening and pouring of the hot food entree out
of the flexible pouch. Exemplary dimensions in this
regard include the following. A preferred minimum depth
of each of these areas is about 0.75 inch or about 2 cm
from the top or bottom edge of the pouch to the area of
the pouch within which a food entree is contained.
Greater widths are also possible where additional
materials can be afforded, whether in terms of cost,
conservation of materials and/or available space. In
addition, the top edge portion may include a hole 49 by
which the pouch and entree combination can be suspended
such as from a peg or rod during display within a retail
store refrigerated case.
Referring more specifically to the polymer
sheeting from which the pouch is constructed, same is
preferably a gas barrier film. Often, a preferred manner
of achieving the desired oxygen barrier properties while
still exhibiting adequate heat sealing properties is to
provide paneling or sheeting which is laminated or coextruded.
A particularly advantageous combination is a
laminate which includes an outer material for toughness,
an inside material for superior heat sealing properties,
and an intermediate material which enhances the gas
barrier properties of the laminate. A suitable outer
material is an oriented polyester such as oriented or
biaxially oriented polyethylene terephthalate. A typical
inner layer is a polyolefin such as a polyethylene or a
polypropylene, for example linear low-density
polyethylene. A typical internal or intermediate gas
barrier layer is a vinyl polymer such as ethylene vinyl
alcohol. Such a laminated or coextruded film is flexible
and can have a thickness of on the order of about 4 mils (0.102
mm). A second intermediate oriented polypropylene layer can
also be included to enhance toughness during
pasteurization and often also to improve appearance after
pasteurization.
With reference to the procedure or method in
accordance with the invention, film or sheeting such as
that described above, which may be preprinted and include
one or more windows as desired, is formed into the pouch
as discussed herein. Such can be accomplished with the
assistance of commercially available equipment such as
Klöckner-Bartlet rotary form/fill/seal pouch packaging
machinery. In such an arrangement, all seals except for
the top seal are made, with the open top forming a mouth.
The food entree is inserted through the mouth in order to
generally fill the open flexible pouch. Next, the pouch
is flushed with gas absent of oxygen (such as nitrogen
gas), and the top edge is sealed so that the chosen
portion of food entree is fully sealed within the sheeting
of the pouch.
Thereafter, these filled pouches are conveyed to
pasteurizing equipment wherein they are heated to an
internal temperature of approximately 165° F. (about
74° C.). Once suitably pasteurized, the combination of
pouch and food entree is cooled to refrigeration
temperatures, such as on the order of 40° F. (about
4.5° C.), the temperature being a non-freezing
temperature, that is being above 32° F. (0° C.). The
temperature is also adequate to properly store the
pasteurized food entree for extended time periods of
several weeks. Thereafter, the combination is ready for
commercial storage, distribution and retail display,
followed by a reasonable period of home storage, all under
refrigerated conditions.
At the appropriate time, the consumer grasps the
top edge, particularly at the sealed grasping area 18 or
19, this being done with one hand, while the other hand
grasps a portion closely spaced therefrom along one of the
side seals. Then, typically with the assistance of a
notch, all or a portion of the top portion is torn away
from the rest of the pouch, thereby opening the pouch.
Next, the consumer places the pouch and entree combination
into a microwave oven or the like and heats same to an
appropriate post-pasteurization and serving temperature.
A suitable internal temperature in this regard is as low
as about 140° F. (60° C.), often between about 160 and
about 170° F. (about 71 to about 77° C.). The heated food
is removed from the pouch, such as by pouring the food
entree through the thus-opened top of the pouch. This
pouring can be facilitated by grasping the pouch at one of
the corner portions of the handle projection or skirt at
the bottom portion of the pouch.
It will be understood that the embodiments of
the present invention which have been described are
illustrative of some of the applications of the principles
of the present invention. Numerous modifications may be
made by those skilled in the art without departing from
the true spirit and scope of the invention.