Convertible Container

This application claims priority to U.S. Application No. 63/639,215, filed on Apr. 26, 2024, the disclosure of which is hereby incorporated by reference in its entirety.

The present disclosure relates generally to packaged products and methods of use, and more particularly to containers, cartons, or trays for heating food products in a cooking appliance, such as a microwave oven.

Cartons for cooking food in a microwave oven are known. Such cartons may include a microwave susceptor, which has the property of increasing its own temperature by partially absorbing energy of the microwave and then transmitting thermal energy to the food. This helps to provide browned or crispened areas where the food product is in contact with the susceptor material. Microwave ovens are typically equipped with a turntable to provide more even cooking.

A variety of container configurations are provided in the prior art. Improvements, however, are desired.

This disclosure is directed to a container, carton, or cooking tray with convertible features for use in microwave ovens. To achieve the advantages disclosed herein, and in accordance with the purposes as embodied and broadly described herein, a convertible carton or tray is provided having a cooking portion defining a quadrilateral panel including at least one diagonal fold line defining at least one corner tab, and a base portion configured to support the cooking portion in an elevated position, wherein the base portion includes at least one invertible corner configured to transition from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the convertible container.

In one aspect, the base portion comprises a first wall and a second wall oriented at a near-orthogonal angle relative to one another and which converge at a corner intersection. In one aspect, the at least one invertible corner is defined by a first fold line positioned along the first wall and a second fold line positioned along the second wall, with the first fold line and the second fold line positioned on opposite sides of the corner intersection.

In one aspect, the first fold line defines a first segment of the first wall positioned between the first fold line and the corner intersection, and the second fold line defines a second segment of the second wall positioned between the second fold line and the corner intersection.

In one aspect, the first fold line and the second fold line act as hinges enabling the first segment and the second segment to pivot relative to other portions of the first wall and the second wall to affect the transition of the at least one invertible corner from the first configuration to the second configuration.

In one aspect, the cooking portion and the base portion are constructed of paperboard material.

In one aspect, the cooking portion defines one or more vent apertures.

In one aspect, a susceptor material covers at least 10% of the cooking portion to define a cooking surface.

In one aspect, the base portion defines at least one wall having a length of less than about four inches in the first configuration.

In one aspect, the base portion defines at least one wall having a length of at least four inches in the first configuration.

In one aspect, the base portion comprises four near-orthogonal walls defining an interior portion configured to house an item.

In one aspect, the base portion comprises four near-orthogonal walls defining an interior portion configured to house a food item having an external dimension of at least four inches.

In one aspect, the base portion comprises a container configured to receive a food item having a diameter of at least four inches, and the cooking portion defines a lid hingedly coupled to the base portion along one edge.

In one aspect, the container further includes a food item oriented within an interior portion. In one aspect, the food item has a dimension of at least four inches.

In one aspect, the food item is a 10-inch pizza.

Another aspect of the present disclosure provides a method of using a microwavable tray, the microwavable tray initially in the form of a flat panel, including a cooking portion at least partially surrounded by four base panels, including forming the flat panel into a quadrilateral tray by folding the four base panels to a near-orthogonal angle relative to the cooking portion along the predefined lines, and securing respective ends of the four base panels to one another to form four corner intersections, wherein each of the four corner intersections defines a near-orthogonal external angle; separating at least one corner tab defined by the cooking portion from an adjacent one or more of the four base panels, wherein the at least one corner tab is positioned at a corner of the cooking portion adjacent to a first corner intersection of the four corner intersections; and inverting the first corner intersection from a first configuration in which the first corner intersection defines a near-orthogonal external angle, to a second configuration in which the first corner intersection defines a near-orthogonal internal angle to reduce a diagonal dimension of the microwavable tray.

In one aspect, the respective ends of the four base panels of the flat panel are secured to one another with at least one of tabs, slots, or glue to form the four corner intersections.

In one aspect, the method further includes bending at least one corner tab along respective diagonal fold lines to reduce a diagonal dimension of the cooking portion.

In one aspect, the first corner intersection is defined by a first fold line positioned along one base panel and a second fold line positioned along another base panel, with the first fold line and the second fold line positioned on opposite sides of the first corner intersection, wherein the first fold line and the second fold line act as hinges enabling transition of the first corner intersection from the first configuration to the second configuration.

In one aspect, the method further includes positioning a food item on the cooking portion.

In one aspect, a susceptor material is operably coupled to the cooking portion, and the food item positioned on the susceptor material.

Another aspect of the present disclosure provides a method of using a microwavable container, the microwavable container comprising a base portion and a cooking portion, the cooking portion serving as a lid hingedly coupled to the base portion along at least one edge, the cooking portion including at least one diagonal fold line defining at least one corner tab, and the base portion including at least one invertible corner, including opening the lid of the microwavable container to access an interior of the base portion; removing a food item from the interior of the base portion; pivoting the lid around the hinged coupling to an inverted state; inverting at least one corner of the base portion from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the base portion; bending at least one corner tab of the cooking portion along the diagonal fold line to reduce a diagonal dimension of the cooking portion; and positioning the food item on the cooking portion. In another aspect, the lid may be fully removed from the microwavable container.

In one aspect, the cooking portion includes a susceptor material.

In one aspect, the method further includes pivoting the susceptor material around the hinged coupling to face away from the base portion.

A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.

In the realm of microwavable food packaging, particularly for larger items such as food items having a major dimension of at least four inches or more, existing arrangements encounter limitations in cooking. One notable problem is that quadrilateral containers, cartons, and trays large enough to accommodate the food item cannot rotate on the microwave's turntable due to spatial constraints within most standard microwave ovens. This lack of rotation leads to uneven cooking, as the microwave energy is not uniformly distributed throughout the food item. Consequently, certain areas of the food item may be overcooked or undercooked, compromising the overall quality and enjoyment of the food item.

One solution to this problem has been to use round or pressed containers, however the use of round and pressed containers introduces another set of challenges. Round or pressed containers, while potentially capable of rotating freely within the microwave, are markedly more expensive to manufacture. Increased production costs stem from complexities involved in manufacturing pressed and formed package shapes, as well as increased waste in cutaway portions of the original stock material. Additionally, round and pressed containers are typically shipped fully formed which reduces shipping density, and thus is more expensive.

Embodiments of the present disclosure address these challenges through the incorporation of invertible corners and bendable corner tabs configured to reduce a diagonal dimension of an otherwise quadrilateral microwavable container. Although specific examples of square or quadrilateral containers are depicted, the concepts as disclosed herein are suitable to other polynomial shapes, including, but not limited to, rectangles, triangles, trapezoids, hexagons, octagons, or any other polygonal shape.

Although the present disclosure exemplifies a microwave oven equipped with a turntable or rotating device/rotating mechanism as a typical cooking appliance for demonstrating the utility of the disclosed containers, it should be understood that the inventive concepts herein are not limited solely to microwave ovens. The disclosed convertible containers are equally applicable to a variety of other cooking or heating appliances that feature a confined interior space equipped with a rotating mechanism. The disclosed convertible containers are also equally applicable to a variety of other cooking appliances that feature a confined interior space without a rotating mechanism. Such appliances include, but are not limited to, toaster ovens, pizza ovens, air fryers, holding cabinets, and other specialty devices designed for the preparation or holding of food products. These appliances, like microwave ovens, benefit from the ability of the containers to adapt to spatial constraints while facilitating even cooking or heating, thereby enhancing the versatility and utility of the disclosed solutions across different culinary technologies.

As used herein, a “container” can refer to any receptacle or enclosure designed to hold, store, transport, or protect items, including food products. Containers can vary widely in size, shape, material, and functionality, catering to the specific needs of the contents they hold. The materials used for containers are often chosen for properties that best suit the item's requirements, such as durability, protection, and environmental conditions. Features of containers may include airtight seals, handles for easy transportation, and mechanisms for controlled dispensing.

A “carton” can refer to a type of packaging container designed to hold, protect, and preserve items during storage, transportation, display, preparation, and consumption, including food products. Cartons can vary in size, shape, and functionality depending on the specific product they are intended for. A carton may include features such as folding closures, perforations for easy opening, cooking surfaces, and coatings or laminates to provide barrier properties against moisture, oxygen, and other environmental factors that could affect the product's quality and freshness.

A “tray” can refer to a shallow platform designed for the carrying, holding, cooking, or presenting of various items, including food products. Trays can vary in size, shape, material, and design, tailored to the specific application or aesthetic preference. The materials used for trays are often selected for properties that complement the tray's intended use, such as lightweight durability, ease of cleaning, or decorative appeal. Features of trays may include raised edges to prevent items from sliding off, compartments for organizing contents, and handles or grips for easy carrying. In some embodiments, a tray and food product may be contained within a carton.

Additionally, a container can function as both a carton and a tray. Typically, a carton is defined as a six-sided enclosure providing comprehensive protection and containment, while a tray is described as an open, five-sided platform designed for ease of access and presentation. In some embodiments, the removal of a lid or cover from a carton can transform it into a tray, offering a versatile solution that accommodates both the secure enclosure of products and their convenient display or access when desired.

“Packaging” refers to any material or structure designed for the enclosing or protection of items, particularly food products, during their storage, transportation, display, preparation, and consumption. This broad definition encompasses containers, cartons, and trays, each serving specific roles within the realm of packaging but united in their purpose to safeguard and maintain the quality of the contents they hold. Packaging materials and designs can be chosen based on the needs of the product, considering factors like durability, environmental conditions, and the preservation of freshness and quality.

Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

Referring to, a microwavable containeris depicted in accordance with an embodiment of the disclosure. In one embodiment, the microwavable containercan include a cooking portionand a base portion.

The cooking portioncan be defined as a quadrilateral panel which can include a susceptor material. The cooking portioncan include one or more diagonal fold linesA-D defining one or more corresponding corner tabsA-D, which can be bent at an angle relative to a cooking surfacedefined by the cooking portion.

In some embodiments, each of the cooking surfaceand the one or more corresponding corner tabsA-D can define a planar surface, wherein an orientation of the corner tabsA-D can be adjusted relative to the cooking surfacealong the one or more diagonal fold linesA-D, such that the surfaces of the cooking surfaceand the one or more corresponding corner tabsA-D are non-coplanar. For example, in some embodiments, the corner tabsA-D can be bent upward relative to the cooking surface, which can have a combined effect of reducing a diagonal dimension of the cooking portion, as well as providing a lateral edge as an aid in maintaining the position of a food item positioned thereon.

Additionally, it should be noted that althoughdepicts the corner tabsA-D as extending upwardly generally away from the base portion, in other embodiments, the corner tabsA-D can be bent downwardly toward the base portion, having the effect of reducing an overall diagonal dimension of the microwavable container. In other embodiments, the corner tabsA-D are substantially coplanar with the cooking surfaceand cooking portion. In other embodiments, the corner tabsA-D may be entirely removed from the microwavable container, such as by tearing off the corner tabsA-D, for example by way of perforations positioned along the diagonal fold linesA-D.

The base portioncan comprise a plurality of base panelsA-D, arranged as walls configured to support the cooking portionin an elevated position, in order to raise the cooking surfaceoff the bottom surface of the interior of the microwave to reduce a heat sink effect which can negatively affect the cooking of the food item within the microwave.

In order to reduce an overall diagonal dimension of the microwavable container, in some embodiments, the base portioncan define one or more invertible cornersA-D configured to transition from a first configuration, defining a near orthogonal external angle (e.g., as depicted in), to a second configuration, defining a near orthogonal internal angle (as depicted in), thereby reducing a diagonal dimension of the microwavable containerto enable unimpeded rotation within a microwave oven equipped with a turntable. With additional reference to, a plan view of a microwavable containerin an initial flat-panelconfiguration is shown. As depicted, the panelcan include a cooking portion, which can include a susceptor materialaffixed thereto. Further, in some embodiments, the cooking portioncan be divided into a cooking surfaceand one or more corner tabsA-D delineated by corresponding diagonal fold linesA-D. In some embodiments, the cooking surfaceand the one or more corner tabsA-D are included as distinct and separate parts of the cooking portion, although any susceptor materialpositioned on the cooking surfacemay (or may not) extend to the one or more corner tabsA-D.

The cooking portioncan be at least partially surrounded by a plurality of base panelsA-D, collectively representing the base portion. As depicted, in some embodiments, the base panels (e.g., second base panelB, etc.) can include a tabconfigured to couple to an adjacent base panel (e.g., first base panelA, third base panelC, etc.) to form a corner intersectionbetween base panels (e.g., as depicted in). In some embodiments, the plurality of base panelsA-D can be delineated from the cooking portionalong fold lines. Additionally, the tabcan be delineated from the base panelvia a fold line. Fold linescan generally be defined as a score line or a bend.

Additionally, in some embodiments, portions of the fold linescan be defined by a precut score line, thereby enabling separation between the first portionA and the corner tabA, and the second portionB and the corner tabA. In some embodiments, each precut score lineextends directly to the corner where, for example, the first portionA and the second portionB meet. In some embodiments, precut score lineis a cut line that does not comprise scoring and instead defines a cut line that permanently separates, for example, the first portionA and second portionB both from the one or more corner tabsA-D.

A “score line” in the context of a container, carton, or tray, is thin, straight path defining a predefined cut or line of reduced thickness or structural integrity. Score lines facilitate precise folding, bending, or separation of the material along the defined path. Score lines can be implemented through various methods such as exerting pressure, or employing cutting techniques, chosen based on the material type and the desired outcome. The primary purpose of a score line is to create a line of weakness in an otherwise sturdy material to aid in manipulation of the container, carton, or tray for functions like folding, bending, opening, assembling, or collapsing the structure.

A “bend” refers to pre-formed curves or angles in the material that facilitate the shaping, assembly, or structural integrity of the packaging. These are intentional deformations made in the packaging material to create corners, edges, or folds without breaking or cutting the material. Bends are positioned to help the container, carton, or tray maintain its form or to assist in its construction and folding into the final shape required for use, and to allow for the efficient transformation of flat sheets of material into complex, three-dimensional structures that can hold, protect, and allow for preparation of products.

“Perforations” refer to small holes or series of holes punched or pressed into the material to facilitate specific actions or outcomes. These perforations create areas of reduced material integrity, making it easier to tear or separate the material along the line of perforations. In some instances, these perforations can be aligned with score lines or bends, enhancing the ease with which portions of the container, carton, or tray can be removed. Perforations can also be placed in locations independent of score lines to serve different functions. For example, perforations can be utilized to allow the passage of moisture or air through the layers of a food container, carton, or tray to ensure even cooking in microwaveable packages.

With additional reference to, the plurality base panelsA-D can be bent relative to the cooking portionat a near-orthogonal angle, with the plurality base panelsA-D coupled to one another along respective endsA,B to form corner intersectionsalso defining near orthogonal external angles.