CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. Provisional Application No. 61/669,740, filed July 10, 2012.

INCORPORATION BY REFERENCE

The entire disclosure of U.S. Provisional Application No. 61/669,740, filed July 10, 2012, is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is generally related to packages or, more specifically, to reinforced pouches.

BACKGROUND

Reinforced pouches are widely used. There is always a desire for reinforced pouches, or components thereof, that provide a new balance of properties.

SUMMARY

In one aspect, this disclosure is directed to a package comprising a flexible pouch at least partially enwrapped by (and optionally joined to) a reinforcing sleeve. The package can be transitioned from a first, generally flattened configuration, to a second, generally expanded (e.g., erected) configuration. In the expanded configuration, the sleeve provides structural stability to the pouch and assists with maintaining the pouch in an open condition so that package may serve as a container for holding and accessing the food. Further, in some embodiments, the sleeve may also allow the package to be able to stand substantially upright.

If desired, the package may be shaped to facilitate on-the-go consumption of food contained in the package (e.g., from fast food restaurants). For example, the package may be shaped and/or dimensioned so the package can be readily inserted into a cup holder of an automobile. As another example, the package may be shaped (e.g., contoured) to facilitate being held in the hand of a user.

In some embodiments, the package may also be used to at least one of heat, brown, and crisp the food, for example, in a microwave oven. In such embodiments, the package may include microwave energy interactive material that alters the effect of microwave energy on the food. In one example, the microwave energy interactive material may be configured as a susceptor. When sufficiently exposed to microwave energy, the susceptor tends to absorb at least a portion of the microwave energy and convert it to thermal energy (i.e., heat) through resistive losses in the layer of microwave energy interactive material. The remaining microwave energy is either reflected by or transmitted through the susceptor. Susceptors often are used to promote browning and/or crisping of the surface of a food item. However, other microwave energy interactive elements may be used.

Such packages may be used to prepare various food items in a microwave oven, for example, pizza rolls, corn dogs, popcorn, snack bites, egg rolls, savory or sweet pastries, breaded food items, or any other generally food item that desirably is heated, browned, and/or crisped. The construct also may be suitable for use in a conventional oven.

The package may generally comprise disposable materials, such as paper, paperboard, and polymer films.

Regarding the package being in the form of a reinforced pouch, the reinforced pouch or package may be characterized as comprising a bag positioned in a carton, wherein the carton may be in the form of a sleeve extending around the bag, and the bag may be mounted to the sleeve. As a more specific example, the carton of the package may have a plurality of panels extending around an interior of the carton, wherein the plurality of panels comprise, consist essentially of, or consist of a pair of biconcave panels that are opposite from one another and each have opposite concave edges, and a pair of biconvex panels that are opposite from one another and each have opposite convex edges. The concave and convex edges may be respectively foldably connected to one another by arcuate fold lines. When the carton is in a fully erected configuration, each of the biconvex panels may be in a

substantially concave configuration with respect to the interior of the carton, wherein the biconvex panels are retained in their substantially concave configurations in response to interplay between forces in the plurality of panels. As an example, the carton optionally may be in the form of a sleeve with opposite open ends that do not include (e.g., are not closed by) end flaps, or the like, wherein the above-mentioned substantially concave configurations of the biconvex panels and/or the interplay between forces in the plurality of panels maintains the sleeve in its erected configuration, such that the sleeve (e.g., the package as a whole) may be able to stand upright on its own.

The foregoing presents a simplified summary of some aspects of this disclosure in order to provide a basic understanding. The foregoing summary is not extensive and is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. The purpose of the foregoing summary is to present some concepts of this disclosure in a simplified form as a prelude to the more detailed description that is presented later. For example, other aspects will become apparent from the following.

BRIEF DESCRIPTION OF THE DRAWINGS

Having described some aspects of this disclosure in general terms, reference will now be made to the accompanying drawings, which may be schematic and are not necessarily drawn to scale. The drawings are exemplary only, and should not be construed as limiting the invention.

Fig. 1 A is a plan view of a first side (e.g., an exterior side) of an exemplary blank for forming a package.

Fig. IB is a schematic plan view of a second side (e.g., an interior side) of the blank of Fig. 1A.

Fig. 1C is a schematic cross-sectional view of the exemplary blank of Fig. IB, taken along line 1C-1C.

Figs. ID and IE are schematic plan views of opposite sides of a package formed from the blank of Figs. 1A and IB, in a substantially flattened configuration.

Figs. 1F-1H are schematic perspective views of the package of Figs. ID and IE in a substantially expanded, upright configuration.

DESCRIPTION

Exemplary embodiments of this disclosure are described below and illustrated in the accompanying figures, in which like numerals refer to like parts throughout the several views. The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and

improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of the present invention. For example, it will be apparent to those skilled in the art that features illustrated or described as part of one embodiment may be used in another embodiment to yield a further embodiment, and that these further embodiments are within the scope of the present invention.

Figs. 1 A and IB schematically illustrate opposite (e.g., first and second) sides of an exemplary blank 100 that may be used to form a package 154 (Figs. 1D-1H). The blank 100 generally includes a first component 102 and a second component 104 joined (e.g., mounted) to one another. The first component 102 may comprise a flexible sheet of material, for example, paper, a polymer film, metallic foil, etc., that may be suitable for forming a flexible package, such as a pouch (e.g., a bag). The second component 104 may comprise a reinforcing sheet comprising a dimensionally stable and/or somewhat rigid or stiff material (e.g., paperboard) that may be suitable for being folded into a desired structure and substantially maintain its configuration, while providing some inherent degree of flexibility so that the panels of the second component can be moved or flexed as needed.

In this example, the first component or sheet 102 generally comprises a single panel or sheet of material, as shown schematically in Fig. IB (which generally illustrates an interior side of the blank 100), and the second component or sheet 104 generally comprises a plurality of panels or portions joined along lines of weakening or disruption (e.g., fold lines), for example, score lines, cut-crease lines, cut-space lines, tear lines, or any other suitable lines of weakening or disruption, or any combination thereof, as shown schematically in Fig. 1A (which generally illustrates an exterior side of the blank 100). However, in other embodiments, the first and/or second components 102, 104 of the blank 100 may include a fewer or greater number of panels, portions, pieces and/or lines of disruption.

When the blank 100 is erected into the package 154, the flexible sheet 102 forms a pouch (e.g., bag) for containing one or more items, and the dimensionally stable sheet 104 defines a carton (e.g., a sleeve or sheath) that extends around the pouch to provide structural support and/or definition for at least a portion of the pouch. The dimensionally stable sleeve or sheath may also assist with maintaining the pouch in an open configuration, as will be discussed further below.

As shown in Figs. 1A and IB, the first and second sheets 102, 104 of the blank 100, the various panels of the sheets, and the blank 100 itself may each have a first dimension, for example, a length, extending in a first direction, for example, a longitudinal direction, Dl, and a second dimension, for example, a width, extending in a second direction, for example, a transverse direction, D2, as generally measured as a distance between opposite peripheral edges of the blank, sheet, or panel. (It will be noted that such directional designations are made only for convenience and do not necessarily refer to or limit the manner in which the blank is manufactured or erected into the construct.) Peripheral edges of the first sheet 102 may include a pair of peripheral edges 106, 108 extending in the longitudinal direction Dl opposite one another, and top and bottom peripheral edges 110, 1 12 extending in the transverse direction D2 opposite one another, such that the first sheet 102 has a substantially rectangular shape. Peripheral edges of the second sheet 104 may likewise include a pair of peripheral edges 1 14, 1 16 extending in the longitudinal direction Dl opposite one another, and top and bottom peripheral edges 1 18, 120 extending in the transverse direction D2 opposite one another, such that the second sheet 104 has a substantially rectangular shape (except that edge 1 14 is somewhat arcuate in shape while edges 1 16, 1 18, 120 are substantially linear). However, other possibilities are contemplated.

The length and width of the first and second sheets 102, 104 may differ or may be substantially equal. For example, in the embodiment shown in the drawings, the length LI of the first sheet 102 is greater than the length L2 of the second sheet 104, while the width Wl, W2 of the sheets 102, 104 may be approximately equal. The overall length L of the blank 100 is the same as the length LI of the first sheet 102, and the overall width W of the blank 100 is greater than the respective width Wl, W2 of the first sheet 102 or the second sheet 104.

The first and second sheets 102, 104 may be separate from one another or may be joined to one another in any suitable manner and using any suitable technique or material (e.g., an adhesive). In this example, the first and second sheets 102, 104 are joined so that the second sheet 104 is substantially centered along the length LI of the first sheet 102, and offset from the first sheet 102 in the second direction D2. Accordingly, as shown in Fig. 1A, peripheral edges 1 14, 1 18, 120 of the second sheet 104 are in a facing, contacting relationship with the exterior side of the first sheet 102, while peripheral edge 1 16 is a free edge that is not joined to the first sheet 102. Peripheral edge 108 of the first sheet 102 is in a facing, contacting relationship with the interior side of the second sheet 104, while peripheral edges 106, 1 10, 112 are free edges that are not joined to the second sheet 104. In one example, the sheets 102, 104 are mounted to one another by way of all of the surfaces of the sheets 102, 104 that are at least generally in opposing face-to-face relation to one another being joined to one another by adhesive material. Notwithstanding and alternatively, typically at least one of the panels of the second sheet 104 is mounted to the first sheet 102 by adhesive material or any other suitable fastening technique. That is and for example, one or more of the panels of the second sheet 104 may not be mounted (e.g., directly adhered) to the first sheet 102.

Viewing the components 102, 104 in greater detail now, the second sheet 104 (e.g., the dimensionally stable sheet 104) may include a first main panel 122, a second main panel 124, a first minor panel 126, a second minor panel 128, and an attachment panel 130 foldably joined to one another, as shown schematically in Fig. 1A. The various panels 122, 124, 126, 128, 130 may be joined in a side by side relationship, so that panels 122, 124, 126, 128, 130 each include a pair of transverse peripheral edges opposite one another that comprise a respective portion of peripheral edges 1 18, 120. Minor panel 126 includes a longitudinal peripheral edge 1 14 comprising peripheral edge 1 14 of the second sheet 104. Similarly, attachment panel 130 includes a longitudinal peripheral edge 116 comprising peripheral edge 1 16 of the second sheet 104.

The first minor panel 126 and the second minor panel 128 are joined to opposite

(generally longitudinal) edges of the first main panel 122 along lines of disruption 132, 134. The second minor panel 128 and attachment panel 130 are joined to opposite (generally longitudinal) edges of the second main panel 124 along lines of disruption 136, 138. The first minor panel 126 and second minor panel 128 are each respectively divided into a first portion 126a, 128a and a second portion 126b, 128b along respective lines of disruption 140, 142 extending in the first direction Dl . The lines of disruption 140, 142 substantially bisect the respective minor panel 126, 128 along its length LI . That is, for each minor panel 126, 128 and its respective line of disruption 140, 142, the line of disruption is positioned substantially midway between the opposite convex edges of the minor panel.

Lines of disruption 132, 134, 136, 138, 140, 142 generally extend in the first direction

Dl substantially between opposite transverse peripheral edges 1 18, 120 of the second sheet 104, such that lines of disruption 132, 134, 136, 138, 140, 142 may each have approximately the same length L2. Likewise, panels 122, 124, 126, 128, 130 may have approximately the same length L2. However, in other embodiments, the dimensions of the various panels and lines of disruption may vary.

Lines of disruption 132, 134, 136, 138 are generally curved or arcuate in shape, and may be considered to be generally inwardly arcuate when viewed from the main panels 122, 124, and generally outwardly arcuate when viewed along the minor panels 126, 128. As a result, the first main panel 122 and second main panel 124 each have a somewhat hourglass or biconcave shape, such that the width of the respective main panel 122, 124 may be least about halfway along its length L2. Conversely, the first minor panel 126 and second minor panel 128 each have a somewhat biconvex or barrel shape, such that the width of the respective minor panel 126, 128 may be greatest about halfway along its length L2. In this regard and in the embodiment shown in the drawings, the main panels 122, 124 (e.g., biconcave panels) each have opposite concave edges, and the minor panels 126, 128 (e.g., biconvex panels) each have opposite convex edges, and these concave and convex edges are respectively foldably connected to one another by the arcuate lines of disruption 132, 134, 136, 138. However, other possibilities are contemplated. It will be noted that in the embodiment shown in the drawings, lines of disruption 132, 134, 136, 138, 140, 142 are fold lines that comprise cut-space lines, that is, a plurality of spaced apart creases or partial depth cuts. However, any type of line of disruption or weakening may be used, for example, score lines, cut-crease lines, or otherwise.

In some embodiments, the first and/or second sheets 102, 104 may comprise microwave energy interactive material configured as one or more microwave energy interactive elements that alter the effect of microwave energy on an adjacent food item. For example, in one exemplary embodiment illustrated schematically in Fig. IB, the first sheet 102 may include microwave energy interactive material 144 (shown schematically with stippling) configured as a susceptor that operative for increasing in temperature in response to microwave energy. However, countless other possibilities are contemplated.

The microwave energy interactive material 144 (e.g., susceptor) may be supported on a polymer film 146 to define a susceptor film 148, as shown schematically in Fig. 1C. The outermost surface (i.e., the exposed surface) 150 of the polymer film 146 may serve as a food-contacting surface of the construct 154 (i.e., for being in facing, substantially contacting relationship with the food item) erected from the blank 100. The susceptor film 148 may be joined (e.g., laminated) to a support layer 152, for example, paper, using an adhesive or otherwise (not shown), to impart dimensional stability to the susceptor film 148 (and resulting package 154) and/or to protect the layer of microwave energy interactive material 144 from being damaged.

To form the package 154 (Figs. 1D-1G) from the blank 100 according to one acceptable method, the blank 100 may be folded along lines of disruption 140, 142. Panels 126a, 130 may be overlapped with one another (e.g., so that peripheral edge 1 16 is substantially aligned with line of disruption 140), and the peripheral margins of the first component 102 adjacent to peripheral edges 106, 108 may be overlapped with one another. The respective overlapping portions of the sheets 102, 104 may be joined to one another in any suitable manner, for example, using an adhesive, to form a substantially flat, tubular structure including an interior space 156 (shown in Figs. IF and 1G) and a pair of open ends 158, 160 e.g., end edges) defined by respective peripheral edges 1 10, 1 12 of sheet 102. In this folded flat configuration, the lines of disruption 132, 138 are substantially superposed with one another, and the lines of disruption 134, 136 are substantially superposed with one another.

If desired, at least one end of the structure (e.g., a peripheral margin along end 160) may be sealed (shown schematically with hatch marks in Figs. ID and IE) to form a package or pouch 154 including one open end (e.g., end 158) and one closed end (e.g., end 160), with the various lines of disruption 132, 134, 136, 138, 140, 142 extending along a portion of the length L of the construct 154.

The package 154 may be transitioned from this substantially flattened configuration to an open, expanded (e.g., erected) configuration by urging lines of disruption 140, 142 towards one another and/or moving panels 122, 124 away from one another, and folding the package 154 along lines of disruption 132, 134, 136, 138, 140, 142. At the same time, panels 126, 128, 130 are moved inwardly so that the reinforcing sheath or sleeve 104 formed from the second sheet 104 defines a contoured package shape with incurved sides. The intermediate lines of disruption 140, 142 are configured for allowing the minor panels 126, 128 to be folded in a manner so that, for each minor panel, its opposite convex edges may be moved both toward and away from one another, for at least partially erecting or unerecting the incurved sides. Further regarding the incurved sides, they comprise each of the minor panels 126, 128 (e.g., biconvex panels) as a whole being in a substantially concave configuration with respect to the interior of the carton (e.g., sleeve) of the package 154, wherein the minor panels are retained in their substantially concave configurations at least partially in response to interplay between forces in the carton of the package 154. Optionally, the package 154 being held by hand or placed in a cup holder, or the like, may also help to at least partially retain the minor panels 126, 128 in their substantially concave configurations. In the embodiment shown in the drawings, the carton of the package 154 has opposite open ends that do not include, and are not closed by, end flaps of the carton, wherein the above- mentioned substantially concave configurations of the panels 126, 128 and/or the interplay between forces in the carton of the package 154 maintain the carton in its erected

configuration. However, the package may be configured to have any other shape, for example, a somewhat tubular or cylindrical shape, a somewhat rectangular shape, or any other regular or irregular shape. As another example and optionally, the carton or sleeve of the package may further include one or more end flaps for at least partially closing one or both of the ends of the carton or sleeve.

If desired, the package 154 may be brought into an upright configuration with the closed end 160 of the package facing downwardly, as shown schematically in Figs. IF and 1G. In this configuration, panels 122, 124, 126, 128, 130 (some of which are hidden from view in Figs. IF and 1G) provide structural stability for the flexible pouch 102 and assist with maintaining the pouch in an open configuration so the food or other package contents can be readily accessed, even when the food is being consumed on the go. Additionally, the incurved portions of the reinforcing sleeve 104 define a curved outer surface of the package that facilitates grasping of the package.

As shown for example in Fig. 1G, the carton portion of the package 154 is in the form of a sleeve having opposite top and bottom ends; the bag portion of the package is positioned in the interior of the sleeve; the top end of the bag extends upwardly, outwardly through an opening of the top end of the sleeve; the sealed closed bottom end of the bag extends downwardly, outwardly through an opening of the bottom end of the sleeve; and the top and bottom ends of the bag are wider than the sleeve.

If desired, the bottom portion of the pouch 102 may be urged upwardly, so that peripheral edge 120 becomes a lowermost portion of the package 154, as shown

schematically in Fig. 1H. In this manner, peripheral edge 120 may serve as a bottom edge for supporting the package when placed on a surface.

A food item may be inserted into the interior space 156 at any suitable time and the open end of the package may be sealed. Alternatively, one end may remain unsealed and the user may be instructed to insert the food into the interior space prior to use.

If the package is used for microwave heating, browning, and/or crisping, the food item within the interior space 156 may be exposed to microwave energy. Upon sufficient exposure to microwave energy, the microwave energy interactive material (i.e., susceptor 144) converts at least a portion of the impinging microwave energy into thermal energy, which then may be transferred to the surface of the food item. As a result, the heating, browning, and/or crisping of the food item may be enhanced. Notably, the somewhat tubular shape of the package 154 allows multiple sides of a food item to be heated, browned, and/or crisped concurrently without having to reposition the food item during the heating cycle.

In some embodiments, the package 154 may be pre-expanded to fit the package contents or to provide a void volume within the interior space 156 to accommodate the expansion of the food during heating. It is also contemplated that the package 154 may expand further during heating, for example, in response to the expansion of the food (e.g., popcorn).

It will be evident that since the package 154 may be configured in a variety of ways, the package may likewise be characterized in a variety of ways. For example, the package 154 may be characterized as a pouch 102 with a reinforced portion 104, or as a package 154 with a flexible portion 102 and a dimensionally stable portion 104. Alternatively, the package 154 may be characterized as a carton or container 104 with a flexible liner 102. Thus, the use of different terminology to describe the package or its components or features should not be limiting in any manner.

Countless materials may be used to form packages according to this disclosure. For example, the first component 102 of the blank 100 (i.e., the flexible portion of the package 154) may comprise any suitable flexible material. For example, the second may comprise paper, a polymer film, metallic layer, or any combination thereof. The paper may have a basis weight of from about 15 to about 60 lb/ream (lb/3000 sq. ft.), for example, from about 20 to about 40 lb/ream, for example, about 25 lb/ream. Suitable polymer films may have a caliper of from about 0.5 mil to about 2 mil. Composites of paper, film, and/or other materials also may be used. Such composites may have a caliper of for example, from about 1.5 to about 5 mils, for example, about 3 mils.

The second component 104 of the blank 100 (i.e., the reinforcing portion of the package 154) may comprise a dimensionally stable and/or semi-rigid material, such as paperboard. The paperboard may have a basis weight of from about 60 to about 330 lb/ream, for example, from about 80 to about 140 lb/ream. The paperboard generally may have a thickness of from about 6 to about 30 mils, for example, from about 8 to about 24 mils. In one particular example, the paperboard has a thickness of from about 12 to about 14 mils. Any suitable paperboard may be used, for example, a solid bleached sulfate board, for example, Fortress® board, commercially available from International Paper Company, Memphis, TN, or solid unbleached sulfate board, such as SUS® board, commercially available from Graphic Packaging International, Marietta, GA.

As mentioned above, the microwave energy interactive material 144 (shown schematically with stippling) may be configured as a susceptor, so that the package 154 may be used to at least one of heat, brown, and crisp the food, for example, in a microwave oven. In such embodiments, the package may include microwave energy interactive material that alters the effect of microwave energy on the food. When the microwave energy interactive material 144 is in the form of a susceptor, it may be configured as a thin layer of microwave energy interactive material generally less than about 100 angstroms in thickness, for example, from about 60 to about 100 angstroms in thickness, and having an optical density of 0.15 to about 0.35, for example, about 0.17 to about 0.28. When sufficiently exposed to microwave energy, the susceptor tends to absorb at least a portion of the microwave energy and convert it to thermal energy (i.e., heat) through resistive losses in the layer of microwave energy interactive material. The remaining microwave energy is either reflected by or transmitted through the susceptor. Susceptors often are used to promote browning and/or crisping of the surface of a food item. However, other microwave energy interactive elements may be used.

Where used, the microwave energy interactive material may comprise an

electroconductive or semiconductive material, for example, a vacuum deposited metal or metal alloy, or a metallic ink, an organic ink, an inorganic ink, a metallic paste, an organic paste, an inorganic paste, or any combination thereof. Examples of metals and metal alloys that may be suitable include, but are not limited to, aluminum, chromium, copper, inconel alloys (nickel-chromium-molybdenum alloy with niobium), iron, magnesium, nickel, stainless steel, tin, titanium, tungsten, and any combination or alloy thereof.

Alternatively, the microwave energy interactive material may comprise a metal oxide, for example, oxides of aluminum, iron, and tin, optionally used in conjunction with an electrically conductive material. Another metal oxide that may be suitable is indium tin oxide (ITO). ITO has a more uniform crystal structure and, therefore, is clear at most coating thicknesses.

Alternatively still, the microwave energy interactive material may comprise a suitable electroconductive, semiconductive, or non-conductive artificial dielectric or ferroelectric. Artificial dielectrics comprise conductive, subdivided material in a polymeric or other suitable matrix or binder, and may include flakes of an electroconductive metal, for example, aluminum.

In other embodiments, the microwave energy interactive material may be carbon- based, for example, as disclosed in U.S. Patent Nos. 4,943,456, 5,002,826, 5, 1 18,747, and 5,410,135.

In still other embodiments, the microwave energy interactive material may interact with the magnetic portion of the electromagnetic energy in the microwave oven. Correctly chosen materials of this type can self-limit based on the loss of interaction when the Curie temperature of the material is reached. An example of such an interactive coating is described in U.S. Patent No. 4,283,427.

As stated above, the microwave energy interactive material (e.g., microwave energy interactive material 144) may be supported on a polymer film (e.g., polymer film 146). The thickness of the film typically may be from about 35 gauge to about 10 mil, for example, from about 40 to about 80 gauge, for example, from about 45 to about 50 gauge, for example, about 48 gauge. Examples of polymer films that may be suitable include, but are not limited to, polyolefins, polyesters, polyamides, polyimides, polysulfones, polyether ketones, cellophanes, or any combination thereof. In one specific example, the polymer film may comprise polyethylene terephthalate (PET). Examples of PET films that may be suitable include, but are not limited to, MELINEX®, commercially available from DuPont Teijan Films (Hopewell, Virginia), SKYROL, commercially available from SKC, Inc. (Covington, Georgia), and BARRIALOX PET, available from Toray Films (Front Royal, VA), and QU50 High Barrier Coated PET, available from Toray Films (Front Royal, VA). The polymer film may be selected to impart various properties to the microwave interactive web, for example, printability, heat resistance, or any other property. As one particular example, the polymer film may be selected to provide a water barrier, oxygen barrier, or any combination thereof. Such barrier film layers may be formed from a polymer film having barrier properties or from any other barrier layer or coating as desired. Suitable polymer films may include, but are not limited to, ethylene vinyl alcohol, barrier nylon, polyvinylidene chloride, barrier

fluoropolymer, nylon 6, nylon 6,6, coextruded nylon 6/EVOH/nylon 6, silicon oxide coated film, barrier polyethylene terephthalate, or any combination thereof.

If desired, the polymer film may undergo one or more treatments to modify the surface prior to depositing the microwave energy interactive material onto the polymer film. By way of example, and not limitation, the polymer film may undergo a plasma treatment to modify the roughness of the surface of the polymer film. While not wishing to be bound by theory, it is believed that such surface treatments may provide a more uniform surface for receiving the microwave energy interactive material, which in turn, may increase the heat flux and maximum temperature of the resulting susceptor structure. Such treatments are discussed in U.S. Patent Application Publication No. 2010/0213192 Al, published August 26, 2010, which is incorporated by reference herein in its entirety.

Other non-conducting substrate materials such as paper and paper laminates, metal oxides, silicates, cellulosics, or any combination thereof, also may be used.

If desired, the susceptor may be used in conjunction with other microwave energy interactive elements and/or structures. Structures including multiple susceptor layers are also contemplated.

By way of example, the susceptor may be used with a foil or high optical density evaporated material having a thickness sufficient to reflect a substantial portion of impinging microwave energy. Such elements typically are formed from a conductive, reflective metal or metal alloy, for example, aluminum, copper, or stainless steel, in the form of a solid "patch" generally having a thickness of from about 0.000285 inches to about 0.005 inches, for example, from about 0.0003 inches to about 0.003 inches. Other such elements may have a thickness of from about 0.00035 inches to about 0.002 inches, for example, 0.0016 inches. In some cases, microwave energy reflecting (or reflective) elements may be used as shielding elements where the food item is prone to scorching or drying out during heating. In other cases, smaller microwave energy reflecting elements may be used to diffuse or lessen the intensity of microwave energy. One example of a material utilizing such microwave energy reflecting elements is commercially available from Graphic Packaging International, Inc. (Marietta, GA) under the trade name MicroRite® packaging material. In other examples, a plurality of microwave energy reflecting elements may be arranged to form a microwave energy distributing element to direct microwave energy to specific areas of the food item. If desired, the loops may be of a length that causes microwave energy to resonate, thereby enhancing the distribution effect. Examples of microwave energy distributing elements are described in U.S. Patent Nos. 6,204,492, 6,433,322, 6,552,315, and 6,677,563.

In still another example, the susceptor may be used with or may be used to form a microwave energy interactive insulating material. Examples of such materials are provided in U.S. Patent No. 7,019,271, U.S. Patent No. 7,351,942, and U.S. Patent Application Publication No. 2008/0078759 Al, published April 3, 2008.

If desired, any of the numerous microwave energy interactive elements described herein or contemplated hereby may be substantially continuous, that is, without substantial breaks or interruptions, or may be discontinuous, for example, by including one or more breaks or apertures that transmit microwave energy. The breaks or apertures may extend through the entire structure, or only through one or more layers. The number, shape, size, and positioning of such breaks or apertures may vary for a particular application depending on the type of construct being formed, the food item to be heated therein or thereon, the desired degree of heating, browning, and/or crisping, whether direct exposure to microwave energy is needed or desired to attain uniform heating of the food item, the need for regulating the change in temperature of the food item through direct heating, and whether and to what extent there is a need for venting.

By way of illustration, a microwave energy interactive element may include one or more transparent areas to effect dielectric heating of the food item. However, where the microwave energy interactive element comprises a susceptor, such apertures decrease the total microwave energy interactive area, and therefore, decrease the amount of microwave energy interactive material available for heating, browning, and/or crisping the surface of the food item. Thus, the relative amounts of microwave energy interactive areas and microwave energy transparent areas must be balanced to attain the desired overall heating characteristics for the particular food item. As another example, one or more portions of the susceptor may be designed to be microwave energy inactive to ensure that the microwave energy is focused efficiently on the areas to be heated, browned, and/or crisped, rather than being lost to portions of the food item not intended to be browned and/or crisped or to the heating environment. Additionally or alternatively, it may be beneficial to create one or more discontinuities or inactive regions to prevent overheating or charring of the food item and/or the construct including the susceptor. By way of example, the susceptor may incorporate one or more "fuse" elements that limit the propagation of cracks in the susceptor structure, and thereby control overheating, in areas of the susceptor structure where heat transfer to the food is low and the susceptor might tend to become too hot. The size and shape of the fuses may be varied as needed. Examples of susceptors including such fuses are provided, for example, in U.S. Patent No. 5,412, 187, U.S. Patent No. 5,530,231, U.S. Patent Application Publication No. US 2008/0035634A1, published February 14, 2008, and PCT Application Publication No. WO 2007/127371 , published November 8, 2007.

In the case of a susceptor, any of such discontinuities or apertures may comprise a physical aperture or void in one or more layers or materials used to form the structure or construct, or may be a non-physical "aperture". A non-physical aperture is a microwave energy transparent area that allows microwave energy to pass through the structure without an actual void or hole cut through the structure. Such areas may be formed by simply not applying microwave energy interactive material to the particular area, by removing microwave energy interactive material from the particular area, or by mechanically deactivating the particular area (thereby rendering the area electrically discontinuous).

Alternatively, the areas may be formed by chemically deactivating the microwave energy interactive material in the particular area, thereby transforming the microwave energy interactive material in the area into a substance that is transparent to microwave energy (i.e., microwave energy inactive). While both physical and non-physical apertures allow the food item to be heated directly by the microwave energy, a physical aperture also provides a venting function to allow steam or other vapors or liquid released from the food item to be carried away from the food item.

As stated above, the susceptor film (e.g., susceptor film 148) (and/or other microwave energy interactive elements) may be joined to a flexible support layer (e.g., support 152), for example, paper, a polymer film, or other suitable material, as described above.

While the present invention is described herein in detail in relation to specific aspects and embodiments, it is to be understood that this detailed description is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the present invention and to set forth the best mode of practicing the invention known to the inventors at the time the invention was made. The detailed description set forth herein is illustrative only and is not intended, nor is to be construed, to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications, and equivalent arrangements of the present invention. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are used only for identification purposes to aid the reader's understanding of the various embodiments of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention unless specifically set forth in the claims. Joinder references (e.g., joined, attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are connected directly and in fixed relation to each other. Further, various elements discussed with reference to the various embodiments may be interchanged to create entirely new embodiments coming within the scope of the present invention.

The above examples are in no way intended to limit the scope of the present invention. It will be understood by those skilled in the art that while the present disclosure has been discussed above with reference to exemplary embodiments, various additions, modifications and changes can be made thereto without departing from the spirit and scope of the invention as set forth in the claims.