Conformable wrap susceptor with releasable seal for microwave cooking

Claim 2

A package useful for cooking food which expands upon cooking in a microwave oven, comprising; (a) a thermally stable film wrapped about said food; (b) at least one layer of heat releasable thermoplastic material located on at least a portion of the surface of said thermally stable film and forming a layered face-to-face seal from at least two surface areas of said thermally stable film, whereby the film is sealed in its wrapped conformation; and (c) a microwave susceptor material contained within at least a part of said seal and extending over at least that portion of the surface of the film which is wrapped about the food, said susceptor material having sufficient microwave absorbance to generate sufficient heat under microwave cooking conditions to brown or crispen the surface of the food and to raise the heat releasable thermoplastic material of the seal above its yield temperature, whereby said seal selectively opens in response to the expansion of said food, thereby maintaining contact between the surface of the food and the microwave susceptor material.

Claim 3

The package of claim 1 wherein the microwave susceptor material comprises a flake material.

Claim 4

The package of claim 2 wherein said flake material is embedded within at least one said layer of heat-releasable material.

Claim 5

The package of claim 3 wherein the flake material is aluminum flake.

Claim 6

The package of claim 4 further comprising a second sheet of microwave susceptor material positioned between said food and an adjacent layer of heat-releasable thermoplastic material containing said flake material.

Claim 7

The package of claim 4 wherein the thermally stable film is selected from the group consisting of polyesters, polyarylates, polycarbonates, polyimides, polyetherimides, semicrystalline polyamides, and polymethylpentene.

Claim 8

The package of claim 6 wherein the thermally stable film is a polyester selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, and copolyesters prepared from the condensation of terephthalic acid or 2,6-naphthalenedicarboxylic acid, with ethylene glycol, butylene glycol, or 1,4-cyclohexanedimethanol.

Claim 9

The package of claim 7 wherein the thermally s film is biaxially oriented polyethylene terephthalate film.

Claim 10

The package of claim 4 wherein the heat-releasable thermoplastic material is selected from the group consisting of polyester copolymers and ethylene copolymers.

Claim 11

The package of claim 9 wherein the layer of heat-releasable thermoplastic material is prepared from polymers selected from the group consisting of copolymers of ethylene glycol, terephthalic acid and azelaic acid; copolymers of ethylene glycol, terephthalic acid, and isophthalic acid; and mixtures of these copolymers.

Claim 12

The package of claim 10 wherein the layer of heat-releasable thermoplastic material is made of a copolymer prepared by the condensation of ethylene glycol with terephthalic acid and azelaic acid, said acids being in the mole ratio of about 50:50 to about 55:45.

Claim 13

The package of claim 4 wherein the heat-releasable thermoplastic material is a blend of polymers selected to provide a seal which releases at a predetermined temperature.

Claim 14

The package of claim 1 wherein said food generates pressure from vapor upon cooking, whereby said selectively heat-releasable seal selectively opens in response to the pressure of said vapor, thereby venting said vapor.

Claim 15

A process for preparing a package for cooking food which expands upon cooking in a microwave oven, comprising the steps of: (a) selecting a conformable film having coated thereon at least one surface layer of a heat-releasable thermoplastic material and a microwave susceptive material in close proximity to said heat-releasable thermoplastic material and extending over at least that portion of the surface of the film which is destined to be in contact with the food, said susceptor material having sufficient microwave absorbance to generate sufficient heat under microwave cooking conditions to brown or crispen the surface of the food and to raise the heat releasable thermoplastic material above its yield temperature, said conformable film being of sufficient size to contain said food when said film is folded over on itself, (b) folding said conformable film over on itself to form two flaps, with the side of said film coated with the surface layer of heat-releasable thermoplastic material facing inward, (c) placing said food between said flaps, and (d) sealing the film around the remaining edges of said food to form at least one layered face-to-face seal in which said microwave susceptive material is in close contact with the heat-releasable thermoplastic material and is contained within the seal, whereby the food is securely enclosed within said film; whereby said seal selectively opens in response to the expansion of said food during cooking, thereby maintaining contact between the surface of the food and the microwave susceptor material.

Claim 16

A process for preparing a package for cooking food which expands upon cooking in a microwave oven, comprising the steps of: (a) selecting a conformable film having coated thereon at least one surface layer of a heat-releasable thermoplastic material and a microwave susceptive material in close proximity to said heat-releasable thermoplastic material and extending over at least that portion of the surface of the film which is destined to be in contact with the food, said susceptor material having sufficient microwave absorbance to generate sufficient heat under microwave cooking conditions to brown or crispen the surface of the food and to raise the heat releasable thermoplastic material above its yield temperature, said conformable film being of sufficient size to contain said food when said film is folded over on itself, (b) folding said conformable film over on itself to form two flaps, with the side of said film coated with the surface layer of heat-releasable thermoplastic material facing inward, (c) placing said food between said flaps, and (d) sealing the film around the remaining edges of said food to form at least one layered face-to-face seal in which said microwave susceptive material is in close contact with the heat-releasable thermoplastic material and is contained within the seal, whereby the food is securely enclosed within said film; whereby said seal selectively opens in response to the expansion of said food during cooking, thereby maintaining contact between the surface of the food and the microwave susceptor material.

Claim 17

The process of claim 14 wherein the geometry of said selectively heat-releasable seal is adjusted to permit the food to expand in a controlled manner upon cooking.

Claim 18

A process for cooking foods in a microwave oven, comprising placing food contained in the package of claim 1 into a microwave oven and operating said oven for a time sufficient to cook said food.

Claim 19

The process of claim 16 wherein vents are placed in said package prior to cooking.

Claim 20

The process of claim 16 wherein said package is elevated above the floor of said microwave oven by about 25 mm to about 30 mm during cooking.

Claim 21

The package of claim 1 wherein the seal progressively peels opens from the inside outward in response to pressure generated under microwave cooking conditions from the food contained in said package.