Perforated susceptor for microwave cooking
First Claim
1. For use in microwave heating of food products, a susceptor comprising:
- a substrate; and
a thin layer of microwave-interactive material deposited on said substrate having a coefficient of thermal expansion different from that of said substrate, said layer having a plurality of perforations distributed over the surface thereof without corresponding openings in said substrate, said perforations are substantially round and between about 0.025 to 0.060 inches in diameter, said perforations inhibiting the breakup of said susceptor when said susceptor is subjected to microwave energy.
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Accused Products
Abstract
A perforated susceptor for use in disposable packaging that functions as the cooking container for a microwaveable food product such as popcorn. The susceptor includes a thin layer of microwave-interactive material, such as aluminum with an optical density of about 0.22 to 0.35. This layer is deposited on a substrate of a flexible plastic film. Perforations in the metallic layer are less than 0.060 inches in diameter, do not extend into the substrate, and are arrayed in rows and columns spaced at regular intervals of between 1/16 and 3/16 of an inch, so that the combined surface area of the perforations represents less than 20 percent of the area of the susceptor. The film can be directly bonded, through the perforations, to a sheet that forms part of a package.
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Citations
34 Claims
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1. For use in microwave heating of food products, a susceptor comprising:
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a substrate; and a thin layer of microwave-interactive material deposited on said substrate having a coefficient of thermal expansion different from that of said substrate, said layer having a plurality of perforations distributed over the surface thereof without corresponding openings in said substrate, said perforations are substantially round and between about 0.025 to 0.060 inches in diameter, said perforations inhibiting the breakup of said susceptor when said susceptor is subjected to microwave energy. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A container for microwave food products comprising:
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a sheet of material forming at least part of said container; and a susceptor bonded to a portion of said sheet, said susceptor having a substrate and a thin layer of microwave-interactive material deposited on said substrate, said layer having a coefficient of thermal expansion different from that of said substrate, said layer having a plurality of perforations distributed over the surface thereof without corresponding openings in said substrate, said perforations are substantially round and between about 0.025 to 0.060 inches in diameter, said perforations inhibiting the breakup of said susceptor when said susceptor is subjected to microwave energy. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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26. A container for microwave food products comprising:
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a sheet of material forming at least part of said container; and a susceptor bonded to a portion of said sheet, said susceptor having a substrate and a thin layer of microwave-interactive material deposited on said substrate, said susceptor positioned relative to said sheet so that said layer is located between said sheet and said substrate, said layer having a plurality of perforations distributed over the surface thereof without corresponding openings in said substrate, said perforations are substantially round and between about 0.025 to 0.060 inches in diameter, wherein said perforations inhibit the breakup of said susceptor when said susceptor is subjected to microwave energy, and wherein said substrate is directly, but discontinuously bonded to said sheet through said perforations.
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27. A combination comprising:
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an edible charge of popping corn; and a container holding said charge and suitable for cooking said charge in a microwave oven, said container having a sheet of material forming at least a portion thereof and a susceptor bonded to said sheet, said susceptor having a substrate and a thin layer of microwave-interactive material deposited on said substrate, said layer having a coefficient of thermal expansion different from that of said substrate, said layer having a plurality of perforations distributed over the surface thereof without corresponding openings in said substrate or said sheet, said perforations are substantially round and between about 0.025 to 0.060 inches in diameter, said perforations inhibiting the breakup of said susceptor when said susceptor is subjected to microwave energy. - View Dependent Claims (28, 29, 30, 31, 32, 33)
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34. A combination comprising:
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an edible charge of popping corn and shortening; and a gussetted, flexible paper bag containing said charge and suitable for cooking said charge in a microwave oven, said bag having gussets openable under pressure of steam generated during cooking, and a susceptor bonded to a portion of the interior surface of said bag, said susceptor having a plastic substrate and a thin layer of microwave-interactive vacuum-metallized aluminum deposited on said substrate, said susceptor positioned relative to said bag so that said layer is located between said substrate and said interior surface of said bag, said layer having a coefficient of thermal expansion different from that of said substrate, said layer also having a plurality of substantially round perforations through which said substrate is directly, but discontinuously bonded to said interior surface of said bag, said perforations also serving to inhibit the breakup of said susceptor when said susceptor is subjected to microwave energy, said perforations being about 0.025 to 0.060 inches in diameter distributed over the surface of said layer and arrayed in parallel rows and columns perpendicular to said rows and spaced at regular intervals of between 1/16 and 3/16 of an inch, wherein the combined area of said perforations represents less than 20 percent of the surface area of said layer, there being no corresponding openings in said substrate.
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Specification