Insulating microwave interactive packaging

• US 7,019,271 B2
• Filed: 02/07/2003
• Issued: 03/28/2006
• Est. Priority Date: 02/08/2002
• Status: Expired due to Term

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Wnek, Patrick H., Robison, Richard G., O'Hagan, Brian R., Middleton, Scott W., Lafferty, Terrence P., Cole, Lorin R.
• Primary Examiner(s): Leung, Philip H.
• Application Number:
  US10/501,003
• Publication Number:
  US 20050173425A1
• Time in Patent Office: 1,145 Days
• Field of Search: 219725-735, 219/759, 219/762, 426/107, 426/109, 426/118, 426/234, 426/241, 426/243, 99D/IG.14
• US Class Current: 219/730
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B65D 2581/344 Geometry or shape factors influencing the microwave heating properties
• CPC Class Codes: B65D 2581/3447 Heat attenuators, blocking agents or heat insulators for temperature control
• CPC Class Codes: B65D 2581/3456 Means for holding the contents at a distance from the base of the package, e.g. raised islands or protrusions B65D2581/3459 takes precedence
• CPC Class Codes: B65D 2581/3458 Convective heating chambers, e.g. hot air channels
• CPC Class Codes: B65D 2581/3462 separate from the package, e.g. separate stands
• CPC Class Codes: B65D 2581/3466 Microwave reactive material applied by vacuum, sputter or vapor deposition
• CPC Class Codes: B65D 2581/3467 Microwave reactive layer shaped by delamination, demetallizing or embossing
• CPC Class Codes: B65D 2581/3472 Aluminium or compounds thereof
• CPC Class Codes: B65D 2581/3489 Microwave reflector, i.e. microwave shield B65D2581/3487 takes precedence
• CPC Class Codes: B65D 2581/3494 Microwave susceptor B65D2581/3487 takes precedence
• CPC Class Codes: B65D 2585/366 Pizza
• CPC Class Codes: B65D 5/52 External stands or display elements for contents
• CPC Class Codes: B65D 5/5455 the lines of weakness being provided in a closure hinged to an edge of the container body
• CPC Class Codes: B65D 81/3453 Rigid containers, e.g. trays, bottles, boxes, cups
• CPC Class Codes: B65D 81/3461 Flexible containers, e.g. bags, pouches, envelopes
• CPC Class Codes: B65D 81/3823 formed of different materials, e.g. laminated or foam filling between walls
• CPC Class Codes: B65D 81/3893 formed with double walls, i.e. hollow
• CPC Class Codes: H05B 6/6494 : for cooking
• CPC Class Codes: Y10S 99/14 : Induction heating
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component

Abstract

The combination of insulating material with microwave interactive food packaging for enhanced cooking properties is disclosed. An insulating microwave packaging material (200) and a method of making the same are also disclosed. In one embodiment, the insulating microwave packaging material (200) is formed by bonding a microwave interactive material substrate (205) that creates sensible heat upon exposure to microwave energy to a second substrate (210) along bond lines (212) arranged in a pattern to form closed cells (214). Upon impingement of the insulating microwave packaging material (200) by microwave energy in a microwave oven, the closed cells (214) expand to form insulating pockets (216). One side of the insulating pocket (216) bulges and lofts above the opposite side. When a food product is situated on the insulating microwave packaging material (200), the insulating pockets (216) insulate the food product from the microwave oven environment.

Claims

1. An insulating microwave packaging material comprising:

a first substantially vapor impermeable substrate;

a layer of microwave interactive material supported by the first substantially vapor impermeable substrate;

a dimensionally stable substrate bonded to the layer of microwave interactive material; and

a second substantially vapor impermeable substrate bonded to the dimensionally stable substrate, wherein

the second substantially vapor impermeable substrate and the dimensionally stable substrate are bonded along bond lines formed in a pattern;

the bond lines are substantially vapor impermeable; and

the pattern defines a plurality of closed cells bounded by the second substantially vapor impermeable substrate, the dimensionally stable substrate, and the bond lines;

wherein,

upon impingement of the insulating microwave packaging material by microwave energy in a microwave oven, each of the plurality of closed cells expands to form an insulating pocket comprising;

a bulging side; and

an opposing side;

wherein

the bulging side comprises a portion of each of the first substantially vapor impermeable substrate, the microwave interactive material layer, and the dimensionally stable substrate;

the opposing side comprises a portion of the second substantially vapor impermeable substrate; and

the bulging side lofts away from the opposing side.

2. The insulating microwave packaging material as described claim 1, wherein when a food product is situated adjacent to the first substantially vapor impermeable substrate, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, each of the insulating pockets insulates at least one of the food product and the layer of microwave interactive material from the microwave oven environment to reduce heat transfer from at least one of the food product and the layer of microwave interactive material to the microwave oven environment.

3. The insulating microwave packaging material as described claim 1, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer creates sensible heat that further heats and softens the first substantially vapor impermeable substrate, decreasing resistance of the first substantially vapor impermeable substrate to the formation of the insulating pocket.

4. The insulating microwave packaging material as described claim 1, wherein

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer creates sensible heat that further heats the second substantially vapor impermeable substrate, and

the second substantially vapor impermeable substrate contracts in at least one of the X and Y directions, enhancing the loft of the bulging side.

5. The insulating microwave packaging material as described claim 1, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, a distance between the second vapor impermeable substrate and the dimensionally stable substrate in a center of each of the plurality of closed cells increases by at least an order of magnitude more than the distance before such impingement.

6. The insulating microwave packaging material as described claim 1, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, a distance between the second vapor impermeable substrate and the dimensionally stable substrate in a center of each of the plurality of closed cells increases by up to 30 times more than the distance before such impingement.

7. The insulating microwave packaging material as described claim 1, further comprising:

a first edge; and

a second edge opposite the first edge;

wherein

the first edge is bonded to the second edge; and

the microwave packaging material forms a sleeve for surrounding the food product.

8. The insulating microwave packaging material as described claim 7, wherein

the first substantially vapor impermeable substrate comprises an interior surface of the sleeve;

and

the second substantially vapor impermeable substrate comprises an exterior surface of the sleeve.

9. The insulating microwave packaging material as described claim 8, wherein the bond between the first edge and the second edge is formed by a heat seal.

10. The insulating microwave packaging material as described claim 7, wherein the bond between the first edge and the second edge is formed by an adhesive.

11. The insulating microwave packaging material as described in claim 1, wherein

a portion of a first sheet of the insulating microwave packaging material is bonded to a portion of a second sheet of the insulating microwave packaging material;

and

the second substantially vapor impermeable substrate of the first sheet faces the second substantially vapor impermeable substrate of the second sheet.

12. The insulating microwave packaging material as described in claim 11, wherein

the first sheet is defined by a first perimeter;

the second sheet is defined by a second perimeter; and

the first sheet is bonded to the second sheet at a plurality of points spaced apart along the first perimeter and the second perimeter, wherein,

the first sheet and the second sheet are substantially unrestricted from contraction in at least one of the X and Y directions, and wherein

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer creates sensible heat that further heats the second substantially vapor impermeable substrate of each of the first sheet and the second sheet, and

the second substantially vapor impermeable substrate of each of the first sheet and the second sheet contracts in at least one of the X and Y directions, enhancing the loft of the bulging side of each of the insulating pockets.

13. The insulating microwave packaging material as described in claim 12, wherein

when the food product is situated over at least a portion of the first sheet, and

the second sheet is situated against a surface of the microwave oven,

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer of the second sheet heats the surface of the microwave oven and the first sheet,

counteracting the heat transfer between the food product and the surface of the microwave oven;

augmenting the contraction of the second substantially vapor impermeable substrate of the first sheet; and

enhancing the expansion of each of the plurality of closed cells of the first sheet.

14. The insulating microwave packaging material as described in claim 11, wherein, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the first sheet deforms into a convex canopy with respect to a plane dividing the first sheet and the second sheet;

wherein

a space is created between the first sheet and the second sheet.

15. The insulating microwave packaging material as described in claim 11, wherein, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the second sheet deforms into a convex canopy with respect to a plane dividing the first sheet and the second sheet;

wherein

a space is created between the first sheet and the second sheet.

16. The insulating microwave packaging material as described in claim 1, wherein

a first sheet of the insulating microwave packaging material defined by a first perimeter is bonded to a second sheet of the insulating microwave packaging material defined by a second perimeter;

at least a portion of the first perimeter is bonded to at least a portion of the second perimeter creating a cavity between the first sheet and the second sheet for receiving a food product; and

the first substantially vapor impermeable substrate of the first sheet faces the first substantially vapor impermeable substrate of the second sheet.

17. The insulating microwave packaging material as described in claim 16, wherein an opening to the cavity between the first sheet and the second sheet is provided.

18. The insulating microwave packaging material as described in claim 17, wherein the opening is large enough to accept the food product, and the cavity comprises a pouch.

19. The insulating microwave packaging material as described in claim 17, wherein the opening is a vent to allow water vapor to escape from the cavity during cooking of the food product.

20. The insulating microwave packaging material as described in claim 16, wherein all of the first perimeter is bonded to all of the second perimeter and the food product in the cavity is completely enclosed by the first sheet and the second sheet.

21. The insulating microwave packaging material as described in claim 16, wherein

a third sheet of the insulating microwave packaging material defined by a third perimeter is bonded to the second sheet at a plurality of points spaced apart along the third perimeter and the second perimeter;

and

the second substantially vapor impermeable substrate of the second sheet faces the second substantially vapor impermeable substrate of the third sheet; and

wherein

when the food product is situated within the cavity, and

the third sheet is situated against a surface of the microwave oven,

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer of the third sheet heats the surface of the microwave oven and the second sheet,

counteracting the heat transfer between the food product and the surface of the microwave oven;

augmenting the contraction of the second substantially vapor impermeable substrate of the second sheet; and

enhancing the expansion of each of the plurality of closed cells of the second sheet.

22. The insulating microwave packaging material as described in claim 1, wherein the first substantially vapor impermeable substrate comprises a biaxially-oriented polyester film.

23. The insulating microwave packaging material as described in claim 1, wherein the second substantially vapor impermeable substrate comprises a biaxially-oriented polyester film.

24. A microwave packaging carton comprising:

a top surface;

a bottom surface;

a first sheet of insulating microwave packaging material according to claim 1; and

a second sheet of insulating microwave packaging material according to claim 1;

wherein

the first sheet of insulating microwave packaging material is affixed to the top surface in a manner allowing the first sheet to contract in at least on of the X and Y directions upon impingement of the insulating microwave packaging material by microwave energy; and

the second sheet of insulating microwave packaging material is affixed to the bottom surface in a manner allowing the first sheet to contract in at least on of the X and Y directions upon impingement of the insulating microwave packaging material by microwave energy.

25. The microwave packaging carton of claim 24, wherein at least one of the first sheet and the second sheet is affixed to the top surface or the bottom surface, respectively, by an adhesive.

26. The microwave packaging carton of claim 24, wherein at least one of the first sheet and the second sheet has at least one slit cut adjacent to a portion of a perimeter of the respective first sheet or the second sheet augmenting the ability of the respective first sheet or the second sheet to contract in at least on of the X and Y directions.

32. The insulating microwave packaging material as described claim 1 or 27, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, moisture trapped in the dimensionally stable substrate heats and expands as a vapor, creating pressure, which forms the insulating pocket.

33. The insulating microwave packaging material as described claim 1 or 27, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer creates sensible heat that further heats moisture trapped in the dimensionally stable substrate, which moisture expands as a vapor, creating pressure, which forms the insulating pocket.

34. The insulating microwave packaging material as described claim 1 or 27, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the opposing side remains substantially flat.

35. The insulating microwave packaging material as described claim 1 or 27, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer becomes insulated from the microwave oven environment to reduce heat transfer from the layer of microwave interactive material to the microwave oven environment.

36. The insulating microwave packaging material as described in claim 1 or 27, wherein the pattern comprises an array of shapes selected from a group comprising:

a circle, an oval, a curvilinear shape, a symmetrical curvilinear shape, a triangle, a square, a rectangle, a polygon, a right polygon, and an equilateral polygon.

37. The insulating microwave packaging material as described in claim 36, wherein the equilateral polygon is a hexagon.

38. The insulating microwave packaging material as described in claim 36, wherein each of the shapes in the array is nested with each adjacent shape in the array in a tile-like pattern.

39. The insulating microwave packaging material as described in claim 36, wherein each of the shapes in the array is elongate and oriented parallel to adjacent shapes.

40. The insulating microwave packaging material as described in claim 1 or 27, wherein the microwave interactive material layer comprises aluminum.

41. The insulating microwave packaging material as described in claim 1 or 27, wherein the dimensionally stable substrate is selected from a group comprising:

paper, paperboard, and plastic.

42. The insulating microwave packaging material as described in claim 1 or 27, wherein the bond lines comprise an adhesive.

43. The insulating microwave packaging material as described in claim 42, wherein the adhesive penetrates the dimensionally stable substrate to form a substantially vapor impermeable barrier in conjunction with the first substantially vapor impermeable substrate.

44. The insulating microwave packaging material as described in claim 1 or 27, wherein the wherein portions of the microwave interactive material are inactivated in the same pattern as the bond lines.

45. The insulating microwave packaging material as described in claim 1 or 27, wherein the bond lines comprise a heat seal.

46. The insulating microwave packaging material as described in claim 45, wherein the heat seal is formed by melting the second substantially vapor impermeable substrate along the bond lines, and wherein a melted portion of the second substantially vapor impermeable substrate penetrates the dimensionally stable substrate to form a substantially vapor impermeable barrier in conjunction with the first substantially vapor impermeable substrate.

122. The microwave package of claim 119, wherein the microwave interactive material comprises insulating microwave packaging material according to claim 1.

124. The microwave cooking container of claim 123, wherein the microwave interactive material comprises an insulating microwave interactive material according to claim 1.

27. An insulating microwave packaging material comprising:

a first substantially vapor impermeable substrate;

a layer of microwave interactive material supported by the first substantially vapor impermeable substrate;

a dimensionally stable substrate bonded to the layer of microwave interactive material; and

a second substantially vapor impermeable substrate bonded to the dimensionally stable substrate, wherein

the second substantially vapor impermeable substrate and the dimensionally stable substrate are bonded along bond lines formed in a pattern;

the bond lines are substantially vapor impermeable; and

the pattern defines a plurality of closed cells bounded by the second substantially vapor impermeable substrate, the dimensionally stable substrate, and the bond lines;

wherein,

upon impingement of the insulating microwave packaging material by microwave energy in a microwave oven, each of the plurality of closed cells expands to form an insulating pocket comprising;

a bulging side; and

an opposing side;

wherein

the bulging side comprises a portion of the second substantially vapor impermeable substrate;

the opposing side comprises a portion of each of the first substantially vapor impermeable substrate, the microwave interactive material layer, and the dimensionally stable substrate; and

the bulging side lofts away from the opposing side.

28. The insulating microwave packaging material as described in claim 27, wherein when a food product is situated adjacent to the second substantially vapor impermeable substrate, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, each of the insulating pockets insulates at least one of the food product and the layer of microwave interactive material from the microwave oven environment to reduce heat transfer from at least one of the food product and the layer of microwave interactive material to the microwave oven environment.

29. The insulating microwave packaging material as described in claim 27, wherein when a food product is situated adjacent to the second substantially vapor impermeable substrate, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, each of the insulating pockets insulates at least one of the food product and the layer of microwave interactive material from a consumer'"'"'s skin to reduce heat transfer from at least one of the food product and the insulating microwave packaging material to the consumer'"'"'s skin when the consumer removes the insulating microwave packaging material from the microwave oven after cooking.

30. The insulating microwave packaging material as described claim 27, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer creates sensible heat that further heats and softens the second substantially vapor impermeable substrate, decreasing resistance of the second substantially vapor impermeable substrate to the formation of the insulating pocket.

31. The insulating microwave packaging material as described in claim 27, wherein the second substantially vapor impermeable substrate comprises an amorphous polyester film.

47. A method of making an insulating microwave packaging material, the method comprising:

providing a first substantially vapor impermeable substrate;

supporting a layer of microwave interactive material on the first substantially vapor impermeable substrate;

bonding a dimensionally stable substrate to the layer of microwave interactive material; and

bonding a second substantially vapor impermeable substrate to the dimensionally stable substrate along bond lines formed in a pattern, wherein

the bond lines are substantially vapor impermeable; and

the pattern defines a plurality of closed cells bounded by the second substantially vapor impermeable substrate, the dimensionally stable substrate, and the bond lines; and

wherein,

upon impingement of the insulating microwave packaging material by microwave energy in a microwave oven, each of the plurality of closed cells expands to form an insulating pocket comprising;

a bulging side; and

an opposing side;

wherein

the bulging side comprises a portion of each of the first substantially vapor impermeable substrate, the microwave interactive material layer, and the dimensionally stable substrate;

the opposing side comprises a portion of the second substantially vapor impermeable substrate; and

the bulging side lofts away from the opposing side.

48. The method as described claim 47, wherein when a food product is situated adjacent to the first substantially vapor impermeable substrate, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, each of the insulating pockets insulates at least one of the food product and the layer of microwave interactive material from the microwave oven environment to reduce heat transfer from at least one of the food product and the layer of microwave interactive material to the microwave oven environment.

49. The method as described claim 47, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer creates sensible heat that further heats and softens the first substantially vapor impermeable substrate decreasing resistance of the first substantially vapor impermeable substrate to the formation of the insulating pocket.

50. The method as described claim 47, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer creates sensible heat that further heats the second substantially vapor impermeable substrate, and

the second substantially vapor impermeable substrate contracts in at least one of the X and Y directions, enhancing the loft of the bulging side.

51. The method as described claim 47, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, a distance between the second vapor impermeable substrate and the dimensionally stable substrate in a center of each of the plurality of closed cells increases by at least an order of magnitude more than the distance before such impingement.

52. The method as described claim 47, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, a distance between the second vapor impermeable substrate and the dimensionally stable substrate in a center of each of the plurality of closed cells increases by up to 30 times more than the distance before such impingement.

53. The method as described claim 47, wherein the insulating microwave packaging material further comprises:

a first edge; and

a second edge opposite the first edge; and

wherein the method further comprises;

bonding the first edge to the second edge;

wherein

the microwave packaging material forms a sleeve for surrounding the food product.

54. The method as described claim 53, wherein the first substantially vapor impermeable substrate comprises an interior surface of the sleeve;

and the second substantially vapor impermeable substrate comprises an exterior surface of the sleeve.

55. The method as described claim 54, wherein the step of bonding the first edge and the second edge further comprises heat sealing the first substantially vapor impermeable substrate along the first edge to the first substantially vapor impermeable substrate along the second edge.

56. The method as described claim 53, wherein the step of bonding the first edge to the second edge further comprises dispensing an adhesive between the first edge and the second edge.

57. The method as described in claim 47, further comprising:

dividing the insulating microwave packaging material to form a first sheet and a second sheet;

placing the second substantially vapor impermeable substrate of the first sheet facing the second substantially vapor impermeable substrate of the second sheet; and

bonding a portion of the first sheet of the insulating microwave packaging material to a portion of the second sheet of the insulating microwave packaging material.

58. The method as described in claim 57, wherein

the first sheet is defined by a first perimeter;

the second sheet is defined by a second perimeter; and

wherein the step of bonding the first sheet to the second sheet further comprises;

bonding the first sheet to the second sheet at a plurality of points spaced apart along the first perimeter and the second perimeter, wherein,

the first sheet and the second sheet are substantially unrestricted from contraction in at least one of the X and Y directions, and wherein

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer creates sensible heat that further heats the second substantially vapor impermeable substrate of each of the first sheet and the second sheet, and

the second substantially vapor impermeable substrate of each of the first sheet and the second sheet contracts in at least one of the X and Y directions, enhancing the loft of the bulging side of each of the insulating pockets.

59. The method as described in claim 58, wherein

when the food product is situated over at least a portion of the first sheet, and

the second sheet is situated against a surface of the microwave oven,

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer of the second sheet heats the surface of the microwave oven and the first sheet,

counteracting the heat transfer between the food product and the surface of the microwave oven;

augmenting the contraction of the second substantially vapor impermeable substrate of the first sheet; and

enhancing the expansion of each of the plurality of closed cells of the first sheet.

60. The method as described in claim 57, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the first sheet deforms into a convex canopy with respect to a plane dividing the first sheet and the second sheet;

and

a space is created between the first sheet and the second sheet.

61. The method as described in claim 57, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the second sheet deforms into a convex canopy with respect to a plane dividing the first sheet and the second sheet;

wherein

a space is created between the first sheet and the second sheet.

62. The method as described in claim 47, further comprising:

dividing the insulating microwave packaging material to form a first sheet and a second sheet, wherein

the first sheet is defined by a first perimeter, and

the second sheet is defined by a second perimeter;

placing the first substantially vapor impermeable substrate of the first sheet facing the first substantially vapor impermeable substrate of the second sheet; and

bonding at least a portion of the first perimeter to at least a portion of the second perimeter creating a cavity between the first sheet and the second sheet for receiving a food product.

63. The method as described in claim 62 further comprising forming an opening to the cavity between the first sheet and the second sheet.

64. The method as described in claim 63, wherein the opening is large enough to accept the food product, and the cavity comprises a pouch.

65. The method as described in claim 63, wherein the opening is a vent to allow water vapor to escape from the cavity during cooking of the food product.

66. The method as described in claim 62, wherein the step of bonding at least a portion of the first perimeter to at least a portion of the second perimeter further comprises bonding all of the first perimeter to all of the second perimeter, wherein the food product in the cavity is completely enclosed by the first sheet and the second sheet.

67. The method as described in claim 62, wherein the step of dividing further comprises

dividing the insulating microwave packaging material to form a third sheet, wherein

the third sheet is defined by a third perimeter;

and

wherein the method further comprises;

placing the second substantially vapor impermeable substrate of the second sheet facing the second substantially vapor impermeable substrate of the third sheet; and

bonding the third sheet to the second sheet at a plurality of points spaced apart along the third perimeter and the second perimeter; and

wherein

when the food product is situated within the cavity, and

the third sheet is situated against a surface of the microwave oven,

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer of the third sheet heats the surface of the microwave oven and the second sheet,

counteracting the heat transfer between the food product and the surface of the microwave oven;

augmenting the contraction of the second substantially vapor impermeable substrate of the second sheet; and

enhancing the expansion of each of the plurality of closed cells of the second sheet.

68. The method as described in claim 47, wherein the first substantially vapor impermeable substrate comprises a biaxially-oriented polyester film.

69. The method as described in claim 47, wherein the second substantially vapor impermeable substrate comprises a biaxially-oriented polyester film.

75. The method as described claim 47 or 70, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, moisture trapped in the dimensionally stable substrate heats and expands as a vapor, creating pressure, which forms the insulating pocket.

76. The method as described claim 47 or 70, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer creates sensible heat that further heats moisture trapped in the dimensionally stable substrate, which moisture expands as a vapor, creating pressure, which forms the insulating pocket.

77. The method as described claim 47 or 70, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the opposing side remains substantially flat.

78. The method as described claim 47 or 70, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer becomes insulated from the microwave oven environment to reduce heat transfer from the microwave interactive material layer to the microwave oven environment.

79. The method as described in claim 47 or 70, wherein the pattern comprises an array of shapes selected from a group comprising:

a circle, an oval, a curvilinear shape, a symmetrical curvilinear shape, a triangle, a square, a rectangle, a polygon, a right polygon, and an equilateral polygon.

80. The method as described in claim 79, wherein the equilateral polygon is a hexagon.

81. The method as described in claim 79, wherein each of the shapes in the array is nested with each adjacent shape in the array in a tile-like pattern.

82. The method as described in claim 79, wherein each of the shapes in the array is elongate and oriented parallel to adjacent shapes.

83. The method as described in claim 47 or 70, wherein the microwave interactive material layer comprises aluminum.

84. The method as described in claim 47 or 70, wherein the dimensionally stable substrate is selected from a group comprising:

paper, paperboard, and plastic.

85. The method as described in claim 47 or 70, wherein the step of bonding the second substantially vapor impermeable substrate and the dimensionally stable substrate further comprises dispensing an adhesive along the bond lines.

86. The method as described in claim 85, wherein the adhesive penetrates the dimensionally stable substrate to form a substantially vapor impermeable barrier in conjunction with the first substantially vapor impermeable substrate.

87. The method as described in claim 47 or 70 further comprising the step of inactivating portions of the microwave interactive material in the same pattern as the bond lines.

88. The method as described in claim 47 or 70, wherein the step of bonding the second substantially vapor impermeable substrate and the dimensionally stable substrate further comprises heat sealing the substantially vapor impermeable substrate to the dimensionally stable substrate along the bond lines.

89. The method as described in claim 88, wherein the step of heat sealing further comprises melting the second substantially vapor impermeable substrate along the bond lines, wherein a melted portion of the second substantially vapor impermeable substrate penetrates the dimensionally stable substrate to form a substantially vapor impermeable barrier in conjunction with the first substantially vapor impermeable substrate.

70. A method of making an insulating microwave packaging material, the method comprising:

providing a first substantially vapor impermeable substrate;

supporting a layer of microwave interactive material on the first substantially vapor impermeable substrate;

bonding a dimensionally stable substrate to the layer of microwave interactive material; and

bonding a second substantially vapor impermeable substrate to the dimensionally stable substrate along bond lines formed in a pattern, wherein

the bond lines are substantially vapor impermeable; and

the pattern defines a plurality of closed cells bounded by the second substantially vapor impermeable substrate, the dimensionally stable substrate, and the bond lines; and

wherein,

upon impingement of the insulating microwave packaging material by microwave energy in a microwave oven, each of the plurality of closed cells expands to form an insulating pocket comprising;

a bulging side; and

an opposing side;

wherein

the bulging side comprises a portion of the second substantially vapor impermeable substrate;

the opposing side comprises a portion of each of the first substantially vapor impermeable substrate, the microwave interactive material layer, and the dimensionally stable substrate; and

the bulging side lofts away from the opposing side.

71. The insulating microwave packaging material as described in claim 70, wherein when a food product is situated adjacent to the first substantially vapor impermeable substrate, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, each of the insulating pockets insulates at least one of the food product and the layer of microwave interactive material from the microwave oven environment to reduce heat transfer from at least one of the food product and the layer of microwave interactive material to the microwave oven environment.

72. The insulating microwave packaging material as described in claim 70, wherein when a food product is situated adjacent to the first substantially vapor impermeable substrate, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, each of the insulating pockets insulates at least one of the food product and the layer of microwave interactive material from a consumer'"'"'s skin to reduce heat transfer from at least one of the food product and the insulating microwave packaging material to the consumer'"'"'s skin when the consumer removes the insulating microwave packaging material from the microwave oven after cooking.

73. The method as described claim 70, wherein upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the microwave interactive material layer creates sensible heat that further heats and softens the second substantially vapor impermeable substrate decreasing resistance of the second substantially vapor impermeable substrate to the formation of the insulating pocket.

74. The method as described in claim 70, wherein the second substantially vapor impermeable substrate comprises an amorphous polyester film.

90. A microwavable baking surface comprising:

a baking substrate containing an aperture;

a first sheet of an insulating microwave packaging material; and

a second sheet of the insulating microwave packaging material;

wherein

the first sheet and the second sheet are arranged adjacent to each other and substantially cover the aperture; and

the insulating microwave packaging material comprises;

a first substantially vapor impermeable substrate;

a layer of microwave interactive material supported by the first substantially vapor impermeable substrate;

a dimensionally stable substrate bonded to the layer of microwave interactive material; and

a second substantially vapor impermeable substrate bonded to the dimensionally stable substrate, wherein

the second substantially vapor impermeable substrate and the dimensionally stable substrate are bonded along bond lines formed in a pattern;

the bond lines are substantially vapor impermeable; and

the pattern defines a plurality of closed cells bounded by the first substantially vapor impermeable substrate, the dimensionally stable substrate, and the bond lines;

wherein

upon impingement of the insulating microwave packaging material by microwave energy in a microwave oven, each of the plurality of closed cells expands to form an insulating pocket comprising;

a bulging side; and

an opposing side;

wherein

the bulging side comprises a portion of each of the first substantially vapor impermeable substrate, the microwave interactive material layer, and the dimensionally stable substrate;

the opposing side comprises a portion of the second substantially vapor impermeable substrate; and

the bulging side lofts away from the opposing side.

91. The microwavable baking surface as described in claim 90, wherein when a food product is situated adjacent to the first sheet, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, each of the insulating pockets of the second sheet insulates at least one of the food product and the first sheet from the microwave oven environment to reduce heat transfer from at least one of the food product and the layer of microwave interactive material of the first sheet to the microwave oven environment.

92. The microwavable baking surface as described in claim 90, wherein the second substantially vapor impermeable substrate of the first sheet faces the second substantially vapor impermeable substrate of the second sheet.

93. The microwavable baking surface as described in claim 92, wherein the baking substrate further comprises:

a top side; and

a bottom side; and

wherein

the first sheet is defined by a first perimeter;

the second sheet is defined by a second perimeter;

a portion of the second substantially vapor impermeable substrate of the first sheet along the first perimeter is bonded to the top side of the baking substrate; and

a portion of the second substantially vapor impermeable substrate of the second sheet along the second perimeter is bonded to the bottom side of the baking substrate.

94. The microwavable baking surface as described in claim 93, wherein the bond between the portion of the second substantially vapor impermeable substrate of the first sheet and the top side of the baking substrate and the bond between the portion of the second substantially vapor impermeable substrate of the second sheet and the bottom side of the baking substrate comprise a temperature sensitive adhesive, and wherein

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer of each of the first sheet and the second sheet creates sensible heat that further heats the temperature sensitive adhesive;

the temperature sensitive adhesive decomposes at a certain temperature, releasing the bonds; and

the second substantially vapor impermeable substrate of each of the first sheet and the second sheet contracts in at least one of the X and Y directions, enhancing the loft of the bulging side of each of the insulating pockets.

95. The microwavable baking surface as described in claim 92, wherein, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the first sheet deforms into a convex canopy with respect to a plane dividing the first sheet and the second sheet;

and

a space is created between the first sheet and the second sheet.

96. The microwavable baking surface as described in claim 92, wherein, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the second sheet deforms into a convex canopy with respect to a plane dividing the first sheet and the second sheet;

wherein

a space is created between the first sheet and the second sheet.

97. The microwavable baking surface as described claim 90, wherein,

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer of each of the first sheet and the second sheet creates sensible heat that further heats the second substantially vapor impermeable substrate of each of the first sheet and the second sheet;

and

the second substantially vapor impermeable substrate of each of the first sheet and the second sheet contracts in at least one of the X and Y directions, enhancing the loft of the bulging side of each of the insulating pockets.

98. The microwavable baking surface as described in claim 97, wherein

when the food product is situated over at least a portion of the first sheet, and

the second sheet is situated against a surface of the microwave oven,

upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven,

the microwave interactive material layer of the second sheet heats the surface of the microwave oven and the first sheet,

counteracting the heat transfer between the food product and the surface of the microwave oven;

augmenting the contraction of the second substantially vapor impermeable substrate of the first sheet; and

enhancing the expansion of each of the plurality of closed cells of the first sheet.

99. The microwavable baking surface as described in claim 90, wherein, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, the opposing side remains substantially flat.

100. The microwavable baking surface as described claim 90, wherein, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, a distance between the second vapor impermeable substrate and the dimensionally stable substrate in a center of each of the plurality of closed cells of at least one of the first sheet and the second sheet increases by at least an order of magnitude more than the distance before such impingement.

101. The microwavable baking surface as described claim 90, wherein, upon impingement of the insulating microwave packaging material by microwave energy in the microwave oven, a distance between the second vapor impermeable substrate and the dimensionally stable substrate in a center of each of the plurality of closed cells of at least one of the first sheet and the second sheet increases by up to 30 times more than the distance before such impingement.

102. The microwavable baking surface as described in claim 90, wherein the pattern comprises an array of shapes selected from the group comprising:

a circle, an oval, a curvilinear shape, a symmetrical curvilinear shape, a triangle, a square, a rectangle, a polygon, a right polygon, and an equilateral polygon.

103. The microwavable baking surface as described in claim 102, wherein the equilateral polygon is a hexagon.

104. The microwavable baking surface as described in claim 102, wherein each of the shapes in the array is nested with each adjacent shape in the array in a tile-like pattern.

105. The microwavable baking surface as described in claim 90, wherein the baking substrate comprises paperboard.

106. The microwavable baking surface as described in claim 90, wherein the baking substrate comprises a susceptor.

107. The microwavable baking surface as described in claim 90, wherein the baking substrate comprises an abuse-tolerant microwave packaging material.

108. The microwavable baking surface as described in claim 90, wherein the baking substrate is disk-shaped.

109. The microwavable baking surface as described in claim 108, wherein the aperture is circular and concentric with the baking surface.

110. The microwavable baking surface as described in claim 90, wherein the food product is a frozen pizza.

111. The microwavable baking surface as described in claim 90, wherein the first substantially vapor impermeable substrate comprises a biaxially-oriented polyester film.

112. The microwavable baking surface as described in claim 90, wherein the second substantially vapor impermeable substrate comprises a biaxially-oriented polyester film.

113. The microwavable baking surface as described in claim 90, wherein the microwave interactive material layer comprises aluminum.

114. The microwavable baking surface as described in claim 90, wherein the dimensionally stable substrate is selected from a group comprising:

paper, paperboard, and plastic.

115. The microwavable baking surface as described in claim 90, wherein the bond lines comprise an adhesive.

116. The microwavable baking surface as described in claim 115, wherein the adhesive penetrates the dimensionally stable substrate to form a substantially vapor impermeable barrier in conjunction with the first substantially vapor impermeable substrate.

117. The microwavable baking surface as described in claim 90, wherein the bond lines comprise a heat seal.

118. The microwavable baking surface as described in claim 117, wherein the heat seal is formed by melting the second substantially vapor impermeable substrate along the bond lines, and wherein a melted portion of the second substantially vapor impermeable substrate penetrates the dimensionally stable substrate to form a substantially vapor impermeable barrier in conjunction with the first substantially vapor impermeable substrate.

119. A microwave package comprising:

a carton form comprising;

a base with a central fold line;

a first side wall hinged to the base along a first fold line; and

a second side wall hinged to the base along a second fold line; and

a pouch comprising microwave interactive material, the pouch supported by the carton form;

wherein

the pouch is positioned between the base, the first side wall, and the second side wall of the carton form;

the carton form and the pouch may be alternately folded flat and erected to open the pouch; and

wherein

when the carton form is erected by opening the folded base into a V-form, the base may be inverted and the carton form is braced open by the base which is held open in tension between the first side wall and the second side wall.

120. The microwave package of claim 119, wherein the first fold line and the second fold line are convexly curved so that, upon inverting, the base of the carton form assumes a concavely curved form with the first side wall and the second side wall of the carton form bowed or convexly curved.

121. The microwave package of claim 119, wherein the pouch is affixed to at least one of the first side wall and the second side wall of the carton form.

123. A microwave cooking container comprising:

a first end, wherein the first end contains a first aperture;

a second end, wherein the second end contains a second aperture; and

a body, wherein the body comprises a microwave interactive material; and

wherein

a food product is at least partially surrounded by the body;

the first end provides a foundation for maintaining the container in an upright position when the first end is placed upon a surface;

the first aperture in the first end is exposed to a source of air in a cooking environment when the first end is placed upon a surface; and

a draft is created during a cooking cycle in a microwave oven wherein air is ported through the first aperture and vented through the second aperture.

125. The microwave cooking container of claim 123, wherein the microwave interactive material comprises an insulating microwave interactive material according to claim 27.

126. The microwave cooking container of claim 123, wherein the body further comprises an exterior surface;

and

the exterior surface further comprises an insulating material that reduces heat transfer from the container to a consumer touching the container.

127. The microwave cooking container of claim 123, wherein the body further comprises an interior surface;

and

at least a first portion of the interior surface further comprises the microwave interactive material.

128. The microwave cooking container of claim 127, wherein a second portion of the interior surface of the body does not comprise the microwave interactive material;

and

the body further comprises an exterior surface;

wherein a portion of the exterior surface opposite the second portion of the interior surface reduces the heat transfer from the container to a consumer touching the container.

129. The microwave cooking container of claim 128, wherein the portion of the exterior surface opposite the second portion of the interior surface is frusto-conical in shape.

130. The microwave cooking container of claim 123, wherein

the body further comprises an upper portion having the first end and a lower portion having the second end;

the upper portion and the lower portion are each of separate construction; and

the upper portion is attached to the lower portion at a common interface between the upper portion and the lower portion.