SYSTEM, ASSEMBLY AND METHOD FOR PREPARING A PALATABLE MICROWAVED SANDWICH

Abstract

A system, assembly and method for cooking a palatable sandwich in the microwave includes a sleeve sized for receiving a compressed sandwich whereby the compressed sandwich maintains contact with the susceptor material of the sleeve while cooking, in spite of sandwich shrinkage. A compression means assists in uniformly compressing the sandwich and insertion into the sleeve. The sleeve can be easily removed after cooking.

Description

RELATED APPLICATIONS

This application claims the benefit of US Provisional Patent Application 61,651,901, filed May 25, 2012.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to articles and methods used in preparing food, and more particularly, to a system and method for inserting an uncooked sandwich into a sleeve for subsequent microwaving.

2. Description of the Prior Art

Sales of microwaves ovens have undergone tremendous growth in the United Sates to the point that they are now extensively available and used in most places where food products are sold or consumed such as home, cafeteria, offices, hospital, school, convenience stores and supermarket food establishments. Usage of the microwave ovens for heating or cooking of food products has led to extensive development by the food industry of products which are capable of rapid cooking or heating. However, because of the unusual manner in which microwave energy heats food products, there are significant difficulties in producing food products that are as palatable as products that has been cooked in a conventional oven, toasted in electric toaster, or grilled in a skillet.

In a classic oven, in a toaster, or in a skillet, the food product cooks by convection, conduction and infrared radiation. The food product is often exposed to high outside environmental temperatures from 300° F. to 450° F. Beneficial aspects of such cooking at high temperatures are browning, crisping, crusting, searing, and/or grilling of the outside surfaces of the food while the inside usually stays moist and tender. These high temperatures induce chemical reactions, recognized as caramelization in foods primarily made of carbohydrates and as Maillard reactions in foods primarily made of proteins. This method produces taste and texture that are expected in traditional cooking.

To the contrary, microwave energy interacts with polarized molecules of the food and instantly produces heat within the food, up to few centimeters deep, and results in the typical rapid efficient cooking obtained by microwave ovens. Under microwave energy, water contained in high moisture and low fat food products, such as bakery, most dairy and meat products, will quickly boil. As a consequence, and because of the evaporative cooling effects that take place on the surface of the food product, the surface temperature of such products will not increase enough to create browning or crisping. Furthermore the air temperature in the cooking space of the microwave oven remains approximately at room temperature. These low temperatures will not permit crisping or browning of many foods. As a result, foods will often taste bland like boiled steam foods. Breads with exposed crumb are a particular problem since these products contains large amount of available moisture that will evaporate when cooked by microwave energy. In fact, bread will shrink, become spongy and soggy, and then harden rapidly as more water evaporates. The white crumb, even if buttered or oiled, will appear light in color, unbaked and will not crisp. For example, a grilled cheese sandwich, prepared from untoasted buttered bread and cheese, and cooked in a microwave oven, will appear light in color, ungrilled and the bread will be soggy. This limits the preparation of such sandwiches to conventional skillet cooking or other conventional ovens.

US Patent Application 20050175738 concerns a method of pre-toasting the bread surfaces before assembly of a sandwich, tenderizing the toasted bread surfaces, assembling the said sandwich, packing, freezing, shipping and finally selling to consumers for easy preparation in any oven. While easy to implement, the method fails to deliver a quality product. The bread hardens quickly, even after freezing, and its texture is mediocre. The ultimate flavor and texture of the reheated sandwich is not acceptable to consumers valuing high quality and fresh toasted taste. Furthermore pre-toasting the bread can be expensive and requires large amounts of energy.

An alternative approach to achieving browning and grilling of bread in microwave cooking is by the use of a microwave susceptor. A susceptor usually comprises a laminate of a support surface, such as paper board, and a foil or metal material which is susceptible to the absorption of microwave radiation and which becomes hot when exposed to microwave radiation. Under intense exposure to microwave radiation, the susceptor surfaces can reach temperatures between 300° F. and up to 400° F. and brown or grill food stuff that comes in its intimate contact. Examples of this type of laminate, or susceptors, designed to brown and grill a product when exposed to microwave energy are disclosed in U.S. Pat. No. 4,267,420.

Limitations of the use of microwave susceptors are that it must stay, during microwave cooking, in permanent intimate contact with the surface of the food product in order to produce a uniform degree of browning, grilling or crisping. Maintaining contact between the food and the susceptor can easily be achieved when only the bottom surface of the food is to be browned and grilled. Indeed gravity, acting as a force, will naturally maintain this contact. This approach is disclosed in U.S. Pat. No. 4,555,605. When both the top surface and bottom surface are targeted for browning and grilling, a top susceptor and a bottom susceptor can be used simultaneously within one package. However, maintaining constant intimate contact between the top surface of the food and the top susceptor is difficult as most food products shrink when exposed to microwave energy. The food product shrinks as water evaporates in the form of vapor and molecules composing the food contract under intense heat. As contact is lost between the top susceptor and the food, the grilling effect is greatly diminished and becomes largely irregular. In this air space, water will freely evaporate and, due to the cooling effect of water vaporization, the surface of the food will be cooler than otherwise if the food product had been maintained in intimate contact with the susceptors. Furthermore, the air space being created between the top susceptor and the food product will now act as an insulator between the hot susceptor and the food. In particular, white crumb will not brown, grill or crisp and instead become soggy initially. From this point, the acceleration of water evaporation will result in drying and hardening of the crumb.

In particular, U.S. Pat. No. 4,777,053 discloses that a rigid paperboard carton with top and bottom susceptors fails to ensure that intimate constant contact is maintained with the food product as the food shrinks while exposed to microwave energy. As a consequence, this invention will not provide a uniform degree of browning and grilling on the top surface of most food products, especially high moisture ones comprising bread, meats, cheese and high moisture fillings.

U.S. Pat. No. 4,590,349 discloses a rigid paperboard carton with top and bottom susceptors, which requires manual inversion of the container during the cooking and crisping in a microwave. While it leads to an acceptable grilling of both side of the food product, the handling and manual inversion of a very hot food product is impractical and possibly dangerous.

WO Patent 2003066435 concerns methods for enhancing the cooking performance of microwave interactive packaging material comprising closed cells. Under the influence of the microwave field, those cells inflate and therefore bring the susceptor layer in closer contact to the food product even as the food shrinks under microwave energy. The problem with such a solution is that, due the non flat surface of the inflated cells, a continuous contact with the food product cannot be guaranteed. The susceptor is therefore not fully in contact with the food product. Furthermore, the composition of the overall packaging material of this patent is complex, and is composed of several layers, which ultimately leads to an expensive solution.

U.S. Pat. No. 4,594,492 concerns methods for enhancing the cooking performance of microwave interactive packaging material comprising of a pair of susceptors and a paper board spring formed from a blank which includes wing sections for resiliently biasing the pair of interactive layers into contact with the food. The problem with such a solution is that it is not possible to guarantee a continuous contact with the food product, because the non-flat surface of the wing surface deforms under heating. The susceptor is therefore not fully in contact with the food product. Also, the composition of the overall packaging material of this patent is complex, is composed of several layers, which ultimately leads to an expensive solution.

US Patent Application 20100297308 concerns methods for enhancing the cooking performance of microwave interactive packaging material comprising of a susceptor sleeve around the food product and a heat shrinking film surrounding the sleeve. In this invention the susceptor sleeve has foldable sides so that during the microwaving, the surrounding heat shrinking film forces these sides to be folded and bring the surface of the susceptor in closer constant contact with the food product, even though the food product may shrink under the microwave energy. However, the composition of the overall packaging material of this patent is complex, and is composed of several layers, which ultimately leads to an expensive solution.

In conclusion, there is a need for a method of producing and packaging a sandwich, or other resilient food product, for subsequent microwave cooking, which yields a palatable product.

SUMMARY OF THE INVENTION

The present invention relates to the methods and assemblies for the preparation and packaging of sandwiches or similar resilient planar food products, to be heated or cooked in a microwave device. A method of the present invention preferably includes:

• • providing a resilient food product than can be heated in a microwave device, said resilient food product having a top major outer surface, a bottom major outer surface spaced apart and parallel to the top wherein H represents a vertical height between the top major outer surface and the bottom outer surface of the resilient food product
  • providing a microwaveable container, surrounding the resilient food product, having a top major microwave interactive surface, a bottom major microwave interactive surface spaced apart and parallel to the top, a pair or more of spaced, parallel side elements, wherein at least said top major microwave interactive surface and bottom major microwave interactive surfaces are made at least partially of a susceptor, and are separated by a vertical distance which is substantially inferior to the vertical height H of said resilient food product.
  • substantially compressing the resilient food product
  • housing the compressed food product in the microwaveable container wherein the major outer surfaces of said food product are in coplanar, contacting relationship with each of the major microwave interactive surfaces of said microwaveable container.
  • thereafter subjecting the container and its compressed content to microwave energy to sufficiently heat the contents of the container while simultaneously grilling the top major outer surfaces and bottom outer surface of the food product
  • said microwaveable container partially or totally shields said food product from direct microwave heating, so most heating occurs through conduction, convection and infrared radiation
  • opening the container and removing the grilled food product
    whereby said sandwich is warm, said outer surfaces of the food product are uniformly grilled and sandwich is ready to eat.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a sandwich;

FIG. 2 depicts a sleeve for receiving a sandwich;

FIG. 3 depicts oiling the outside surfaces of a sandwich;

FIG. 4 depicts compressing a sandwich;

FIG. 5 depicts inserting a compressed sandwich into a sleeve;

FIG. 6 depicts a sandwich fully inserted into a sleeve;

FIG. 7 schematically represents the optional step of freezing;

FIG. 8 schematically represents additional method steps known in the art;

FIG. 9 depicts a sandwich assembly ready for heating

FIG. 9A depicts the same sandwich assembly of FIG. 9, except including packaging;

FIG. 10 depicts the step of microwaving the sandwich assembly;

FIG. 11 depicts a microwaved sandwich assembly with the sleeve partially removed;

FIG. 11A depicts the same microwaved sandwich assembly of FIG. 11, except the sandwich is halved;

FIG. 12 depicts a sandwich assembly inserted between flat pinchers;

FIG. 13 depicts the same sandwich assembly of FIG. 12 being compressed between the same flat pinchers of FIG. 12;

FIG. 14 depicts the compressed sandwich assembly between the same flat pinchers of FIG. 12;

FIG. 15 depicts the same compressed sandwich assembly of FIG. 14 being inserted into a sleeve;

FIG. 16 depicts the same compressed sandwich assembly of FIG. 15 fully inserted inside the same sleeve of FIG. 15;

FIG. 17 depicts another sandwich assembly inserted between flat pinchers;

FIG. 18 depicts the same sandwich assembly of FIG. 17 being compressed between the same flat pinchers of FIG. 17;

FIG. 19 depicts the compressed sandwich assembly between the same flat pinchers of FIG. 17;

FIG. 20 depicts the same compressed sandwich assembly of FIG. 19 being inserted into microwave interactive packaging;

FIG. 21 depicts the same compressed sandwich assembly of FIG. 20 fully inserted inside the same microwave interactive packaging of FIG. 20, with the sides of the packaging folded closed;

FIG. 22 depicts another sandwich assembly inserted between flat pinchers;

FIG. 23 depicts the same sandwich assembly of FIG. 22 being compressed between the same flat pinchers of FIG. 22;

FIG. 24 depicts an embodiment of a microwave interactive packaging sleeve;

FIG. 25 depicts a piston being used to push the compressed sandwich assembly and flat pinchers of FIG. 23 inside the same microwave interactive packaging sleeve of FIG. 24;

FIG. 26 depicts the same piston of FIG. 25 with the same compressed sandwich assembly and flat pinchers of FIG. 23 fully inserted inside the same microwave interactive packaging sleeve of FIG. 24;

FIG. 27 depicts the same piston of FIG. 25 fully inserted between the same flat pinchers of FIG. 23 to fully push the same compressed sandwich assembly of FIG. 23 from between the flat pinchers of FIG. 23 to the inside of the same microwave interactive packaging sleeve of FIG. 24;

FIG. 28 depicts the same compressed sandwich assembly of FIG. 23 fully inserted into the same microwave interactive packaging sleeve of FIG. 24;

FIG. 29 depicts another sandwich assembly inserted between flat pinchers;

FIG. 30 depicts the same sandwich assembly of FIG. 29 being compressed between the same flat pinchers of FIG. 29;

FIG. 31 depicts an embodiment of microwave interactive packaging having folding sides on each end;

FIG. 32 depicts a piston being used to push the compressed sandwich assembly and flat pinchers of FIG. 30 inside the same microwave interactive packaging of FIG. 31;

FIG. 33 depicts the same piston of FIG. 32 with the same compressed sandwich assembly and flat pinchers of FIG. 30 fully inserted inside the same microwave interactive packaging of FIG. 31;

FIG. 34 depicts the same piston of FIG. 32 fully inserted between the same flat pinchers of FIG. 30 to fully push the same compressed sandwich assembly of FIG. 30 from between the flat pinchers of FIG. 30 to the inside of the same microwave interactive packaging of FIG. 31;

FIG. 35 depicts the same compressed sandwich assembly of FIG. 30 fully inserted into the same microwave interactive packaging of FIG. 31;

FIG. 36 depicts the same microwave interactive packaged compressed sandwich assembly of FIG. 35 with the sides of the packaging folded to a closed position;

FIG. 37 depicts an embodiment of a microwave interactive wraparound sleeve in the open position;

FIG. 38 depicts the same wraparound sleeve in the open position of FIG. 37 with a sandwich assembly inserted;

FIG. 39 depicts the same wraparound microwave interactive sleeve of FIG. 37 folded around the same sandwich assembly of FIG. 38, with a series of spring loaded rotating rollers compressing the sandwich and pushing the sleeve into the closed position;

FIG. 40 depicts the compressed sandwich assembly within the same wraparound microwave interactive sleeve of FIG. 37 in the closed position;

FIG. 41 depicts another embodiment of a microwave interactive wraparound container in the open position;

FIG. 42 depicts the same wraparound container in the open position of FIG. 41 with a sandwich assembly inserted;

FIG. 43 depicts the same wraparound microwave interactive container of FIG. 41 folded around the same sandwich assembly of FIG. 42, with a series of spring loaded rotating rollers compressing the sandwich and pushing the container into the closed position;

FIG. 44 depicts the compressed sandwich assembly within the same wraparound microwave interactive container of FIG. 41 in the closed position;

FIG. 45 depicts another embodiment of a microwave interactive wraparound sleeve in the open position, with said sleeve having a self-locking feature of matching appendices and cuts;

FIG. 46 depicts the same wraparound sleeve in the open position of FIG. 45 with a sandwich assembly inserted;

FIG. 47 depicts the same wraparound microwave interactive sleeve of FIG. 45 folded around the same sandwich assembly of FIG. 46, with a series of spring loaded rotating rollers compressing the sandwich and pushing the sleeve into the closed position;

FIG. 48 depicts the compressed sandwich assembly within the same wraparound microwave interactive sleeve of FIG. 45 in the closed and locked position;

FIG. 49 depicts another embodiment of a microwave interactive wraparound container in the open position, with said container having a self-locking feature of matching appendices and cuts;

FIG. 50 depicts the same wraparound container in the open position of FIG. 49 with a sandwich assembly inserted;

FIG. 51 depicts the same wraparound microwave interactive container of FIG. 49 folded around the same sandwich assembly of FIG. 50, with a series of spring loaded rotating rollers compressing the sandwich and pushing the container into the closed position;

FIG. 52 depicts the compressed sandwich assembly within the same wraparound microwave interactive container of FIG. 49 in the closed and locked position;

FIG. 53 depicts another embodiment of a microwave interactive wraparound container in the open position, with said container having another embodiment of a self-locking feature of matching appendices and cuts;

FIG. 54 depicts the same wraparound container in the open position of FIG. 53 with a sandwich assembly inserted;

FIG. 55 depicts the same wraparound microwave interactive container of FIG. 53 folded around the same sandwich assembly of FIG. 54, with a series of spring loaded rotating rollers compressing the sandwich and pushing the container into the closed position;

FIG. 56 depicts the compressed sandwich assembly within the same wraparound microwave interactive container of FIG. 53 in the closed position, with the appendices of the locking assembly in the open position;

FIG. 57 depicts the same closed container of FIG. 56, with the appendices being folded into the matching cuts of the locking assembly;

FIG. 58 depicts the same closed container of FIG. 56 in the closed and locked position;

FIG. 59 depicts a slice of bread inserted between flat pinchers;

FIG. 60 depicts the same slice of bread of FIG. 59 being compressed between the same flat pinchers of FIG. 59;

FIG. 61 depicts the upper flat pincher of FIG. 59 being raised off of the compressed slice of bread of FIG. 59;

FIG. 62 depicts the process of combining two compressed slices of bread with a filling to create a compressed sandwich assembly;

FIG. 63 depicts the process of inserting the compressed sandwich assembly of FIG. 62 into a microwave interactive sleeve;

FIG. 64 depicts the compressed sandwich assembly of FIG. 62 fully inserted into a microwave interactive sleeve;

FIG. 65 depicts another embodiment of a slice of bread inserted between flat pinchers;

FIG. 66 depicts the same slice of bread of FIG. 65 being compressed between the same flat pinchers of FIG. 65;

FIG. 67 depicts the upper flat pincher of FIG. 65 being raised off of the compressed slice of bread of FIG. 65;

FIG. 68 depicts the process of combining two compressed slices of bread with a filling to create a compressed sandwich assembly;

FIG. 69 depicts the process of inserting the compressed sandwich assembly of FIG. 68 into a microwave interactive sleeve with closing sides;

FIG. 70 depicts the compressed sandwich assembly of FIG. 68 fully inserted and enclosed in the microwave interactive sleeve with closing sides of FIG. 69;

FIG. 71 depicts another embodiment of a microwave interactive wraparound sleeve in the open position, with said sleeve having a self-locking feature of matching appendices and cuts;

FIG. 72 depicts the same wraparound sleeve in the open position of FIG. 71 with a sandwich assembly inserted;

FIG. 73 depicts the same sandwich assembly of FIG. 72 fully enclosed and locked inside the same sleeve of FIG. 71;

FIG. 74 depicts another embodiment of a microwave interactive packaging container in an unfolded position, with said container having a self-locking feature of matching appendices and cuts;

FIG. 75 depicts the same packaging container of FIG. 74 in the folded and assembled position;

FIG. 76 depicts the same packaging container of FIG. 74 with a sandwich assembly inserted;

FIG. 77 depicts the same sandwich assembly of FIG. 74 fully enclosed and locked inside the same packaging container of FIG. 74;

FIG. 78 depicts another embodiment of a microwave interactive packaging container in an assembled position, with said container having a self-locking feature of matching appendices and cuts;

FIG. 79 depicts the same packaging container of FIG. 78 with a sandwich assembly inserted;

FIG. 80 depicts the same sandwich assembly of FIG. 79 fully enclosed inside the same packaging container of FIG. 78, with the locking assembly in the unlocked position;

FIG. 81 depicts the same sandwich assembly of FIG. 79 fully enclosed inside the same packaging container of FIG. 78, with the locking assembly being folded into the locked position; and

FIG. 82 depicts the same sandwich assembly of FIG. 79 fully enclosed and locked inside the same packaging container of FIG. 78.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the following detailed description of this invention may be better understood. Additional features and advantages of this invention will be described hereinafter which form the subject of the claims of this invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of this invention as set forth in the appended claims. The novel invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only, and is not intended as a definition of the limits of the present invention.

A goal of this invention is to offer a solution for keeping the pair of top and bottom susceptors in constant, intimate, intense flat-wise contact with the top and bottom outer surfaces of a substantially planar resilient food product while exposed to microwave energy, in particular the outer top and bottom surfaces of the bread slices of a sandwich. Indeed most food products shrink (lose size) during microwaving, thus the top susceptor may lose its contacts with the top surface to be grilled. With the methods and assembly of this invention, it is possible to solve this problem. This invention in which constant intimate stronger flat wise contact is maintained between the top and bottom susceptors and the top and bottom outer surfaces of a substantially planar resilient food product results in uniform grilling, better texture and other sensory attributes of the food product. Furthermore, with this invention, the strength of the contact between susceptor and surfaces of the resilient food product can be adjusted. Therefore the level of grilling and toasting of the outer surfaces of said food product can be adjusted. Under better texture, we understand a controlled softness, a better crispiness and controlled hardness. Under other sensory attributes, we understand an improved appearance like grilling and browning. Also the intensity and intimate contact between the susceptor and the outer surface of the resilient food product limit water evaporation resulting in controlled humidity, controlled softness of the food product, especially the crumb if bread slices comprise the food product, as well as control hardness and crispiness if desired. This solution can easily be implemented. This invention provides a solution that is less expensive that other solutions proposed in the prior art.

The solution uses the natural resiliency of soft fresh bread or like substantially resilient foods. Soft breads or the like will deform when compressed. For example, resilient fresh bread almost returns to its initial shape when the pressures of compression are removed. The speed and degree at which this happens is called resilience. In the art of texture analysis, the sensory definition of resilience is the measurement of how a sample recovers from deformation in relation to speed and forces derived and the instrumental definition of resilience (how resilience is measured) is the ratio of work (where work is the force applied multiplied by the distance) returned by the sample as compressive strain is removed, also known as recoverable work done, to the work required for compression also known as hardness work done. Not wishing to be bound by theory, it is believed that gluten and starch play a key role in bread resilience. The resilience of the bread crumb is believed to originate in the elastic properties of the gluten protein network and the gel network from the starch. While naturally resilient, bread crumb resilience can be increased though the dough formulation adding active enzymes. Commercially available enzymes that improve resiliency of the crumb are sold by Puratos under the brand name Soft'r Intens.

As stated above, resilient bread or the like substantially resilient foods has the physical property to return work, equal to the recoverable work done, after an initial compression. In fact, even if maintained under compression for extended period of time, in a fresh or frozen state, resilient bread or the like keeps its property to return work (after thawing if the bread has been frozen) as the initial compression force is removed. As the compressed bread returns work, the bread will gain size. In particular, if the bread slices or the like resilient food products have previously been compressed along their flat sides, the bread slices or the like will regain thickness once released from the compressing pressure. In commercially available fresh bread, the bread compressed to half its natural thickness will return to 75% to 95% of its original size. Most commercially available resilient breads will work well with this invention. With bread enriched with a resilience improver such as Soft'r Intens from Puratos, bread compressed to 50% of its natural thickness may return to 95% to 100% of its original size. In other words, we now have bread slices or the like resilient food products and ultimately a sandwich or the like that can grow in size (thickness) from its compressed state.

This invention uses the forces stored in compressed resilient bread or like resilient food product to oppose and neutralize the shrinking forces developing in said food product when exposed to microwave energy. The amount of force stored in the compressed bread is the recoverable work done and is expressed in Joule Units and this amount is predetermined by the initial compression given to the bread and the resilient characteristic of the bread or the like resilient food products. As long as the recoverable work stored in the pre-compressed resilient food product, bread slices for example, exceeds the shrinking forces resulting from microwave energy application (shrinking forces believed to grow out of water evaporation and protein contractions), strong and intimate contact between the top and bottom susceptors and the top and bottom outer surfaces of said planar resilient food product will be maintained. This is true in particular for a food product comprising two slices of a resilient untoasted bread with an interior filling, such as a sandwich with two bread slices and cheese or cheese and meat. Uniform grilling and crisping of the outer surface of the food product, a planar sandwich in particular, will occur while cooking or heating in a microwave oven. The concept behind this invention is easily understood if one visualize that thickness growth potential of the compressed resilient food product, as described in the prior paragraphs, surpasses the tendency of the food product to shrink when exposed to microwave energy. Because this invention allows for varied level of stored work (recoverable work done as defined earlier) in the compressed resilient food product (by applying different degree of pre-compression or using food product, fresh bread slices for example, with increasing resilience characteristic), this invention can control the degree of pressure expressed on each top and bottom susceptor by the food product during the entire microwave cooking and as a result, this invention can control the degree of crispiness of the outside surfaces of the food product and the overall softness of the bread (limiting the degree of water evaporation) if the food product is a sandwich with bread slices and filings. In addition, with this invention, because of the better heat transfer between susceptor and the outer surfaces of the food product, we can also obtain quicker heating steps and better heat distribution.

According to this invention, there are at least four different embodiments:

1/ Assemble a substantially planar sandwich which is comprised of two slices or more of resilient untoasted bread with interior fillings. Compress the said sandwich using a mechanical press and insert the sandwich in a microwave interactive packaging sleeve. Said packaging to have at least two parallel susceptor surfaces and where the vertical height of the packaging from the undersurface of the top susceptor and to the upper surface of lower susceptor is substantially less than the height of the naturally assembled sandwich so that the surfaces of the bread slices will always be under compression. Sleeve can be open ended or close ended depending on application. Sandwich is kept under pressure inside said packaging, fresh or frozen, until and during heating or cooking in microwave oven by end user.

2/ Assemble a substantially planar sandwich which is comprised of two slices or more of resilient untoasted bread with an interior filling. Place the sandwich in an open wrap-around microwave interactive packaging. Said packaging has at least two parallel susceptor surfaces. Sandwich is pressure wrapped until the vertical height the packaging from the undersurface of the top susceptor and to the upper surface of lower susceptor is substantially less than the height of the naturally assembled sandwich so that the surfaces of the bread slices will always be under compression. Packaging is sealed, using compatible adhesive. Sandwich is kept under pressure inside said packaging, fresh or frozen, until and during heating or cooking in microwave oven by end user. Packaging can be open ended or close ended depending on application. Alternatively, a second solution for this embodiment is the use of a pre-manufactured microwave interactive packaging, sleeve or box, which includes a mechanical closure in place of adhesive and will maintain the sandwich under pressure, fresh or frozen, until and during heating or cooking in microwave oven use by end user.

3/ Compress two or more slices of resilient untoasted bread, rapidly assemble a sandwich comprising said compressed slices and an edible filling, rapidly meaning before the bread slices return to their uncompressed physical states. Insert the sandwich in a microwave interactive packaging sleeve, said packaging to have at least two parallel susceptor surfaces and where the vertical height of the packaging from the undersurface of the top susceptor and to the upper surface of lower susceptor is substantially less than the height of the naturally assembled sandwich so that the surfaces of the bread slices will always be under compression. Sleeve can be open ended or close ended depending on application. Sandwich is kept under pressure inside said packaging until and during heating or cooking in microwave oven use by end user.

4/ Assemble the substantially planar sandwich which is comprised of two slices or more of resilient untoasted bread with an interior filling. A microwave interactive container is provided. Said container to have at least two parallel susceptor surfaces and where the vertical height of the packaging from the undersurface of the top susceptor and to the upper surface of lower susceptor is substantially less than the height of the naturally assembled sandwich so that the surfaces of the bread slices will always be under compression. Sandwich is placed by hand in said microwave interactive container. Interactive container is manually closed in a manner resulting in substantial pressurization of the sandwich. Mechanical closure or adhesive will maintain the sandwich under pressure until and during heating or cooking in microwave oven. Container can be sold separately from the sandwich. End user may assemble sandwich and use invention as directed.

As illustrated in FIG. 1 (FIG. 1), the sandwich 103a (103a-FIG. 1, 103a-FIG. 3, 103a-FIG. 4) is assembled from a first and second slices of fresh resilient untoasted bread 100 (100-FIG. 1) or the like, said slices having inner and outer surfaces, and one or more layers of edible sandwich filler ingredients, such as sliced filings 101 (101-FIG. 1) and optional soft fillings 102 (102-FIG. 1) between the inner surfaces of said first and second bread slices or the like for completing the sandwich. Top bread slice and bottom bread slice define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 12, H-FIG. 17, H-FIG. 22, H-FIG. 29) represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 12, 103a-FIG. 17, 103a-FIG. 22, 103a-FIG. 29)

Two or more bread slices can be used for constructing the sandwich. In particular, the sandwich can have multiple levels of alternate bread slices and fillings. The top bread slice and bottom bread slice of the sandwich still define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 12, H-FIG. 17, H-FIG. 22, H-FIG. 29) still represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich.

The reference numeral 100 (100-FIG. 1) denotes a resilient farinaceous food product. The reference numerals 101 (101-FIG. 1) and 102 (102-FIG. 1) denote edible food products which may be interposed between the bread slices. The numbers and the nature of the fillers may vary.

An important part of this invention relates to the buttering, oiling 107 (107-FIG. 3) or application of edible fat on the outermost surfaces of the upper and lower bread slices 100 (100-FIG. 3) of Sandwich 103a (103a-FIG. 3). Optionally, the outer side edge of the bread slices 100 (100-FIG. 3) can also be butter or oiled. The buttering, oiling or application of edible fat lubricates theses outside surfaces and will, as described thereafter, facilitate the insertion of the compressed sandwich 103b (103b-FIG. 4, 103b-FIG. 5, 103b-FIG. 14, 103b-FIG. 19, 103b-FIG. 23. 103b-FIG. 30) into the microwave interactive sleeve 104a (104a-FIG. 2, 104a-FIG. 15, 104a-FIG. 24) and 104 b (104b-FIG. 20, 104b-FIG. 31). Also, the buttering, oiling or application of fat effectively further precludes the loss of moisture from the bread or like farinaceous product and results in a delightful flavor and aroma when said surfaces are grilled by heating of packaged sandwich in the microwave oven 109 (109-FIG. 10). Butter, oil or edible fat can be either sprayed 107 (107-FIG. 3) or spread on the bread surfaces. Dipping of the bread slices in warm liquid butter, oil and liquid edible fat is also an acceptable method. Amount of butter, oil and edible fat deposited on the bread slices can vary from 0.1% to 30% of the weight of the bread slices and preferably from 0.5% to 5%. The buttering, oiling or coating of edible fat can occur either before, during or after the sandwich assembly. Due to the ample amount of butter or shortening in some type of breads such as Danish pastry or croissant type pastries, the buttering or oiling of the bread or pastry slices can be totally eliminated; a sandwich assembled with the use of such bread may be packaged in accordance with the teaching herein disclosed but with the omission of the step of buttering or oiling the outer surfaces of the bread.

The microwave interactive container is a sleeve 104a (104a-FIG. 2, 104a-FIG. 15, 104a-FIG. 24) and sleeve 104b (104b-FIG. 20, 104b-FIG. 31) having at least a top microwave interactive major surface, a bottom microwave interactive major surface spaced apart and parallel to the top, a pair or more of spaced, parallel side elements, wherein said top microwave interactive major surface and bottom microwave interactive major surface are made at least partially of a susceptor or the like microwave absorbing heating elements. Reference SS1 (SS1-FIG. 2, SS1-FIG. 15, SS1-FIG. 20, SS1-FIG. 24, SS1-FIG. 31) is the top microwave interactive major surface and reference SS2 (SS2-FIG. 2, SS2-FIG. 15, SS2-FIG. 20, SS2-FIG. 24, SS2-FIG. 31) is the bottom microwave interactive major surface. Top microwave major interactive surface and bottom microwave interactive surface are parallel and separated by a vertical height h1 (h1-FIG. 2, h1-FIG. 15, h1-FIG. 20, h1-FIG. 24, h1-FIG. 31).

In FIG. 2 (FIG. 2) to FIG. 36 (FIG. 36), the susceptors of microwave interactive surfaces SS1 and SS2 are placed on the internal surfaces of the sleeves 104a (104a-FIG. 2, 104a-FIG. 15, 104a-FIG. 24) and sleeves 104b (104b-FIG. 20, 104b-FIG. 31) so to be later on in direct contact of the outer surfaces of the top and bottom bread slices of the sandwich.

The nature and numbers of susceptors, beyond the one comprising microwave interactive surfaces SS1 (SS1-FIG. 2, SS1-FIG. 15, SS1-FIG. 20, SS1-FIG. 24, SS1-FIG. 31) and SS2 (SS2-FIG. 2, SS2-FIG. 15, SS2-FIG. 20, SS2-FIG. 24, SS2-FIG. 31), placed on the internal surfaces of the sleeves 104a (104a-FIG. 2, 104a-FIG. 15, 104a-FIG. 24) and sleeves 104b (104b-FIG. 20, 104b-FIG. 31) may vary. In particular, susceptors can be added to cover the sides, edges or all surfaces of container 104a (104a-FIG. 2, 104a-FIG. 15, 104a-FIG. 24) and 104b (104b-FIG. 20, 104b-FIG. 31). Supplemental susceptors can also be inserted between the layers of a multi deck sandwich or between sandwiches in a multiple sandwich offer pack.

The assembled sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 12, 103a FIG. 17, 103a FIG. 22, 103a-FIG. 29) which has a natural height of H (H-FIG. 1, H-FIG. 12, H-FIG. 17, H-FIG. 22, H-FIG. 29) is compressed by a pair of flat pinchers 108 (108-FIG. 4, 108-FIG. 5, 108-FIG. 13, 108-FIG. 18, 108-FIG. 23, 108-FIG. 30) to the smaller height of h2 (h2-FIG. 4, h2-FIG. 5, h2-FIG. 13, h2-FIG. 18, h2-FIG. 23, h2-FIG. 30). The ratio of compression C, which is equal to the height h2 divided by the height H, is comprised for this invention between 0.4 and 0.99 and preferably between 0.70 and 0.95.

For illustration purposes and in all attached illustrations, the sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 12, 103a-FIG. 17, 103a-FIG. 22, 103a-FIG. 29) becomes after compression, sandwich 103b (103b-FIG. 4, 103b-FIG. 5, 103b-FIG. 14, 103b-FIG. 19, 103b-FIG. 23. 103b-FIG. 30). Sandwich 103b has different physical characteristics, properties and dimensions when compared to the uncompressed sandwich 103a.

Sandwich 103b (103b-FIG. 5, 103b-FIG. 14, 103b-FIG. 19, 103b-FIG. 23, 103b-FIG. 30) is introduced inside a microwave interactive sleeve 104a (104a-FIG. 2, 104a-FIG. 5, 104a-FIG. 15, 104a-FIG. 24) or microwave interactive sleeve 104b (104b-FIG. 20, 104b-FIG. 31).

For this invention the height h2 (h2-FIG. 4, h2-FIG. 5, h2-FIG. 13, h2-FIG. 18, h2-FIG. 23, h2-FIG. 30) is less than the height h1 (h1-FIG. 2, h1-FIG. 15, h1-FIG. 20, h1-FIG. 24, h1-FIG. 31) and allows for insertion of the compressed sandwich in the sleeve 104a (104a-FIG. 2, 104a-FIG. 5, 104a-FIG. 15, 104a-FIG. 24) and sleeve 104b (104b-FIG. 20, 104b-FIG. 31).

FIG. 12 to FIG. 16 show how the compressed sandwich 103b is introduced manually into the microwave interactive sleeve 104a. FIG. 22 to FIG. 28 show how the compressed sandwich 103 b is introduced in the sleeve 104a using a piston 111 (111-FIG. 26) that pushes the sandwich in position, thus inserting it inside the sleeve. As shown in FIG. 28, and after completion of the different steps, the compressed sandwich 103b is now inserted in the interactive packaging 104a (104a-FIG. 28) in its exact position. Alternatively the piston 111 (111-FIG. 26) could be fixed and the flat pinchers 108 (108-FIG. 26) could be mobile, inserting the compressed sandwich inside the interactive packaging in a similar fashion. Alternatively, both the piston 111 and the flat pinchers 108 can be mobile and in coordinated movements, achieve insertion of the compressed sandwich into the interactive packaging 104a. FIG. 17 to FIG. 21 show how the compressed sandwich 103b is manually introduced in the microwave interactive sleeve 104b (104b-FIG. 20, 104b-FIG. 21). FIG. 29 to FIG. 36 show how the compressed sandwich 103 b is introduced in microwave interactive packaging 104b using a piston 111 (111-FIG. 32) that pushes the sandwich in position, thus inserting it inside the sleeve. As shown in FIG. 35, and after completion of the different steps, the compressed sandwich is now inserted in the interactive packaging 104 b (104b-FIG. 35) in its exact position. Alternatively the piston 111 (111-FIG. 32) could be fixed and the flat pinchers 108 (108-FIG. 32) could be mobile, inserting the compressed sandwich inside the interactive packaging in a similar fashion. Alternatively, both the piston 111 and the flat pinchers 108 can be mobile and in coordinated movements, achieve insertion of the compressed sandwich into the interactive packaging 104b. The sides 110b (110b-FIG. 20, 110b-FIG. 21, 110b-FIG. 31, 110b-FIG. 33, 110b-FIG. 36) of microwave interactive packaging 104b (104b-FIG. 20, 104b-FIG. 21, 104b-FIG. 33, 104b-FIG. 36) can be closed as shown in FIG. 21 (FIG. 21) and FIG. 36 (FIG. 36). Benefits of closing the end of the microwave interactive packaging 104b (104b-FIG. 21, 104b-FIG. 36) are physical protection of the sandwich, optional added susceptors as mentioned earlier and, as explained later, selective shielding from microwave.

It is important to note that the vertical height h1 of the microwave interactive container from the undersurface of the top microwave interactive major surface SS1 (SS1-FIG. 15, SS1-FIG. 20, SS1-FIG. 24, SS1-FIG. 31) and to the upper surface of the bottom microwave interactive major surface SS2 (SS2-FIG. 15, SS2-FIG. 20, SS2-FIG. 24, SS2-FIG. 31) is substantially less than the height H (H-FIG. 12, H-FIG. 17, H-FIG. 22, H-FIG. 29) of sandwich 103a and therefore sandwich 103b (103b-FIG. 16, 103b-FIG. 21, 103b-FIG. 28, 103b-FIG. 36) is always kept under compression within microwave interactive containers 104a and 104b. The ratio of packaging compression PC, which is equal to the height h1 divided by the height H, is comprised for this invention between 0.4 and 0.99 and preferably between 0.75 and 0.95.

The ratio of packaging compression PC for this invention is predetermined so the susceptors of the top and bottom microwave interactive major surfaces of sleeves 104a and 104b remain, during the entire time the sandwich is exposed to microwave energy, in intimate constant intense flat wise contact with the top and bottom major outer surfaces of the sandwich despite the shrinking effect of microwave energy on the bread slices and filings composing the sandwich.

Furthermore and according to the teaching of this invention, the packaging compression PC value further determine the degree and intensity of intimate flat wise contact between the bread slices and the susceptors during microwaving and therefore the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces. In particular the lower the packaging compression PC the more grilling and toasting is generated on the surface of the sandwich during microwaving. Being able to control the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces is a key feature of this invention.

In another feature of this embodiment, predetermined microwave shielding can be added to the microwave interactive container 104a (104a-FIG. 2, 104a-FIG. 5, 104a-FIG. 6, 104a-FIG. 15, 104a-FIG. 16, 104a-FIG. 24, 104a-FIG. 25, 104a-FIG. 26, 104a-FIG. 28) and microwave interactive container 104b (104b-FIG. 20, 104b-FIG. 21, 104b-FIG. 31, 104b-FIG. 32, 104b-FIG. 33, 104b-FIG. 35, 104b-FIG. 36). In the art of microwave interactive packaging, shielding describes either a high degree of microwave absorption by susceptors and subsequent heat generation on their surfaces, or a reflection of the microwaves away from the product using microwave impervious material, or a combination of high absorption and reflection. Such shielding limits the microwave penetration into food products and can be beneficial. Concerning susceptor microwave absorption shielding characteristics, it is known in the art of susceptor manufacturing that depending on the density of metal deposited on the microwave interactive surfaces, or by choosing specific metal composition, the microwave interactive material will absorb little, some or all of the microwave energy to which it is exposed. The more absorption of microwaves by the susceptors, the more heat is generated on the surface of the susceptor and the fewer microwaves will penetrate the food product. Also the less overheating of the bread and filling is likely to occur. When using such shielding susceptor interactive packaging, it is believed most of the heating of the food product occurs through conduction and convection and infrared radiation arising from the hot susceptor surfaces. Heating by conduction, convection and infrared is believed to be beneficial for browning, crisping and grilling of the sandwich surface and for the overall quality of the sandwich. The bread slices or the like retain more moisture and are more tender. Concerning microwave reflection, a thin layer of a metal, such as aluminum, continuous or in a pattern, can be used. In this case, microwaves will be blocked from penetrating the food product through the reflecting shielded areas. Many patterns of microwave shielding can be designed in microwave interactive packaging 104a (104a-FIG. 2, 104a-FIG. 5, 104a-FIG. 6, 104a-FIG. 15, 104a-FIG. 16, 104a-FIG. 24, 104a-FIG. 25, 104a-FIG. 26, 104a-FIG. 28) and 104b (104b-FIG. 20, 104b-FIG. 21, 104b-FIG. 31, 104b-FIG. 32, 104b-FIG. 33, 104b-FIG. 35, 104b-FIG. 36) and these patterns will allow further control of the degree of browning, crisping, grilling and heating of the food product or sandwich. Patterns include diverse areas of low to high susceptor absorbing shielding and combination of susceptor absorbing shielding and or reflecting shielding. Often, the less filling in the sandwich, the more microwave shielding will be used. Also the more fat rich fillings the sandwich contains, the more shielding will be used. In a first example, for a classic grilled cheese sandwich, the shielding will be high and the microwave interactive package will take the form of an enclosed box with large shielding zone such as suggested in packaging 104b. In fact, in a grilled cheese application, at least 75% of the internal surfaces of microwave interactive packaging 104a (104a-FIG. 2, 104a-FIG. 5, 104a-FIG. 6, 104a-FIG. 15, 104a-FIG. 16, 104a-FIG. 24, 104a-FIG. 25, 104a-FIG. 26, 104a-FIG. 28) and 104b (104b-FIG. 20, 104b-FIG. 21, 104b-FIG. 31, 104b-FIG. 32, 104b-FIG. 33, 104b-FIG. 35, 104b-FIG. 36), top, bottom and sides, will be covered with susceptors having predetermined high shielding properties. In some cases, multiple layers of susceptor material can be used to achieve closer to 100% shielding of the product from microwave without requiring the addition of any expensive reflecting shielding material. Excess direct microwave energy on a grilled cheese sandwich will result in over heating of the cheese and even burning of the cheese. In a second example, for a grilled cheese and meat sandwich, a filling containing less fat and more moisture, less shielding is often necessary. To achieve less shielding, lower absorption susceptors and area totally transparent to microwave energy are used in the construction of the microwave interactive container. With predetermined lower shielding and microwave transparent areas, higher moisture fillings can be heated directly by some microwave energy while the bread will still be uniformly grilled by top and bottom susceptors of the microwave interactive package. In fact, in a grilled cheese and meat sandwich application, at least 50% of the internal surfaces of microwave interactive packaging 104a (104a-FIG. 2, 104a-FIG. 5, 104a-FIG. 6, 104a-FIG. 15, 104a-FIG. 16, 104a-FIG. 24, 104a-FIG. 25, 104a-FIG. 26, 104a-FIG. 28) and 104b (104b-FIG. 20, 104b-FIG. 21, 104b-FIG. 31, 104b-FIG. 32, 104b-FIG. 33, 104b-FIG. 35, 104b-FIG. 36), often the top and bottom major surfaces, will be covered with susceptors having predetermined high shielding properties. In a third example, for a sandwich with large quantity of moist filling, containing more meats or soft fillings such as dressings or sauces or vegetables, the microwave interactive package will be a sleeve such as 104a where the end sides of the package are totally open to microwave energy. Indeed, a large amount of microwave energy is required to warm these larger quantity high moisture fillings. For a sandwich with large quantity of moist filling, at least 25% of the internal surfaces of microwave interactive packaging 104a (104a-FIG. 2, 104a-FIG. 5, 104a-FIG. 6, 104a-FIG. 15, 104a-FIG. 16, 104a-FIG. 24, 104a-FIG. 25, 104a-FIG. 26, 104a-FIG. 28) and 104b (104b-FIG. 20, 104b-FIG. 21, 104b-FIG. 31, 104b-FIG. 32, 104b-FIG. 33, 104b-FIG. 35, 104b-FIG. 36), often the top major surfaces, will be covered with susceptors having predetermined high shielding properties.

Another feature of the microwave interactive packaging described in the embodiment would be an easy open tear off strip 119 (119-FIG. 9) or the like running along the sleeve so the consumer can easily open microwave interactive package after heating in the microwave oven, as illustrated in FIG. 9 (FIG. 9) and FIG. 11 (FIG. 11). Other features of the microwave interactive packaging described in the embodiment would be a handle 120 (120-FIG. 9) for easy handling of the package.

Another feature of the microwave interactive packaging described in the embodiment would be a protective over-wrapping 120a (120a-FIG. 9A) placed around the microwave interactive container. This overwrapping by it predetermined design and composition provide protection to the sandwich or the like and insulation protecting the consumer from the hot food once microwaved. Such protecting insulating over-wrappings comprise paper bag, grease proof paper bag, corrugated board, pressed paper, chip board, plastic film. Another solution for providing insulation protecting the consumer from the hot food once microwaved is to add an insulating substrate to the microwave interactive sleeve, such as pressed paper, cardboard, corrugated board, fluted paper or the like.

Further comprised in the invention are two sandwiches 103d (103d-FIG. 11A) and 103e (103e-FIG. 11A) or the like that are placed in said microwave interactive container in a side by side relationship.

Using the assembly and methods described previously in this first embodiment:

• • providing a substantially resilient food product, such as sandwich, to be heated and grilled on its outside top and bottom major surfaces,
  • providing an microwave interactive container as described and of predetermined dimension
  • providing a compressing mean in combination with said microwave interactive container
  • and further adding the steps comprising of:
  • keeping the sandwich or the like compressed within the container until and during heating in the microwave device
  • thereafter subjecting, the container and its compressed content to microwave energy using a microwave device 109 (109-FIG. 10) of predetermined power, preferably between 500 Watts to 5000 Watts and a predetermined exposure time to microwave energy, preferably of one (1) to (10) minutes depending on watt power of said microwave device, to sufficiently heat the contents of the container while simultaneously grilling the outer surfaces of the bread slices
  • opening the container and removing the grilled sandwich

The finished product 103c (103c-FIG. 11), after heating and cooking in the microwave, will be uniformly grilled, have crisp golden outer surfaces and its texture will be moist and tender, a result that has not been achieved before or made commercially successful. Furthermore, this invention, as applied in the first embodiment, uses a simple sandwich assembly methods and a lower cost microwave interactive container than previously disclosed in the art of microwave grilled sandwich, while achieving more consistent grilling of the sandwich after exposure to microwave radiation.

For the second embodiment, several solutions exist. For the first solution, an assembly comprising of:

• • A sandwich to be heated or cooked in a microwave device.
  • A microwave interactive container.

As illustrated in FIG. 1 (FIG. 1), the sandwich 103a (103a-FIG. 1, 103a-FIG. 3, 103a-FIG. 4) is assembled from a first and second slices of fresh resilient untoasted bread 100 (100-FIG. 1) or the like, said slices having inner and outer surfaces, and one or more layers of edible sandwich filler ingredients, such as sliced filings 101 (101-FIG. 1) and optional soft fillings 102 (102-FIG. 1) between the inner surfaces of said first and second bread slices or the like for completing the sandwich. Top bread slice and bottom bread slice define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 38, H-FIG. 39, H-FIG. 42, H-FIG. 43) represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 38, 103a-FIG. 39, 103a-FIG. 42, 103a-FIG. 43)

Two or more bread slices can be used for constructing the sandwich. In particular, the sandwich can have multiple levels of alternate bread slices and fillings. The top bread slice and bottom bread slice of the sandwich still define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 38, H-FIG. 39, H-FIG. 42, H-FIG. 43) still represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich.

The reference numeral 100 (100-FIG. 1) denotes a resilient farinaceous food product. The reference numeral 101 (101-FIG. 1) and 102 (102-FIG. 1) denote edible food products which may be interposed between the bread slices. The numbers and the nature of the fillers may vary.

An important part of this invention relates to the buttering, oiling 107 (107-FIG. 3) or application of edible fat on the outermost surfaces of the upper and lower bread slices 100 (100-FIG. 3) of Sandwich 103a (103a-FIG. 3). Optionally, the outer side edge of the bread slices 100 (100-FIG. 3) can also be butter or oiled. The buttering, oiling or application of edible fat lubricates theses outside surfaces and will, as described thereafter, facilitate the insertion of the sandwich 103a (103a-FIG. 38, 103a-FIG. 39, 103a-FIG. 42. 103a-FIG. 43) into the microwave interactive sleeve 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and 104 d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44). Also, the buttering, oiling or application of fat effectively further precludes the loss of moisture from the bread or like farinaceous product and results in a delightful flavor and aroma when said surfaces are grilled by heating of packaged sandwich in the microwave oven 109 (109-FIG. 10). Butter, oil or edible fat can be either sprayed 107 (107-FIG. 3) or spread on the bread surfaces. Dipping of the bread slices in warm liquid butter, oil and liquid edible fat is also an acceptable method. Amount of butter, oil and edible fat deposited on the bread slices can vary from 0.1% to 30% of the weight of the bread slices and preferably from 0.5% to 5%. The buttering, oiling or coating of edible fat can occur either before, during or after the sandwich assembly. Due to the ample amount of butter or shortening in some type of breads such as Danish pastry or croissant type pastries, the buttering or oiling of the bread or pastry slices can be totally eliminated; a sandwich assembled with the use of such bread may be packaged in accordance with the teaching herein disclosed but with the omission of the step of buttering or oiling the outer surfaces of the bread.

The microwave interactive container is wraparound sleeve 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and wraparound sleeve 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44) having at least a top microwave interactive major surface, a bottom microwave interactive major surface spaced apart and parallel to the top, a pair or more of spaced, parallel side elements, wherein said top microwave interactive major surface and bottom microwave interactive major surface are made at least partially of a susceptor or the like microwave absorbing heating elements. Reference SS1 (SS1-FIG. 37, SS1-FIG. 38, SS1-FIG. 40, SS1-FIG. 41, SS1-FIG. 42. SS1-FIG. 44) is the top microwave interactive major surface and reference SS2 (SS2-FIG. 37, SS2-FIG. 38, SS2-FIG. 40, SS2-FIG. 41, SS2-FIG. 42. SS2-FIG. 44) is the bottom microwave interactive major surface. When container is closed, top microwave major interactive surface and bottom microwave interactive surface are parallel and separated by a vertical height h1 (h1-FIG. 37, h1-FIG. 39, h1-FIG. 40, h1-FIG. 41, h1-FIG. 43, h1-FIG. 44).

In FIG. 37 (FIG. 37) to FIG. 44 (FIG. 44), the susceptors of microwave interactive surfaces SS1 and SS2 are placed on the internal surfaces of the wraparound sleeve 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 40) and wraparound sleeve 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 44) so to be later on in direct contact of the outer surfaces of the top and bottom bread slices of the sandwich.

The nature and numbers of susceptors, beyond the one comprising microwave interactive surfaces SS1 (SS1-FIG. 37, SS1-FIG. 38, SS1-FIG. 40, SS1-FIG. 41, SS1-FIG. 42. SS1-FIG. 44) and SS2 (SS2-FIG. 37, SS2-FIG. 38, SS2-FIG. 40, SS2-FIG. 41, SS2-FIG. 42. SS2-FIG. 44), placed on the internal surfaces of the wraparound sleeves 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and wraparound sleeve 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44) may vary. In particular, susceptors can be added to cover the sides, edges or all surfaces of wraparound sleeve 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and wraparound sleeve 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44). Supplemental susceptors can also be inserted between the layers of a multi deck sandwich or between sandwiches in a multiple sandwich offer pack.

The assembled sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 38, 103a-FIG. 39, 103a-FIG. 42, 103a-FIG. 43) which has a natural height of H (H-FIG. 1, H-FIG. 38, H-FIG. 39, H-FIG. 42, H-FIG. 43) is placed, as illustrated in FIG. 38 (FIG. 38) and FIG. 42 (FIG. 42), into microwave interactive sleeve 104c and 104d. As illustrated in FIG. 39 (FIG. 39) and FIG. 43 (FIG. 43) the wrap around microwave interactive container 104c (104C-FIG. 39) and 104d (104d-FIG. 43) are folded and closed around sandwich 103a (103a-FIG. 39, 103a-FIG. 42). In doing so, pressure is applied on sandwich 103a and sandwich 103a is compressed into sandwich 103b to a vertical height h1 (h1-FIG. 39, h1-FIG. 43). For example, as illustrated in FIG. 39 (FIG. 39) and in FIG. 43 (FIG. 43) the assembled sandwich 103a (103a-FIG. 38, 103a-FIG. 39, 103a FIG. 41, 103a FIG. 42) which has a natural height of H is compressed within the wrap around microwave interactive sleeve 104c (104C-FIG. 39) and 104d (104d-FIG. 43) by a series of spring loaded rotating rollers 114 (114-FIG. 39, 114-FIG. 43) to the smaller height of h1 (h1-FIG. 39, h1-FIG. 43).

For illustration purposes and in all attached illustrations, the sandwich 103a becomes after compression, sandwich 103b. Sandwich 103b has different physical characteristics, properties and dimensions when compared to the uncompressed sandwich 103a.

Adhesive is used to seal and hold in place the wraparound packaging around the compressed sandwich 103b, keeping sustained pressure around sandwich 103b. Compression between two belt conveyors is also acceptable. Use of mechanical wrap around packaging machine is also envisioned.

It is important to note that the vertical height h1 of the microwave interactive container from the undersurface of the top microwave interactive major surface SS1 (SS1-FIG. 37, SS1-FIG. 38, SS1-FIG. 40, SS1-FIG. 41, SS1-FIG. 42. SS1-FIG. 44) and to the upper surface of the bottom microwave interactive major surface SS2 (SS2-FIG. 37, SS2-FIG. 38, SS2-FIG. 40, SS2-FIG. 41, SS2-FIG. 42. SS2-FIG. 44) is substantially less than the height H (H-FIG. 1, H-FIG. 4, H-FIG. 38, H-FIG. 39, H-FIG. 42, H-FIG. 43) of sandwich 103a and therefore sandwich 103b (103b-FIG. 39, 103b-FIG. 40, 103b-FIG. 43, 103b-FIG. 44) is always kept under compression within microwave interactive containers 104a and 104b. The ratio of packaging compression PC, which is equal to the height h1 divided by the height H, is comprised for this invention between 0.4 and 0.99 and preferably between 0.75 and 0.95.

The ratio of packaging compression PC for this invention is predetermined so the susceptors of the top and bottom microwave interactive major surfaces of sleeves 104c and 104d remain, during the entire time the sandwich is exposed to microwave energy, in intimate constant intense flat wise contact with the top and bottom major outer surfaces of the sandwich despite the shrinking effect of microwave energy on the bread slices and filings composing the sandwich.

Furthermore and according to the teaching of this invention, the packaging compression PC value further determines the degree and intensity of intimate flat wise contact between the bread slices and the susceptors during microwaving and therefore the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces. In particular the lower the packaging compression PC the more grilling and toasting is generated on the surface of the sandwich during microwaving. Being able to control the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces is a key feature of this invention.

In another feature of this embodiment, predetermined microwave shielding can be added to the microwave interactive container wraparound sleeve 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and microwave interactive container wraparound sleeve 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44). In the art of microwave interactive packaging, shielding describes either a high degree of microwave absorption by susceptors and subsequent heat generation on their surfaces, or a reflection of the microwaves away from the product using microwave impervious material, or a combination of high absorption and reflection. Such shielding limits the microwave penetration into food products and can be beneficial. Concerning susceptor microwave absorption shielding characteristics, it is known in the art of susceptor manufacturing that depending on the density of metal deposited on the microwave interactive surfaces, or by choosing specific metal composition, the microwave interactive material will absorb little, some or all of the microwave energy to which it is exposed. The more absorption of microwaves by the susceptors, the more heat is generated on the surface of the susceptor and the fewer microwaves will penetrate the food product. Also the less overheating of the bread and filling is likely to occur. When using such shielding susceptor interactive packaging, it is believed most of the heating of the food product occurs through conduction and convection and infrared radiation arising from the hot susceptor surfaces. Heating by conduction, convection and infrared is believed to be beneficial for browning, crisping and grilling of the sandwich surface and for the overall quality of the sandwich. The bread slices or the like retain more moisture and are tenderer. Concerning microwave reflection, a thin layer of a metal, such as aluminum, continuous or in a pattern, can be used. In this case, microwaves will be blocked from penetrating the food product through the reflecting shielded areas. Many patterns of microwave shielding can be designed in microwave interactive container 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44) and these patterns will allow further control of the degree of browning, crisping, grilling and heating of the food product or sandwich. Patterns include diverse areas of low to high susceptor absorbing shielding and combination of susceptor absorbing shielding and or reflecting shielding. Often, the less filling in the sandwich, the more microwave shielding will be used. Also the more fat rich fillings the sandwich contains, the more shielding will be used. In a first example, for a classic grilled cheese sandwich, the shielding will be high and the microwave interactive package will take the form of an enclosed box with large shielding zone such as suggested in wraparound sleeve 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44). In fact, in a grilled cheese application, at least 75% of the internal surfaces of microwave interactive container wraparound sleeve 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44), top, bottom and sides, will be covered with susceptors having predetermined high shielding properties. In some cases, multiple layers of susceptor material can be used to achieve closer to 100% shielding of the product from microwave without requiring the addition of any expensive reflecting shielding material. Excess direct microwave energy on a grilled cheese sandwich will result in over heating of the cheese and even burning of the cheese. In a second example, for a grilled cheese and meat sandwich, a filling containing less fat and more moisture, less shielding is often necessary. To achieve less shielding, lower absorption susceptors and area totally transparent to microwave energy are used in the construction of the microwave interactive container. With predetermined lower shielding and microwave transparent areas, higher moisture fillings can be heated directly by some microwave energy while the bread will still be uniformly grilled by top and bottom susceptors of the microwave interactive package. In fact, in a grilled cheese and meat sandwich application, at least 50% of the internal surfaces of microwave interactive container wraparound sleeve 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) and 104d (104d-FIG. 41, 104d-FIG. 42, 104d-FIG. 43, 104d-FIG. 44), often the top and bottom major surfaces, will be covered with susceptors having predetermined high shielding properties. In a third example, for a sandwich with large quantity of moist filling, containing more meats or soft fillings such as dressings or sauces or vegetables, the microwave interactive package will be a wraparound sleeve such as 104c (104c-FIG. 37, 104c-FIG. 38, 104c-FIG. 39, 104c-FIG. 40) where the end sides of the package are totally open to microwave energy. Indeed, a large amount of microwave energy is required to warm these larger quantity high moisture fillings. For a sandwich with large quantity of moist filling, at least 25% of the internal surfaces of microwave interactive container wraparound sleeve 104c and 104d, often the top major surfaces, will be covered with susceptors having predetermined high shielding properties.

Another feature of the microwave interactive packaging described in the embodiment would be an easy open tear off strip 119 (119-FIG. 9) or the like running along the sleeve so the consumer can easily open microwave interactive package after heating in the microwave oven, as illustrated in FIG. 9 (FIG. 9) and FIG. 11 (FIG. 11). Other features of the microwave interactive packaging described in the embodiment would be a handle 120 (120-FIG. 9) for easy handling of the package.

Another feature of the microwave interactive packaging described in the embodiment would be a protective over-wrapping 120a (120a-FIG. 9A) placed around the microwave interactive container. This overwrapping by it predetermined design and composition provide protection to the sandwich or the like and insulation protecting the consumer from the hot food once microwaved. Such protecting insulating over-wrappings comprise paper bag, grease proof paper bag, corrugated board, pressed paper, chip board, plastic film. Another solution for providing insulation protecting the consumer from the hot food once microwaved is to add an insulating substrate to the microwave interactive sleeve, such as pressed paper, cardboard, corrugated board, fluted paper or the like.

Further comprised in the invention are two sandwiches 103d (103d-FIG. 11A) and 103e (103e-FIG. 11A) or the like that are placed in said microwave interactive container in a side by side relationship.

Using the assembly and methods described previously in this second embodiment and its first solution:

• • providing a substantially resilient food product, such as sandwich, to be heated and grilled on its outside top and bottom major surfaces,
  • providing an microwave interactive container as described and of predetermined dimension
  • providing a compressing mean in combination with said microwave interactive container
  • and further adding the steps comprising of:
  • keeping the sandwich or the like compressed within the container until and during heating in the microwave device
  • hereafter subjecting, the container and its compressed content to microwave energy using a microwave device 109 (109-FIG. 10) of predetermined power, preferably between 500 Watts to 5000 Watts and a predetermined exposure time to microwave energy, preferably of one (1) to (10) minutes depending on watt power of said microwave device, to sufficiently heat the contents of the container while simultaneously grilling the outer surfaces of the bread slices
  • opening the container and removing the grilled sandwich

The finished product 103c (103c-FIG. 11), after heating and cooking in the microwave, will be warm, uniformly grilled, have crisp golden outer surfaces and its texture will be moist and tender, a result that has not been achieved before or made commercially successful. Furthermore, this invention, as applied in the first embodiment, uses a simple sandwich assembly methods and a lower cost microwave interactive container than previously disclosed in the art of microwave grilled sandwich, while achieving more consistent grilling of the sandwich after exposure to microwave radiation.

For the second embodiment, several solutions exist. For the second solution, an assembly comprising of:

• • A sandwich to be heated or cooked in a microwave device.
  • A microwave interactive container.

As illustrated in FIG. 1 (FIG. 1), the sandwich 103a (103a-FIG. 1, 103a-FIG. 3, 103a-FIG. 4) is assembled from a first and second slices of fresh resilient untoasted bread 100 (100-FIG. 1) or the like, said slices having inner and outer surfaces, and one or more layers of edible sandwich filler ingredients, such as sliced filings 101 (101-FIG. 1) and optional soft fillings 102 (102-FIG. 1) between the inner surfaces of said first and second bread slices or the like for completing the sandwich. Top bread slice and bottom bread slice define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 46, H-FIG. 47, H-FIG. 50, H-FIG. 51, H-FIG. 54, H-FIG. 55) represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 46, 103a-FIG. 47, 103a-FIG. 50, 103a-FIG. 51, 103a-FIG. 54, 103a-FIG. 55).

Two or more bread slices can be used for constructing the sandwich. In particular, the sandwich can have multiple levels of alternate bread slices and fillings. The top bread slice and bottom bread slice of the sandwich still define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 46, H-FIG. 47, H-FIG. 50, H-FIG. 51, H-FIG. 54, H-FIG. 55) still represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich.

The reference numeral 100 (100-FIG. 1) denotes a resilient farinaceous food product. The reference numeral 101 (101-FIG. 1) and 102 (102-FIG. 1) denote edible food products which may be interposed between the bread slices. The numbers and the nature of the fillers may vary.

An important part of this invention relates to the buttering, oiling 107 (107-FIG. 3) or application of edible fat on the outermost surfaces of the upper and lower bread slices 100 (100-FIG. 3) of Sandwich 103a (103a-FIG. 3). Optionally, the outer side edge of the bread slices 100 (100-FIG. 3) can also be butter or oiled. The buttering, oiling or application of edible fat lubricates theses outside surfaces and will, as described thereafter, facilitate the insertion of the sandwich 103a (103a-FIG. 46, 103a-FIG. 50, 103a-FIG. 54) into the microwave interactive sleeve 104e (104e-FIG. 46) and 104 f (104f-FIG. 50) and 104g (104g-FIG. 54) and the compression of sandwich 103a (103a-FIG. 46, 103a-FIG. 50, 103a-FIG. 54) into sandwich 103b(103b-FIG. 47, 103b-FIG. 51, 103b-FIG. 55). Also, the buttering, oiling or application of fat effectively further precludes the loss of moisture from the bread or like farinaceous product and results in a delightful flavor and aroma when said surfaces are grilled by heating of packaged sandwich in the microwave oven 109 (109-FIG. 10). Butter, oil or edible fat can be either sprayed 107 (107-FIG. 3) or spread on the bread surfaces. Dipping of the bread slices in warm liquid butter, oil and liquid edible fat is also an acceptable method. Amount of butter, oil and edible fat deposited on the bread slices can vary from 0.1% to 30% of the weight of the bread slices and preferably from 0.5% to 5%. The buttering, oiling or coating of edible fat can occur either before, during or after the sandwich assembly. Due to the ample amount of butter or shortening in some type of breads such as Danish pastry or croissant type pastries, the buttering or oiling of the bread or pastry slices can be totally eliminated; a sandwich assembled with the use of such bread may be packaged in accordance with the teaching herein disclosed but with the omission of the step of buttering or oiling the outer surfaces of the bread.

The microwave interactive container is wraparound sleeve 104e (104e-FIG. 45, 104e-FIG. 46) and wraparound sleeve 104f (104f-FIG. 49, 104f-FIG. 50) and wraparound sleeve 104g (104g-FIG. 53, 104g-FIG. 54) having at least a top microwave interactive major surface, a bottom microwave interactive major surface spaced apart and parallel to the top, a pair or more of spaced, parallel side elements, wherein said top microwave interactive major surface and bottom microwave interactive major surface are made at least partially of a susceptor or the like microwave absorbing heating elements. Reference SS1 (SS1-FIG. 45, SS1-FIG. 49, SS1-FIG. 53) is the top microwave interactive major surface and reference SS2 (SS2-FIG. 45, SS2-FIG. 49, SS2-FIG. 53) is the bottom microwave interactive major surface. When container is closed, top microwave major interactive surface and bottom microwave interactive surface are parallel and separated by a vertical height h1 (h1-FIG. 48, h1-FIG. 52, h1-FIG. 58).

In FIG. 45 (FIG. 45) to FIG. 58 (FIG. 58), the susceptors of microwave interactive surfaces SS1 (SS1-FIG. 45, SS1-FIG. 49, SS1-FIG. 53) and SS2 (SS2-FIG. 45, SS2-FIG. 49, SS2-FIG. 53) are placed on the internal surfaces of the wraparound sleeve 104e (104e-FIG. 45, 104e-FIG. 46) and wraparound sleeve 104f (104f-FIG. 49, 104f-FIG. 50) and wraparound sleeve 104g (104g-FIG. 53, 104g-FIG. 54) so to be later on in direct contact of the outer surfaces of the top and bottom bread slices of the sandwich.

The nature and numbers of susceptors, beyond the one comprising microwave interactive surfaces SS1 (SS1-FIG. 45, SS1-FIG. 49, SS1-FIG. 53) and SS2 (SS2-FIG. 45, SS2-FIG. 49, SS2-FIG. 53), placed on the internal surfaces of the wraparound sleeves 104e (104e-FIG. 45, 104e-FIG. 46) and wraparound sleeve 104f (104f-FIG. 49, 104f-FIG. 50) and wraparound 104g (104g-FIG. 53, 104g-FIG. 54) may vary. In particular, susceptors can be added to cover the sides, edges or all surfaces of wraparound sleeve 104e (104e-FIG. 45, 104e-FIG. 46) and wraparound sleeve 104f (104f-FIG. 49, 104f-FIG. 50) and wraparound sleeve 104g (104g-FIG. 53, 104g-FIG. 54). Supplemental susceptors can also be inserted between the layers of a multi deck sandwich or between sandwiches in a multiple sandwich offer pack.

Wraparound sleeve 104e, 104f and 104g have a self-locking feature that will lock in place the interactive packaging 104e, 104f and 104g around the sandwich. The self-locking features are the matching locking package appendices and cuts 116e (116e-FIG. 45) and 117e (117e-FIG. 45) for sleeve 104e, 116f (116f-FIG. 49) and 117f (117f-FIG. 49) for package 104f and 118g (118g-FIG. 53) and 119g (119g-FIG. 53) for package 104g. Of course multiples other designs, known in the art of interlocking packaging appendices, can be envisioned that will work with this second solution for the second embodiment.

The assembled sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 46, 103a-FIG. 47, 103a-FIG. 50, 103a-FIG. 51, 103a-FIG. 54, 103a-FIG. 55) which has a natural height of H (H-FIG. 1, H-FIG. 4, H-FIG. 46, H-FIG. 47, H-FIG. 50, H-FIG. 51, H-FIG. 54, H-FIG. 55) is placed, as illustrated in FIG. 46 (FIG. 46) and FIG. 50 (FIG. 50) and FIG. 54 (FIG. 54), into microwave interactive sleeve 104e (104e-FIG. 46) and 104f (104f-FIG. 50) and 104g (104g-FIG. 54). As illustrated in FIG. 47 (FIG. 47) and FIG. 51 (FIG. 51) and FIG. 55 (FIG. 55) the wrap around microwave interactive container 104e (104e-FIG. 47) and 104f (104f-FIG. 51) and 104g (104g-FIG. 55) are folded and closed around sandwich 103a (103a-FIG. 47, 103a-FIG. 51, 103a-FIG. 55). In doing so, pressure is applied on sandwich 103a and sandwich 103a is compressed into sandwich 103b to a vertical height h1 (h1-FIG. 47, h1-FIG. 51, h1-FIG. 55). For example, as illustrated in FIG. 47 (FIG. 47) and in FIG. 51 (FIG. 51) and FIG. 55 (FIG. 55) the assembled sandwich 103a (103a-FIG. 46, 103a-FIG. 47, 103a-FIG. 50, 103a-FIG. 51, 103a FIG. 54, 103a FIG. 55) which has a natural height of H is compressed within the wrap around microwave interactive sleeve 104e (104e-FIG. 46) and 104 f (104f-FIG. 50) and 104g (104g-FIG. 54) by a series of spring loaded rotating rollers 114 (114-FIG. 47, 114-FIG. 51, 114-FIG. 55) to the smaller height of h1 (h1-FIG. 47, h1-FIG. 51. h1-FIG. 55). Compression between two belt conveyors is also acceptable. Use of mechanical wrap around packaging machine is also envisioned.

For illustration purposes and in all attached illustrations, the sandwich 103a(103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 46, 103a-FIG. 47, 103a-FIG. 50, 103a-FIG. 51, 103a-FIG. 54, 103a-FIG. 55) becomes after compression, sandwich 103b (103b-FIG. 47, 103b-FIG. 51, 103b-FIG. 55). Sandwich 103b has different physical characteristics, properties and dimensions when compared to the uncompressed sandwich 103a.

Self-locking feature 116e (116e-FIG. 45), 117e (117e-FIG. 45), 116f (116f-FIG. 49), 117f (117f-FIG. 49), 118g (118g-FIG. 53), 119g (119g-FIG. 53) are used to seal and hold in place the wrap around packaging around the compressed sandwich 103b, keeping sustained pressure around sandwich 103b(103b-FIG. 48, 103b-FIG. 52, 103b-FIG. 58).

It is important to note that the vertical height h1 of the microwave interactive container from the undersurface of the top microwave interactive major surface SS1 (SS1-FIG. 48, SS1-FIG. 52, SS1-FIG. 58) and to the upper surface of the bottom microwave interactive major surface SS2 (SS2-FIG. 48, SS2-FIG. 52, SS2-FIG. 58) is substantially less than the height H (H-FIG. 1, H-FIG. 4, H-FIG. 45, H-FIG. 50, H-FIG. 54) of sandwich 103a and therefore sandwich 103b (103b-FIG. 47, 103b-FIG. 48, 103b-FIG. 51, 103b-FIG. 52, 103b-FIG. 55, 103b-FIG. 56) is always kept under compression within microwave interactive containers 104e and 104f and 104g. The ratio of packaging compression PC, which is equal to the height h1 divided by the height H, is comprised for this invention between 0.4 and 0.99 and preferably between 0.75 and 0.95.

The ratio of packaging compression PC for this invention is predetermined so the susceptors of the top and bottom microwave interactive major surfaces of sleeves 104e and 104f and 104g remain, during the entire time the sandwich is exposed to microwave energy, in intimate constant intense flat wise contact with the top and bottom major outer surfaces of the sandwich despite the shrinking effect of microwave energy on the bread slices and filings composing the sandwich.

Furthermore and according to the teaching of this invention, the packaging compression PC value further determines the degree and intensity of intimate flat wise contact between the bread slices and the susceptors during microwaving and therefore the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces. In particular the lower the packaging compression PC the more grilling and toasting is generated on the surface of the sandwich during microwaving. Being able to control the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces is a key feature of this invention.

In another feature of this embodiment, predetermined microwave shielding can be added to the microwave interactive container wraparound sleeve 104e (104e-FIG. 45, 104e-FIG. 46, 104e-FIG. 47, 104e-FIG. 48) and microwave interactive container wraparound sleeve 104f (104f-FIG. 49, 104f-FIG. 50, 104f-FIG. 51, 104f-FIG. 52) and microwave interactive container wraparound sleeve 104g (104g-FIG. 53, 104g-FIG. 54, 104g-FIG. 55, 104g-FIG. 56, 104g-FIG. 57, 104g-FIG. 58). In the art of microwave interactive packaging, shielding describes either a high degree of microwave absorption by susceptors and subsequent heat generation on their surfaces, or a reflection of the microwaves away from the product using microwave impervious material, or a combination of high absorption and reflection. Such shielding limits the microwave penetration into food products and can be beneficial. Concerning susceptor microwave absorption shielding characteristics, it is known in the art of susceptor manufacturing that depending on the density of metal deposited on the microwave interactive surfaces, or by choosing specific metal composition, the microwave interactive material will absorb little, some or all of the microwave energy to which it is exposed. The more absorption of microwaves by the susceptors, the more heat is generated on the surface of the susceptor and the fewer microwaves will penetrate the food product. Also the less overheating of the bread and filling is likely to occur. When using such shielding susceptor interactive packaging, it is believed most of the heating of the food product occurs through conduction and convection and infrared radiation arising from the hot susceptor surfaces. Heating by conduction, convection and infrared is believed to be beneficial for browning, crisping and grilling of the sandwich surface and for the overall quality of the sandwich. The bread slices or the like retain more moisture and are tenderer. Concerning microwave reflection, a thin layer of a metal, such as aluminum, continuous or in a pattern, can be used. In this case, microwaves will be blocked from penetrating the food product through the reflecting shielded areas. Many patterns of microwave shielding can be designed in microwave interactive container 104e (104e-FIG. 45, 104e-FIG. 46, 104e-FIG. 47, 104e-FIG. 48) and 104f (104f-FIG. 49, 104f-FIG. 50, 104f-FIG. 51, 104f-FIG. 52) and 104g and these patterns will allow further control of the degree of browning, crisping, grilling and heating of the food product or sandwich. Patterns include diverse areas of low to high susceptor absorbing shielding and combination of susceptor absorbing shielding and or reflecting shielding. Often, the less filling in the sandwich, the more microwave shielding will be used. Also the more fat rich fillings the sandwich contains, the more shielding will be used. In a first example, for a classic grilled cheese sandwich, the shielding will be high and the microwave interactive package will take the form of an enclosed box with large shielding zone such as suggested in wraparound sleeve 104f and 104g (104g-FIG. 53, 104g-FIG. 54, 104g-FIG. 55, 104g-FIG. 56, 104g-FIG. 57, 104g-FIG. 58). In fact, in a grilled cheese application, at least 75% of the internal surfaces of microwave interactive container wraparound sleeve 104e (104e-FIG. 45, 104e-FIG. 46, 104e-FIG. 47, 104e-FIG. 48) and 104f (104f-FIG. 49, 104f-FIG. 50, 104f-FIG. 51, 104f-FIG. 52) and 104g (104g-FIG. 53, 104g-FIG. 54, 104g-FIG. 55, 104g-FIG. 56, 104g-FIG. 57, 104g-FIG. 58), top, bottom and sides, will be covered with susceptors having predetermined high shielding properties. In some cases, multiple layers of susceptor material can be used to achieve closer to 100% shielding of the product from microwave without requiring the addition of any expensive reflecting shielding material. Excess direct microwave energy on a grilled cheese sandwich will result in over heating of the cheese and even burning of the cheese. In a second example, for a grilled cheese and meat sandwich, a filling containing less fat and more moisture, less shielding is often necessary. To achieve less shielding, lower absorption susceptors and area totally transparent to microwave energy are used in the construction of the microwave interactive container. With predetermined lower shielding and microwave transparent areas, higher moisture fillings can be heated directly by some microwave energy while the bread will still be uniformly grilled by top and bottom susceptors of the microwave interactive package. In fact, in a grilled cheese and meat sandwich application, at least 50% of the internal surfaces of microwave interactive container wraparound sleeve 104e (104e-FIG. 45, 104e-FIG. 46, 104e-FIG. 47, 104e-FIG. 48) and 104f (104f-FIG. 49, 104f-FIG. 50, 104f-FIG. 51, 104f-FIG. 52) and 104g (104g-FIG. 53, 104g-FIG. 54, 104g-FIG. 55, 104g-FIG. 56, 104g-FIG. 57, 104g-FIG. 58), often the top and bottom major surfaces, will be covered with susceptors having predetermined high shielding properties. In a third example, for a sandwich with large quantity of moist filling, containing more meats or soft fillings such as dressings or sauces or vegetables, the microwave interactive package will be a wraparound sleeve such as 104e (104e-FIG. 45, 104e-FIG. 46, 104e-FIG. 47, 104e-FIG. 48) where the end sides of the package are totally open to microwave energy. Indeed, a large amount of microwave energy is required to warm these larger quantity high moisture fillings. For a sandwich with large quantity of moist filling, at least 25% of the internal surfaces of microwave interactive container wraparound sleeve 104e (104e-FIG. 45, 104e-FIG. 46, 104e-FIG. 47, 104e-FIG. 48) and 104f (104f-FIG. 49, 104f-FIG. 50, 104f-FIG. 51, 104f-FIG. 52) and 104g (104g-FIG. 53, 104g-FIG. 54, 104g-FIG. 55, 104g-FIG. 56, 104g-FIG. 57, 104g-FIG. 58), often the top major surfaces, will be covered with susceptors having predetermined high shielding properties.

Another feature of the microwave interactive packaging described in the embodiment would be a protective over-wrapping 120a (120a-FIG. 9A) placed around the microwave interactive container. This overwrapping by it predetermined design and composition provide protection to the sandwich or the like and insulation protecting the consumer from the hot food once microwaved. Such protecting insulating over-wrappings comprise paper bag, grease proof paper bag, corrugated board, pressed paper, chip board, plastic film. Another solution for providing insulation protecting the consumer from the hot food once microwaved is to add an insulating substrate to the microwave interactive sleeve, such as pressed paper, cardboard, corrugated board, fluted paper or the like.

Further comprised in the invention are two sandwiches 103d (103d-FIG. 11A) and 103e (103e-FIG. 11A) or the like that are placed in said microwave interactive container in a side by side relationship.

Using the assembly and methods described previously in this second embodiment and its second solution:

• • providing a substantially resilient food product, such as sandwich, to be heated and grilled on its outside top and bottom major surfaces,
  • providing an microwave interactive container as described and of predetermined dimension
  • providing a compressing mean in combination with said microwave interactive container
  • and further adding the steps comprising of:
  • keeping the sandwich or the like compressed within the container until and during heating in the microwave device
  • thereafter subjecting, the container and its compressed content to microwave energy using a microwave device 109 (109-FIG. 10) of predetermined power, preferably between 500 Watts to 5000 Watts and a predetermined exposure time to microwave energy, preferably of one (1) to (10) minutes depending on watt power of said microwave device, to sufficiently heat the contents of the container while simultaneously grilling the outer surfaces of the bread slices
  • opening the container and removing the grilled sandwich

The finished product 103c (103c-FIG. 11), after heating and cooking in the microwave, will be warm, uniformly grilled, have crisp golden outer surfaces and its texture will be moist and tender, a result that has not been achieved before or made commercially successful. Furthermore, this invention, as applied in the first embodiment, uses a simple sandwich assembly methods and a lower cost microwave interactive container than previously disclosed in the art of microwave grilled sandwich, while achieving more consistent grilling of the sandwich after exposure to microwave radiation.

For the third embodiment, an assembly comprising:

• • Resilient bread slices 100 (100 FIG. 1, 100-FIG. 59, 100-FIG. 65) or the like
  • Edible sandwich fillers 101 (101-FIG. 1, 101-FIG. 62, 101-FIG. 68)
  • A microwave interactive container
  • A sandwich be assembled as described thereafter and to be heated or cooked in a microwave device.

Hb (Hb-FIG. 59 and Hb-FIG. 65) represents a vertical height between the top surface and bottom surface of a bread slice 100 (100-FIG. 59, 100-FIG. 65) or thickness of the bread slice. For this invention, the vertical height Hb can vary from one slice of bread to another slice of bread.

Hf (Hf-FIG. 62 and Hf-FIG. 68) represents a vertical height between the top surface and bottom surface of the edible sandwich fillers 101 (101-FIG. 1, 101-FIG. 62, 101-FIG. 68) or total thickness of the sandwich fillers.

As illustrated in FIG. 1 (FIG. 1), the sandwich is to be assembled from a first and second slices of fresh resilient untoasted bread 100 (100-FIG. 1) or the like, said slices having inner and outer surfaces and one or more layers of edible sandwich filler ingredients, such as sliced filings 101 (101-FIG. 1) and optional soft fillings 102 (102-FIG. 1) between the inner surfaces of said first and second bread slices or the like for completing the sandwich. Top bread slice and bottom bread slice define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top.

Two or more bread slices can be used for constructing the sandwich. In particular, the sandwich can have multiple levels of alternate breads and fillings. The top bread slice and bottom bread slice of the sandwich still define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top.

The reference numeral 100 (100-FIG. 1) denotes a resilient farinaceous food product. The reference numerals 101 (101-FIG. 1) and 102 (102-FIG. 1) denote edible food products which may be interposed between the bread slices. The numbers and the nature of the fillers may vary.

The microwave interactive container is a sleeve 104a (104a-FIG. 63, 104a-FIG. 64) and sleeve 104b (104b-FIG. 69, 104b-FIG. 70) having at least a top microwave interactive major surface, a bottom microwave interactive major surface spaced apart and parallel to the top, a pair or more of spaced, parallel side elements, wherein said top microwave interactive major surface and bottom microwave interactive major surface are made at least partially of a susceptor or the like microwave absorbing heating elements. Reference SS1 (SS1-FIG. 63, SS1-FIG. 64, SS1-FIG. 69, SS1-FIG. 70) is the top microwave interactive major surface and reference SS2 (SS2-FIG. 63, SS2-FIG. 64, SS2-FIG. 69, SS2-FIG. 70) is the bottom microwave interactive major surface. Top microwave major interactive surface and bottom microwave interactive surface are parallel and separated by a vertical height h1 (h1-FIG. 63, h1-FIG. 64, h1-FIG. 69, h1-FIG. 70).

In FIG. 63 (FIG. 63), FIG. 64 (FIG. 64), FIG. 69 (FIG. 69) and FIG. 70 (FIG. 70), the susceptors of microwave interactive surfaces SS1 and SS2 are placed on the internal surfaces of the sleeves 104a (104a-FIG. 63, 104a-FIG. 64) and sleeves 104b (104b-FIG. 69, 104b-FIG. 70) so to be later on in direct contact of the outer surfaces of the top and bottom bread slices of the sandwich.

The nature and numbers of susceptors placed, beyond the one comprising microwave interactive surfaces SS1 (SS1-FIG. 63, SS1-FIG. 64, SS1-FIG. 69, SS1-FIG. 70) and SS2 (SS2-FIG. 63, SS2-FIG. 64, SS2-FIG. 69, SS2-FIG. 70), on the internal surfaces of the sleeves 104a (104a-FIG. 2, 104a-FIG. 63, 104a-FIG. 64) and sleeves 104b (104b-FIG. 69, 104b-FIG. 70) may vary. In particular, susceptors can be added to cover the sides, edges or all surfaces of container 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70). Supplemental susceptors can also be inserted between the layers of a multi deck sandwich or between sandwiches in a multiple sandwich offer pack.

At least a first and second slices of fresh resilient untoasted bread 100 (100-FIG. 1, 100-FIG. 59, 100-FIG. 65) of thickness Hb (Hb-FIG. 59, Hb-FIG. 65) are compressed buy a pair of flat pinchers 108 (108-FIG. 59, 108-FIG. 60, 108-FIG. 61, 108-FIG. 65, 108-FIG. 66, 108-FIG. 67) to the smaller height of hb (hb-FIG. 61, hb-FIG. 67). The ratio of bread compression Cb, which is equal to the height hb divided by the height Hb, is comprised for this invention between 0.4 and 0.99 and preferably between 0.75 and 0.95.

For illustration purposes and in all attached illustrations, a bread slice 100 (100-FIG. 1, 100-FIG. 59, 100-FIG. 65) becomes after compression bread slice 100b (100b-FIG. 61, 100b-FIG. 67). Bread slice 100b has different physical characteristics, properties and dimensions when compared to the uncompressed bread slices 100.

As described in FIG. 62 (FIG. 62) and FIG. 68 (FIG. 68) a sandwich 103b (103b-FIG. 63, 103b-FIG. 64, 103b-FIG. 69, 103b-FIG. 70) is rapidly assembled from a first and second slices of fresh resilient untoasted compressed bread 100b (100b-FIG. 60, 100b-FIG. 61, 100b-FIG. 62), and one or more layers of edible sandwich filler ingredients, such as sliced filings 101 (101-FIG. 1, 101-FIG. 62, 101-FIG. 68), between the inner surfaces of said first and second bread slices or the like for completing the sandwich. Soft fillings 102 (102-FIG. 1) can also comprise the sandwich 103b (103b-FIG. 63, 103b-FIG. 64, 103b-FIG. 69, 103b-FIG. 70). Top bread slice and bottom bread slice define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. h2 (h2-FIG. 63, h2-FIG. 69) represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich 103b (103b-FIG. 63, 103b-FIG. 64, 103b-FIG. 69, 103b-FIG. 70)

Sandwich 103b (103b-FIG. 63, 103b-FIG. 69) is rapidly and manually introduced inside sleeve 104a (104a-FIG. 63, 104a-FIG. 64) or sleeve 104b (104b-FIG. 69, 104b-FIG. 70)

For this invention the height h2 (h2-FIG. 63, h2-FIG. 69) is less than the height h1 (h1-FIG. 63, h1-FIG. 64, h1-FIG. 69, h1-FIG. 70) and allows for insertion of the assembled compressed sandwich 103b (103b-FIG. 63, 103b-FIG. 69) in the sleeve 104a (104a-FIG. 63, 104a-FIG. 64) and sleeve 104b (104b-FIG. 69, 104b-FIG. 70).

The compressed sandwich 103b (103b-FIG. 63, 103b-FIG. 69) can also be introduced in the interactive packaging 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70) automatically using a mechanical device, that comprises pinchers, pistons, pushers, guides and conveyors.

The sides 110b (110b-FIG. 69, 110b-FIG. 70) of microwave interactive packaging 104b (104b-FIG. 69, 104b-FIG. 70) can be closed as shown in FIG. 70 (FIG. 70). Benefits of closing the end of the microwave interactive packaging 104b (104b-FIG. 69, 104b-FIG. 70) are physical protection of the sandwich and, as explained later, selective shielding from microwave.

It is important to note that the vertical height h1 of the microwave interactive container from the undersurface of the top microwave interactive major surface SS1 (SS1-FIG. 63, SS1-FIG. 64, SS1-FIG. 69, SS1-FIG. 70) and to the upper surface of the bottom microwave interactive major surface SS2 (SS2-FIG. 63, SS2-FIG. 64, SS2-FIG. 69, SS2-FIG. 70) is substantially less than the combined vertical height H of the uncompressed fresh resilient untoasted bread slices and of the edible fillers used in the assembly of the sandwich. Therefore sandwich 103b (103b-FIG. 63, 103b-FIG. 64, 103b-FIG. 69, 103b-FIG. 70) is always kept under compression within microwave interactive containers 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70).

The ratio of packaging compression PC, which is equal to the height h1 divided by the height H, is comprised for this invention between 0.4 and 0.99 and preferably between 0.75 and 0.95.

The ratio of packaging compression PC for this invention is predetermined so the susceptors of the top and bottom microwave interactive major surfaces of sleeves 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70) remain, during the entire time the sandwich is exposed to microwave energy, in intimate constant intense flat wise contact with the top and bottom major outer surfaces of the sandwich despite the shrinking effect of microwave energy on the bread slices and filings composing the sandwich.

Furthermore and according to the teaching of this invention, the packaging compression PC value further determine the degree and intensity of intimate flat wise contact between the bread slices and the susceptors during microwaving and therefore the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces. In particular the lower the packaging compression PC the more grilling and toasting is generated on the surface of the sandwich during microwaving. Being able to control the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces is a key feature of this invention.

In another feature of this embodiment, predetermined microwave shielding can be added to the microwave interactive container sleeve 104a (104a-FIG. 63, 104a-FIG. 64) and microwave interactive container sleeve 104b (104b-FIG. 69, 104b-FIG. 70). In the art of microwave interactive packaging, shielding describes either a high degree of microwave absorption by susceptors and subsequent heat generation on their surfaces, or a reflection of the microwaves away from the product using microwave impervious material, or a combination of high absorption and reflection. Such shielding limits the microwave penetration into food products and can be beneficial. Concerning susceptor microwave absorption shielding characteristics, it is known in the art of susceptor manufacturing that depending on the density of metal deposited on the microwave interactive surfaces, or by choosing specific metal composition, the microwave interactive material will absorb little, some or all of the microwave energy to which it is exposed. The more absorption of microwaves by the susceptors, the more heat is generated on the surface of the susceptor and the fewer microwaves will penetrate the food product. Also the less overheating of the bread and filling is likely to occur. When using such shielding susceptor interactive packaging, it is believed most of the heating of the food product occurs through conduction and convection and infrared radiation arising from the hot susceptor surfaces. Heating by conduction, convection and infrared is believed to be beneficial for browning, crisping and grilling of the sandwich surface and for the overall quality of the sandwich. The bread slices or the like retain more moisture and are tenderer. Concerning microwave reflection, a thin layer of a metal, such as aluminum, continuous or in a pattern, can be used. In this case, microwaves will be blocked from penetrating the food product through the reflecting shielded areas. Many patterns of microwave shielding can be designed in microwave interactive packaging 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70) and these patterns will allow further control of the degree of browning, crisping, grilling and heating of the food product or sandwich. Patterns include diverse areas of low to high susceptor absorbing shielding and combination of susceptor absorbing shielding and or reflecting shielding. Often, the less filling in the sandwich, the more microwave shielding will be used. Also the more fat rich fillings the sandwich contains, the more shielding will be used. In a first example, for a classic grilled cheese sandwich, the shielding will be high and the microwave interactive package will take the form of an enclosed box with large shielding zone such as suggested in packaging 104b (104b-FIG. 69, 104b-FIG. 70). In fact, in a grilled cheese application, at least 75% of the internal surfaces of microwave interactive packaging 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70), top, bottom and sides, will be covered with susceptors having predetermined high shielding properties. In some cases, multiple layers of susceptor material can be used to achieve closer to 100% shielding of the product from microwave without requiring the addition of any expensive reflecting shielding material. Excess direct microwave energy on a grilled cheese sandwich will result in over heating of the cheese and even burning of the cheese. In a second example, for a grilled cheese and meat sandwich, a filling containing less fat and more moisture, less shielding is often necessary. To achieve less shielding, lower absorption susceptors and area totally transparent to microwave energy are used in the construction of the microwave interactive container. With predetermined lower shielding and microwave transparent areas, higher moisture fillings can be heated directly by some microwave energy while the bread will still be uniformly grilled by top and bottom susceptors of the microwave interactive package. In fact, in a grilled cheese and meat sandwich application, at least 50% of the internal surfaces of microwave interactive packaging 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70), often the top and bottom major surfaces, will be covered with susceptors having predetermined high shielding properties. In a third example, for a sandwich with large quantity of moist filling, containing more meats or soft fillings such as dressings or sauces or vegetables, the microwave interactive package will be a sleeve such as 104a (104a-FIG. 63, 104a-FIG. 64) where the end sides of the package are totally open to microwave energy. Indeed, a large amount of microwave energy is required to warm these larger quantity high moisture fillings. For a sandwich with large quantity of moist filling, at least 25% of the internal surfaces of microwave interactive packaging 104a (104a-FIG. 63, 104a-FIG. 64) and 104b (104b-FIG. 69, 104b-FIG. 70), often the top major surfaces, will be covered with susceptors having predetermined high shielding properties.

An important part of this invention relates to the buttering, oiling or application of edible fat on the outermost surfaces of the upper and lower bread slices 100 (100-FIG. 59, 100-FIG. 65). Optionally, the outer side edge of the bread slices 100 (100-FIG. 59, 100-FIG. 65) can also be butter or oiled. The buttering, oiling or application of edible fat lubricates theses outside surfaces and will, as described thereafter, facilitate the insertion of the compressed sandwich 103b (103b-FIG. 63, 103b-FIG. 69) into the microwave interactive sleeve 104a (104a-FIG. 63, 104a-FIG. 64) and 104 b (104b-FIG. 69, 104b-FIG. 70. Also, the buttering, oiling or application of fat also effectively further precludes the loss of moisture of the bread or farinaceous product and results in a delightful flavor and aroma when said surfaces are grilled by heating of packaged sandwich in the microwave oven 109 (109-FIG. 10). Butter, oil or edible fat can be either sprayed or spread on the bread surfaces. Dipping of the bread slices in warm liquid butter, oil and liquid edible fat is also an acceptable method. Amount of butter, oil and edible fat deposited on the bread slices can vary from 0.1% to 30% of the weight of the bread slices and preferably from 0.5% to 5%. The buttering, oiling or coating of edible fat can occur either before, during or after the sandwich assembly. Due to the ample amount of butter or shortening in some type of breads such as Danish pastry or croissant type pastries, the buttering or oiling of the bread or pastry slices can be totally eliminated; a sandwich assembled with the use of such bread may be packaged in accordance with the teaching herein disclosed but with the omission of the step of buttering or oiling the outer surfaces of the bread.

Another feature of the microwave interactive packaging described in the embodiment would be an easy open tear off strip 119 (119-FIG. 9) or the like running along the sleeve so the consumer can easily open microwave interactive package after heating in the microwave oven, as illustrated in FIG. 9 (FIG. 9) and FIG. 11 (FIG. 11). Other features of the microwave interactive packaging described in the embodiment would be a handle 120 (120-FIG. 9) for easy handling of the package.

Another feature of the microwave interactive packaging described in the embodiment would be a protective over-wrapping 120a (120a-FIG. 9A) placed around the microwave interactive container. This overwrapping by it predetermined design and composition provide protection to the sandwich or the like and insulation protecting the consumer from the hot food once microwaved. Such protecting insulating over-wrappings comprise paper bag, grease proof paper bag, corrugated board, pressed paper, chip board, plastic film. Another solution for providing insulation protecting the consumer from the hot food once microwaved is to an insulating substrate to the microwave interactive sleeve, such as pressed paper, cardboard, corrugated board, fluted paper or the like.

Further comprised in the invention are two sandwiches 103d (103d-FIG. 11A) and 103e (103e-FIG. 11A) or the like that are placed in said microwave interactive container in a side by side relationship.

Using the assembly and methods described previously in this third embodiment:

• • providing a substantially resilient food product, such as sandwich, to be heated and grilled on its outside top and bottom major surfaces,
  • providing an microwave interactive container as described and of predetermined dimension
  • providing a compressing mean in combination with said microwave interactive container
  • and further adding the steps comprising of:
  • keeping the sandwich or the like compressed within the container until and during heating in the microwave device
  • thereafter subjecting, the container and its compressed content to microwave energy using a microwave device 109 (109-FIG. 10) of predetermined power, preferably between 500 Watts to 5000 Watts and a predetermined exposure time to microwave energy, preferably of one (1) to (10) minutes depending on watt power of said microwave device, to sufficiently heat the contents of the container while simultaneously grilling the outer surfaces of the bread slices
  • opening the container and removing the grilled sandwich

The finished product 103c (103c-FIG. 11), after heating and cooking in the microwave, will be uniformly grilled, have crisp golden outer surfaces and its texture will be moist and tender, a result that has not been achieved before or made commercially successful. Furthermore, this invention, as applied in the first embodiment, uses a simple sandwich assembly methods and a lower cost microwave interactive container than previously disclosed in the art of microwave grilled sandwich, while achieving more consistent grilling of the sandwich after exposure to microwave radiation.

For the fourth embodiment, several solutions exist. For the second solution, an assembly comprising of:

• • A sandwich to be heated or cooked in a microwave device.
  • A microwave interactive container

As illustrated in FIG. 1 (FIG. 1), the sandwich 103a (103a-FIG. 1, 103a-FIG. 3, 103a-FIG. 4) is assembled from a first and second slices of fresh resilient untoasted bread 100 (100-FIG. 1) or the like, said slices having inner and outer surfaces, and one or more layers of edible sandwich filler ingredients, such as sliced filings 101 (101-FIG. 1) and optional soft fillings 102 (102-FIG. 1) between the inner surfaces of said first and second bread slices or the like for completing the sandwich. Top bread slice and bottom bread slice define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 72, H-FIG. 76, H-FIG. 79) represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich 103a (103a-FIG. 1, 103a-FIG. 4, 103a-FIG. 72, 103a-FIG. 76, 103a-FIG. 79).

Two or more bread slices can be used for constructing the sandwich. In particular, the sandwich can have multiple levels of alternate bread slices and fillings. The top bread slice and bottom bread slice of the sandwich still define a top major outer surface, a bottom major outer surface spaced apart and parallel to the top. H (H-FIG. 1, H-FIG. 4, H-FIG. 72, H-FIG. 76, H-FIG. 79) still represents a vertical height between the top major outer surface and the bottom outer surface of the assembled sandwich.

The reference numeral 100 (100-FIG. 1) denotes a resilient farinaceous food product. The reference numeral 101 (101-FIG. 1) and 102 (102-FIG. 1) denote edible food products which may be interposed between the bread slices. The numbers and the nature of the fillers may vary.

An important part of this invention relates to the buttering, oiling 107 (107-FIG. 3) or application of edible fat on the outermost surfaces of the upper and lower bread slices 100 (100-FIG. 3) of Sandwich 103a (103a-FIG. 3). Optionally, the outer side edge of the bread slices 100 (100-FIG. 3) can also be butter or oiled. The buttering, oiling or application of edible fat lubricates theses outside surfaces and will, as described thereafter, facilitate the insertion of the sandwich 103a (103a-FIG. 72, 103a-FIG. 76, 103a-FIG. 79) into the microwave interactive sleeve 104e (104e-FIG. 71) and 104 f (104f-FIG. 75) and 104g (104g-FIG. 78) and the compression of sandwich 103a into sandwich 103b. Also, the buttering, oiling or application of fat effectively further precludes the loss of moisture from the bread or like farinaceous product and results in a delightful flavor and aroma when said surfaces are grilled by heating of packaged sandwich in the microwave oven 109 (109-FIG. 10). Butter, oil or edible fat can be either sprayed 107 (107-FIG. 3) or spread on the bread surfaces. Dipping of the bread slices in warm liquid butter, oil and liquid edible fat is also an acceptable method. Amount of butter, oil and edible fat deposited on the bread slices can vary from 0.1% to 30% of the weight of the bread slices and preferably from 0.5% to 5%. The buttering, oiling or coating of edible fat can occur either before, during or after the sandwich assembly. Due to the ample amount of butter or shortening in some type of breads such as Danish pastry or croissant type pastries, the buttering or oiling of the bread or pastry slices can be totally eliminated; a sandwich assembled with the use of such bread may be packaged in accordance with the teaching herein disclosed but with the omission of the step of buttering or oiling the outer surfaces of the bread.

The microwave interactive container is wraparound sleeve 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) and wraparound sleeve 104f (104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and wraparound sleeve 104g (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82) having at least a top microwave interactive major surface, a bottom microwave interactive major surface spaced apart and parallel to the top, a pair or more of spaced, parallel side elements, wherein said top microwave interactive major surface and bottom microwave interactive major surface are made at least partially of a susceptor or the like microwave absorbing heating elements. Reference SS1 (SS1-FIG. 71, SS1-FIG. 75, SS1-FIG. 78) is the top microwave interactive major surface and reference SS2 (SS2-FIG. 71, SS2-FIG. 75, SS2-FIG. 78) is the bottom microwave interactive major surface. When container is closed, top microwave major interactive surface and bottom microwave interactive surface are parallel and separated by a vertical height h1 (h1-FIG. 73, h1-FIG. 77, h1-FIG. 82).

In FIG. 71 (FIG. 71) to FIG. 82 (FIG. 82), the susceptors of microwave interactive surfaces SS1 and SS2 are placed on the internal surfaces of the wraparound sleeve 104e (104e-FIG. 71, 104e-FIG. 72) and wraparound sleeve 104f (104f-FIG. 75, 104f-FIG. 76) and wraparound sleeve 104g (104g-FIG. 78, 104g-FIG. 79) so to be later on in direct contact of the outer surfaces of the top and bottom bread slices of the sandwich.

The nature and numbers of susceptors, beyond the one comprising microwave interactive surfaces SS1 (SS1-FIG. 71, SS1-FIG. 75, SS1-FIG. 78) and SS2 (SS2-FIG. 71, SS2-FIG. 75, SS2-FIG. 78), placed on the internal surfaces of the wraparound sleeves 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) and wraparound sleeve 104f (104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and wraparound 104g (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82) may vary. In particular, susceptors can be added to cover the sides, edges or all surfaces of wraparound sleeve 104e (104e-FIG. 71) and wraparound sleeve 104f (104f-FIG. 74, 104f-FIG. 75) and wraparound sleeve 104g (104g-FIG. 78). Supplemental susceptors can also be inserted between the layers of a multi deck sandwich or between sandwiches in a multiple sandwich offer pack.

Wraparound sleeve 104e, 104f and 104g have a self-locking feature that will lock in place the interactive packaging 104e, 104f and 104g around the sandwich. The self-locking features are the matching locking package appendices and cuts 116e (116e-FIG. 71) and 117e (117e-FIG. 71) for sleeve 104e (104e-FIG. 71), 116f (116f-FIG. 75) and 117f (117f-FIG. 75) for package 104f (104f-FIG. 75) and 118g (118g-FIG. 78) and 119g (119g-FIG. 78) for package 104g (104g-FIG. 78). Of course multiples other designs, known in the art of interlocking packaging appendices, can be envisioned that will work with this second solution for the second embodiment.

The assembled sandwich 103a (103a-FIG. 72, 103a-FIG. 76, 103a FIG. 79) which has a vertical height of H (H-FIG. 72, H-FIG. 76, H-FIG. 79) is placed, as illustrated in FIG. 72 (FIG. 72), FIG. 76 (FIG. 76) and FIG. 79 (FIG. 79), into microwave interactive packaging 104e, 104f and 104g

The microwave interactive packaging 104e, 104f and 104g are closed around sandwich 103a (103a-FIG. 72, 103a-FIG. 76, 103a FIG. 79) as symbolized by the arrows on FIG. 72 (FIG. 72), FIG. 76 (FIG. 76) and FIG. 79 (FIG. 79).

In doing so, pressure is applied on sandwich 103a. Sandwich 103a is compressed into sandwich 103b to a vertical height h1 (h1-FIG. 73, h1-FIG. 77, h1-FIG. 80).

For illustration purposes and in all attached illustrations, the sandwich 103a becomes after compression, sandwich 103b. Sandwich 103b has different physical characteristics, properties and dimensions when compared to the uncompressed sandwich 103a.

Self-locking feature 116e (116e-FIG. 71, 116e-FIG. 73), 117e (117e-FIG. 71, 117e-FIG. 73), 116f (116f-FIG. 75, 116f-FIG. 77), 117f (117f-FIG. 75), 118g (118g-FIG. 78, 118g-FIG. 82), 119g (119g-FIG. 78, 119g-FIG. 82) are used to seal and hold in place the wrap around packaging around the compressed sandwich 103b, keeping sustained pressure around sandwich 103b (103b-FIG. 73, 103b-FIG. 77, 103b-FIG. 82). Compression between two belt conveyors is also acceptable. Use of mechanical wrap around packaging machine is also envisioned

It is important to note that the vertical height h1 of the microwave interactive container from the undersurface of the top microwave interactive major surface SS1 (SS1-FIG. 73, SS1-FIG. 77, SS1-FIG. 82) and to the upper surface of the bottom microwave interactive major surface SS2 (SS2-FIG. 73, SS2-FIG. 77, SS2-FIG. 82) is substantially less than the height H (H-FIG. 1, H-FIG. 4, H-FIG. 72, H-FIG. 76, H-FIG. 79) of sandwich 103a and therefore sandwich 103b (103b-FIG. 73, 103b-FIG. 77, 103b-FIG. 81, 103b-FIG. 82) is always kept under compression within microwave interactive containers 104e (104e-FIG. 73) and 104f (104f-FIG. 77) and 104g (104g-FIG. 82). The ratio of packaging compression PC, which is equal to the height h1 divided by the height H, is comprised for this invention between 0.4 and 0.99 and preferably between 0.75 and 0.95.

The ratio of packaging compression PC for this invention is predetermined so the susceptors of the top and bottom microwave interactive major surfaces of sleeves 104e and 104f and 104g remain, during the entire time the sandwich is exposed to microwave energy, in intimate constant intense flat wise contact with the top and bottom major outer surfaces of the sandwich despite the shrinking effect of microwave energy on the bread slices and filings composing the sandwich.

Furthermore and according to the teaching of this invention, the packaging compression PC value further determines the degree and intensity of intimate flat wise contact between the bread slices and the susceptors during microwaving and therefore the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces. In particular the lower the packaging compression PC the more grilling and toasting is generated on the surface of the sandwich during microwaving. Being able to control the degree of toasting, grilling and browning of the bread surface in contact with the susceptor surfaces is a key feature of this invention.

In another feature of this embodiment, predetermined microwave shielding can be added to the microwave interactive container wraparound sleeve 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) and microwave interactive container wraparound sleeve 104f (104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and microwave interactive container wraparound sleeve 104g (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82). In the art of microwave interactive packaging, shielding describes either a high degree of microwave absorption by susceptors and subsequent heat generation on their surfaces, or a reflection of the microwaves away from the product using microwave impervious material, or a combination of high absorption and reflection. Such shielding limits the microwave penetration into food products and can be beneficial. Concerning susceptor microwave absorption shielding characteristics, it is known in the art of susceptor manufacturing that depending on the density of metal deposited on the microwave interactive surfaces, or by choosing specific metal composition, the microwave interactive material will absorb little, some or all of the microwave energy to which it is exposed. The more absorption of microwaves by the susceptors, the more heat is generated on the surface of the susceptor and the fewer microwaves will penetrate the food product. Also the less overheating of the bread and filling is likely to occur. When using such shielding susceptor interactive packaging, it is believed most of the heating of the food product occurs through conduction and convection and infrared radiation arising from the hot susceptor surfaces. Heating by conduction, convection and infrared is believed to be beneficial for browning, crisping and grilling of the sandwich surface and for the overall quality of the sandwich. The bread slices or the like retain more moisture and are tenderer. Concerning microwave reflection, a thin layer of a metal, such as aluminum, continuous or in a pattern, can be used. In this case, microwaves will be blocked from penetrating the food product through the reflecting shielded areas. Many patterns of microwave shielding can be designed in microwave interactive container 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) and 104f (104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and 104g (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82) and these patterns will allow further control of the degree of browning, crisping, grilling and heating of the food product or sandwich. Patterns include diverse areas of low to high susceptor absorbing shielding and combination of susceptor absorbing shielding and or reflecting shielding. Often, the less filling in the sandwich, the more microwave shielding will be used. Also the more fat rich fillings the sandwich contains, the more shielding will be used. In a first example, for a classic grilled cheese sandwich, the shielding will be high and the microwave interactive package will take the form of an enclosed box with large shielding zone such as suggested in wraparound sleeve 104f (104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and 104g (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82). In fact, in a grilled cheese application, at least 75% of the internal surfaces of microwave interactive container wraparound sleeve 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) and 104f (104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and 104 (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82)g, top, bottom and sides, will be covered with susceptors having predetermined high shielding properties. In some cases, multiple layers of susceptor material can be used to achieve closer to 100% shielding of the product from microwave without requiring the addition of any expensive reflecting shielding material. Excess direct microwave energy on a grilled cheese sandwich will result in over heating of the cheese and even burning of the cheese. In a second example, for a grilled cheese and meat sandwich, a filling containing less fat and more moisture, less shielding is often necessary. To achieve less shielding, lower absorption susceptors and area totally transparent to microwave energy are used in the construction of the microwave interactive container. With predetermined lower shielding and microwave transparent areas, higher moisture fillings can be heated directly by some microwave energy while the bread will still be uniformly grilled by top and bottom susceptors of the microwave interactive package. In fact, in a grilled cheese and meat sandwich application, at least 50% of the internal surfaces of microwave interactive container wraparound sleeve 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) and 104f (104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and 104g (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82), often the top and bottom major surfaces, will be covered with susceptors having predetermined high shielding properties. In a third example, for a sandwich with large quantity of moist filling, containing more meats or soft fillings such as dressings or sauces or vegetables, the microwave interactive package will be a wraparound sleeve such as 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) where the end sides of the package are totally open to microwave energy. Indeed, a large amount of microwave energy is required to warm these larger quantity high moisture fillings. For a sandwich with large quantity of moist filling, at least 25% of the internal surfaces of microwave interactive container wraparound sleeve 104e (104e-FIG. 71, 104e-FIG. 72, 104e-FIG. 73) and 104f(104f-FIG. 74, 104f-FIG. 75, 104f-FIG. 76, 104f-FIG. 77) and 104g (104g-FIG. 78, 104g-FIG. 79, 104g-FIG. 80, 104g-FIG. 81, 104g-FIG. 82), often the top major surfaces, will be covered with susceptors having predetermined high shielding properties.

Another feature of the microwave interactive packaging described in the embodiment would be an easy open tear off strip 119 (119-FIG. 9) or the like running along the sleeve so the consumer can easily open microwave interactive package after heating in the microwave oven, as illustrated in FIG. 9 (FIG. 9) and FIG. 11 (FIG. 11). Other features of the microwave interactive packaging described in the embodiment would be a handle 120 (120-FIG. 9) for easy handling of the package.

Another feature of the microwave interactive packaging described in the embodiment would be a protective over-wrapping 120a (120a-FIG. 9A) placed around the microwave interactive container. This overwrapping by it predetermined design and composition provide protection to the sandwich or the like and insulation protecting the consumer from the hot food once microwaved. Such protecting insulating over-wrappings comprise paper bag, grease proof paper bag, corrugated board, pressed paper, chip board, plastic film. Another solution for providing insulation protecting the consumer from the hot food once microwaved is to an insulating substrate to the microwave interactive sleeve, such as pressed paper, cardboard, corrugated board, fluted paper or the like.

Further comprised in the invention are two sandwiches 103d (103d-FIG. 11A) and 103e (103e-FIG. 11A) or the like that are placed in said microwave interactive container in a side by side relationship.

Using the assembly and methods described previously in this fourth embodiment:

• • providing a substantially resilient food product, such as sandwich, to be heated and grilled on its outside top and bottom major surfaces,
  • providing an microwave interactive container as described and of predetermined dimension
  • providing a compressing mean in combination with said microwave interactive container
    and further adding the steps comprising of:
  • keeping the sandwich or the like compressed within the container until and during heating in the microwave device
  • thereafter subjecting, the container and its compressed content to microwave energy using a microwave device 109 (109-FIG. 10) of predetermined power, preferably between 500 Watts to 5000 Watts and a predetermined exposure time to microwave energy, preferably of one (1) to (10) minutes depending on watt power of said microwave device, to sufficiently heat the contents of the container while simultaneously grilling the outer surfaces of the bread slices
  • opening the container and removing the grilled sandwich

The finished product 103c (103c-FIG. 11), after heating and cooking in the microwave, will be uniformly grilled, have crisp golden outer surfaces and its texture will be moist and tender, a result that has not been achieved before or made commercially successful. Furthermore, this invention, as applied in the first embodiment, uses a simple sandwich assembly methods and a lower cost microwave interactive container than previously disclosed in the art of microwave grilled sandwich, while achieving more consistent grilling of the sandwich after exposure to microwave radiation.

In this fourth embodiment, it is envisioned that the compression and locking of sandwich 103a into the interactive packaging 104e, 104f and 104g can happen in an industrial or food service setting, the packaged sandwich being distributed and sold thereafter. It is also envisioned that a consumer can purchase the microwave interactive containers generally described in this invention, construct his own sandwich and in applying the methods disclosed in this invention easily prepare a grilled sandwich in a microwave oven. Finally it is envisioned that the sandwich and its packaging be sold together and consumer can package, heat, cook and grill the sandwich as per the methods disclosed in this invention.

Practical applications of this invention are multiple and simple.

In more general terms, this invention is a grilled food product made from components that are in a planar mode. The product and packaging are configured for rapid reheating in a microwave oven resulting in a product that appears to have been conventionally grilled on a hot grill surface. The food item, generally qualified as sandwich, may be any planar food that is fresh, frozen, or chilled and thereafter microwaved for human consumption. The food can include one or more components. The planar components can be assembled into a food that can be formed with a circular, rectangular, or square edge profile.

Many types of bread and fillings can be used in conjunction with these inventions. The most obvious are described below. In fact most substantially resilient farinaceous products along with most edible filling can be used in conjunction of this invention and will result in improved browning, crisping and grilling of the planar surface and better overall quality of the food product. Most food products that make use of this invention can be heated in a microwave for 1 to 10 minutes depending on the size of the food items, preferably for 1 to 5 minutes, and most often 2 to 3 minutes for individual sandwiches. After easy single heating or cooking in the microwave oven, the food product will be both warm and tender inside and the outside surface will be browned, grilled and crispy.

The fillings can include such materials as meats, fish, eggs, vegetables, cheeses, and other similar savory ingredients. The meat may be beef (e.g., roast beef, barbecued beef, barbecue pulled beef, steak, steak strips, hamburger, brisket, etc.), chicken (e.g., chicken breast, chicken deli meats, chicken burger, barbecued chicken, barbecue pulled chicken, chicken salad, etc.), turkey (turkey breast, turkey burger), veal, pork (e.g., ham, barbecued pork, ham salad, breakfast sausage, etc.). The meat filling also may be processed meats like ham, bacon, sausage, breakfast sausage, salami, bologna, olive loaf, pepperoni, salami, corned beef, pastrami, liverwurst, sliced deli meats so forth. The meat filling may be in a sliced, shaved, shredded, chopped, or pre-cooked in a patty shape, or other convenient form, for inclusion as a filling layer in the sandwich. Minced meat in savory sauce may also be added, for example.

The fish may be cod, salmon, sole, hake, tuna, tuna salad, lox for example.

The eggs may be hard-boiled or scrambled eggs, pre-cooked egg patties, cubed, mix with vegetable for example.

The whole vegetables may be maize seeds, peas or beans, for example. The vegetable pieces may be tomatoes, sweet peppers, mushrooms, potatoes, onions, celery, carrots, or broccoli, for example. The whole vegetables and/or vegetable pieces may be blanched or precooked before adding them as a filling. They may also be added in the form of a puree, for example.

The cheese may be processed cheese, cheddar cheese, Swiss cheese, American cheese, provolone cheese, mozzarella cheese, parmesan cheese, blue cheese, Monterey jack cheese, romano cheese, cream cheese, havarti cheese, gouda cheese, muenster cheese, asiago cheese, gorgonzola cheese, gruyere, emmental, flavored cream cheese and combinations of different cheeses and flavoring such as herbs, garlic, spinach for example. The form of cheese filling that may be used is not particularly limited to one type. A cheese filling may be used in a layered form convenient for incorporation into the sandwich, such as sliced, shredded, shaved, flaked, powdered, crumbed, slabbed, creamed, and so forth, or combination of. The sliced forms of the cheese may include holes (eyes), or not.

Sauce may be added and the sauce may be mustard, ketchup, tomato sauce or a white sauce, Alfredo sauce, tartar sauce, salad dressing, for example. The sauce may be a vanilla sauce, a caramel sauce or a chocolate sauce, for example.

Cereals may be added and the cereals may be breakfast cereals, granola, polished rice or pearl barley which may be precooked, or sesame or poppy, for example.

Spices may be added and the spices may be pepper, rosemary, sage, ginger, thyme, chili, cumin, cinnamon or vanilla for example.

If it is desired to prepare a savory sandwich, a savory filling comprising of pieces of meat, fish, eggs, a sauce, whole vegetables and/or vegetable pieces, cheese, spices and/or cereals may be placed in the sandwich. Precooked or raw meat or fish pieces may be added, for example.

If it is desired to prepare a sweet toast, a filling comprising whole fruits and/or fruit pieces, fruit puree, fruit jam, eggs, a sauce, spices and/or cereals may be placed in the sandwich. For example, the whole fruits may be strawberries, raspberries, bilberries, cherries, red currants or blackberries, for example. The fruit pieces may be apples, pears, pineapples or apricots, for example. Other sweet food materials that may be combined in the formulations can include honey, marshmallows, vanilla and vanilla sauce, chocolate, brown sugar, maple syrup, peanut butter, fruit jam, caramel, custard, nuts etc.

Soy products may be used as a protein source in place of a meat filling or in combination with a meat filling. For example, soy meal patties and the like may be used to form a protein layer or layers in the sandwich filling in place of meat filling(s). Egg alternative products also may be used as a source of protein in a vegetarian sandwich for example.

These fillings can also have an identifiable flavor character including barbeque, Italian, Oriental, South Asian, Thai, Indian, Middle Eastern, Mediterranean, Mexican, Southwestern, Hawaiian, etc.

Specific and easily identifiable formulations can be used in this invention including cheese, ham and cheese, pizza fillings, chicken nuggets, nachos cheese, tortilla, salsa, seafood, peanut butter, peanut butter and jelly fillings, peanut butter and chocolate fillings, peanut butter and banana fillings, banana pudding, marshmallow and chocolate, s'more, coconut and chocolate.

The type of resilient bread used as the source of the bread slices used in embodiments of the present invention is not particularly limited, as long as it is available in shapes from which slices may be prepared so to have generally flat opposite faces. The bread may have a crust bounding at least part of the crumb, or the bread may be crust less.

The three basic types of breads that may be used are white bread, brown bread, whole wheat bread, natural bread, crust less bread, oat bran, sourdough bread, rye bread, hawaiian bread, pumpernickel bread, baguette, english muffin, danish sweet bread, bagel, soda bread, corn bread, focaccia bread, ciabatta bread and naan bread or the like. The bread shapes from which slices can be obtained, include, for example, tin, sandwich loaf, baguette, croissant, split tin, farmhouse, batch loaf, plait, Coburg, bloomer, Vienna, cottage, and barrel.

The microwaveable interactive containers 104a, 104b, 104c, 104d, 104f, 104g and like container that would make use of this invention, comprise a dielectric substrate substantially transparent to microwave in combination with an absorbing coating—i.e. susceptor material—which is responsive to the electric and magnetic field of the microwave radiation and generates substantial amount of heat when subject to microwave radiation.

The dielectric substrate may be rigid, semi-rigid or flexible, may be selected from the group of paper, pulp paper, coated paper, pressed paper, corrugated paper, cardboard, chipboard, plastic such as polyolefins, poly-esters, polyamides, polyimides, polysulfones, polyether ketones, cellophanes, and various blends of such materials.

A variety of electrically conductive materials can be used for the absorbing coating, for example, a single metal, a metal alloy, a metal oxide, a mixture of metal oxides, a dispersion of conductive metallic or non-metallic materials in a binder, or any combination of the foregoing. Suitable exemplary metals include aluminum, iron, tin, tungsten, nickel, stainless steel, titanium, magnesium, copper and chromium. Suitable exemplary metal oxides include oxides of aluminum, iron, and tin, however, if not electrically conductive, they must be used in combination with an electrically conductive material. Generally, the conductive materials are suspended or dispersed into a vehicle to allow for ease of coating the substrate. Suitable exemplary dispersion materials include carbon black, graphite, powdered metals, and metal whiskers. The absorbing coating may be suspended in an appropriate vehicle having the viscosity necessary for proper transfer in a press inking system. This combination is also referred to as susceptor ink. The susceptor may include a pattern that is specific for a particular food item in order to heat the food item evenly. Various patterns include, but are not limited to square matrix, shower flower, hexagonal, slot matrix and or concentric circles.

It is also contemplated that the susceptor include a selectively permeable reflecting coating or laminate. Examples of such coatings or laminates include, but are not limited to metals or metallic alloys, oxides or mixtures thereof either alone, or as a dispersion in a binder. By varying the reflectivity of coating, a membrane is created which is selectively permeable to microwave energy—i.e., it has the ability to control the amount of microwave energy reaching the absorbing coating.

It is also envisioned that the substrate may comprise a third coating for shielding. The microwave shielding layer attenuates microwave energy to spread microwave transmission more evenly within the container and minimizes contact of microwave energy with the food item.

Using a highly reflecting or a highly shielding coating in the construction of microwave interactive container 104a, 104b, 104c, 104d, 104f, 104g or the like, and under microwave energy, most of the heating of the food product will occurs through conduction convection and infrared radiation and such a heating is believed to be beneficial for browning, crisping and grilling.

Generally, the term susceptor refers to a substrate having a microwave-absorptive layer, a shielding layer, a reflective layer, or any combination thereof to produce the desired heating requirements for any given food item.

As shown in FIG. 9 (FIG. 9) the tear-strip 119 can be positioned either horizontally (FIG. 9) or vertically around the food container 104a, 104b, 104c, 104d, 104f, 104g container, and similar container that would make use of this invention. The present invention is not limited to the easy open feature of the tear-strip 119 and it is understood that other kinds of easy open mechanisms can be used. The tear-strip 119 or any other easy open mechanism can be positioned at any location on the container in order to open the container such that an adequately sized container is provided that will perform as a receptacle for any given food item. It is also understood that the any easy open mechanism, including tear-strip 119, can wrap around the entire container or partially wrap around the container.

Various shapes of containers 104a, 104b, 104c, 104d, 104f, 104g container, and similar container that would make use of this invention are contemplated in the present invention. Exemplary shapes include, but are not limited to square, rectangle, octagon, a hexagon, a polyhedron, a cylinder, a prism, sphere, ellipsoid, circular or egg-shaped, or a variant thereof or a pouch shaped container.

The present invention also includes a thermal insulating material to protect the food item and/or to protect the consumer from the hot food item. The thermal insulating material is positioned outside the susceptor and may cover the entire container or only a portion of the container and protect the consumer from being burned when holding the container after heating in the microwave. Suitable materials for the thermal insulation preferably include materials that are capable of being stored and handled at temperatures typical for frozen and/or chilled foods that can also be cooked in the package or container. Materials include for example, cardboard, paper bag, grease proof paper bag, pulp paper, pressed paper, corrugated or fluted paper or board such as micro fluted board with E, F, B, or C shaped flutes, or single or double faced fluting in which the flutes are facing either in or out, in which these materials have a low moisture content. These materials can be coated or laminated in order to prevent moisture absorption. Also included is embossed paper, polystyrene foam, polypropylene foam, polyethylene terephthalate foam, or other similar types of plastic foam and poly-ester in any form. The thermal insulating surface can be adhered to the container using adhesives well known to those skilled in the art of packaging. The thermal insulating surface may also surround the container in a loose fashion, creating an independent insulating layer.

The microwave interactive container 104a, 104b, 104c, 104d, 104f, 104g, and similar container that would make use of this invention are contemplated in the present invention, may further include graphics on the outside or inside of the container. It is envisioned that the graphics are printed on the outside or inside of the container using thermo tropic ink or resin to display or provide instructions for handling the food item.

It should be understood that the numerical ranges and parameters set forth are approximations, with +/−5% within the scope of the stated value, where applicable. Terms like “substantially” should be construed to include deviations which would arise in normal use due to variations in the operator, materials, manufacture, and so forth. Ranges disclosed include the endpoints and all increments and subranges between. It should also be understood that the same structures discussed herein may be referred to using varying nomenclature.

Claims

1) A system for microwaving a sandwich comprising:

A) A hollow sleeve having substantially planar sides with opposing sides of substantially similar dimensions; and

B) A compression means having two opposable substantially planar surfaces, said substantially planar sides sized to fit within said sleeve.

2) The system of claim 1 wherein said sleeve includes a susceptor material.

3) The system of claim 1 wherein said sleeve further includes end closure tabs.

4) The system of claim 1 wherein said sleeve defines a tab and slit for opening and closing.

5) A labor saving assembly for preparing a warmed sandwich comprising:

A) A compressed sandwich comprising at least two slices of bread; and

B) A hollow sleeve including susceptor material surrounding said sandwich on at least four sides.

6) The labor saving assembly of claim 5 wherein at least one of said slices of bread includes a coating including a component selected from a fat, carbohydrate, protein or combination thereof.

7) The labor saving assembly of claim 5 wherein said sandwich is cut into portions.

8) The labor saving assembly of claim 5 wherein said sleeve includes material selected from the group consisting of paper, pressed paper, coated paper, cardboard, chipboard, pulp paper, corrugated paper, plastic, metal coatings, nonmetal coatings, microwave reflective materials and combinations thereof.

9) The labor saving assembly of claim 5 further comprising a vented overwrap surrounding said sleeve.

10) The labor saving assembly of claim 5 wherein said sleeve defines a handle.

11) A method of producing a sandwich that can be heated in a microwave comprising the steps of:

A) providing a first and a second slice of bread, said first and said second slices each having an inner surface and an outer surface;

B) interposing at least one layer of edible sandwich filler ingredients between the inner surfaces of said first and said second bread slices to form a sandwich;

C) compressing said sandwich; and

D) inserting said compressed sandwich into a cooking sleeve.

12) The method of claim 11 further comprising the step of applying microwave energy to said compressed sandwich in cooking sleeve.

13) The method of claim 11 further comprising the step of removing said sandwich from said cooking sleeve.

14) The method of claim 11 wherein said step of inserting said compressed sandwich into a cooking sleeve includes the step of employing a cooking sleeve having a thickness less than the thickness of said sandwich in the uncompressed state.

15) The method of claim 14 wherein said step of inserting said compressed sandwich into a cooking sleeve includes the step of employing a cooking sleeve having a thickness of approximately 95% of the thickness of said sandwich in the uncompressed state.

16) The method of claim 14 wherein said step of inserting said compressed sandwich into a cooking sleeve includes the step of employing a cooking sleeve having thickness of approximately 90% of the thickness of said sandwich in the uncompressed state.

17) The method of claim 11 wherein said step of inserting said compressed sandwich into a cooking sleeve includes the step of employing a cooking sleeve having a susceptor.