US6677563B2 — Abuse-tolerant metallic pattern arrays for microw…

Claim 1

Independent Claim 111 words

An abuse-tolerant microwave packaging material comprising: a substrate; and a plurality of uniform solid shapes comprised of microwave energy reflective material arranged in an array, wherein said array is supported by said substrate; wherein each of said plurality of solid shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said plurality of solid shapes in said array is spaced apart from each adjacent shape by a respective predetermined spacing; and wherein a combination of said predetermined shape, said predetermined size, and said predetermined spacing provides substantial resistance to arcing or burning of said packaging material under abusive looking conditions in an operating microwave oven.

Claim 2

Dependent Claim 111 words

An abuse-tolerant microwave packaging material comprising: a substrate; and a plurality of uniform solid shapes comprised of microwave energy reflective material arranged in an array, wherein said array is supported by said substrate; wherein each of said plurality of solid shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said plurality of solid shapes in said array is spaced apart from each adjacent shape by a respective predetermined spacing; and wherein a combination of said predetermined shape, said predetermined size, and said predetermined spacing provides substantial resistance to arcing or burning of said packaging material under abusive looking conditions in an operating microwave oven.

Claim 3

Dependent Claim 22 words

The abuse-tolerant microwave packaging material as described in claim 1 , further comprising a microwave interactive material layer supported by said substrate.

Claim 4

Dependent Claim 21 words

The abuse-tolerant microwave packaging material as described in claim 2 , wherein said microwave interactive material layer comprises a susceptor film.

Claim 5

Dependent Claim 25 words

The abuse-tolerant microwave packaging material as described in claim 3 , wherein said susceptor film comprises a deposition of aluminum on a microwave transparent substrate.

Claim 6

Dependent Claim 21 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein said microwave energy reflective material comprises a metal foil.

Claim 7

Dependent Claim 18 words

The abuse-tolerant microwave packaging material as described in claim 5 , wherein said metal foil comprises aluminum foil.

Claim 8

Dependent Claim 30 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein said microwave energy reflective material comprises a high optical density evaporated material deposited on a microwave transparent substrate.

Claim 9

Dependent Claim 20 words

The abuse-tolerant microwave packaging material as described in claim 7 , wherein said high optical density evaporated material comprises aluminum.

Claim 10

Dependent Claim 51 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein said predetermined shape comprises a shape selected from the group of shapes comprising: a circle, an oval, a curvilinear shape, a symmetrical curvilinear shape, a triangle, a square, a rectangle, a polygon, a right polygon, and an equilateral polygon.

Claim 11

Dependent Claim 18 words

The abuse-tolerant microwave packaging material as described in claim 9 , wherein said equilateral polygon is a hexagon.

Claim 12

Dependent Claim 36 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein each of said plurality of solid shapes in said array is nested with each said adjacent shape in said array in a tile-like pattern.

Claim 13

Dependent Claim 22 words

The abuse-tolerant microwave packaging material as described in claim 11 , wherein said predetermined spacing is a distance of about 1 mm.

Claim 14

Dependent Claim 32 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein said predetermined spacing comprises an equal distance apart from and with respect to each said adjacent shape in said array.

Claim 15

Dependent Claim 21 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein said predetermined size is about 4 mm in width.

Claim 16

Dependent Claim 17 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein said substrate is microwave transparent.

Claim 17

Dependent Claim 28 words

The abuse-tolerant microwave packaging material as described in claim 1 , wherein said substrate is selected from a group of substrates comprising: paper, paperboard, plastic, glass, and ceramic.

Claim 18

Dependent Claim 42 words

The abuse-tolerant microwave packaging material as described in claim 3 , wherein said packaging material reflects between 80 and 85 percent of microwave energy incident upon said microwave packaging material when said microwave packaging material is placed in said operating microwave oven.

Claim 19

Independent Claim 125 words

A method of manufacturing a microwave packaging material comprising: providing a substrate; and adhering a microwave energy reflective layer to said substrate; wherein said microwave energy reflective layer comprises a plurality of uniform solid shapes comprised of microwave energy reflective material arranged in an array; and wherein each of said plurality of shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said plurality of solid shapes in said array is spaced apart from each adjacent shape by a respective predetermined spacing; and wherein a combination of said predetermined shape, said predetermined size, and said predetermined spacing provides substantial resistance to arcing by or burning of said microwave packaging material under abusive cooking conditions in an operating microwave oven.

Claim 20

Independent Claim 125 words

A method of manufacturing a microwave packaging material comprising: providing a substrate; and adhering a microwave energy reflective layer to said substrate; wherein said microwave energy reflective layer comprises a plurality of uniform solid shapes comprised of microwave energy reflective material arranged in an array; and wherein each of said plurality of shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said plurality of solid shapes in said array is spaced apart from each adjacent shape by a respective predetermined spacing; and wherein a combination of said predetermined shape, said predetermined size, and said predetermined spacing provides substantial resistance to arcing by or burning of said microwave packaging material under abusive cooking conditions in an operating microwave oven.

Claim 21

Dependent Claim 19 words

The method as described in claim 18 , further comprising cutting said microwave packaging material into a packaging shape.

Claim 22

Dependent Claim 24 words

The method as described in claim 19 , further comprising compression molding said microwave packaging material to create a pan or tray with sidewalls.

Claim 23

Dependent Claim 22 words

The method as described in claim 18 , further comprising adhering a microwave interactive material layer to said microwave energy reflective layer.

Claim 24

Dependent Claim 18 words

The method as described in claim 21 , wherein said microwave interactive material layer comprises a susceptor film.

Claim 25

Dependent Claim 22 words

The method as described in claim 22 , wherein said susceptor film comprises a deposition of aluminum on a microwave transparent substrate.

Claim 26

Dependent Claim 18 words

The method as described in claim 18 , wherein said microwave energy reflective material comprises a metal foil.

Claim 27

Dependent Claim 15 words

The method as described in claim 24 , wherein said metal foil comprises aluminum foil.

Claim 28

Dependent Claim 27 words

The method as described in claim 18 , wherein said microwave energy reflective material comprises a high optical density evaporated material deposited on a microwave transparent substrate.

Claim 29

Dependent Claim 17 words

The method as described in claim 26 , wherein said high optical density evaporated material comprises aluminum.

Claim 30

Dependent Claim 48 words

The method as described in claim 18 , wherein said predetermined shape comprises a shape selected from the group of shapes comprising: a circle, an oval, a curvilinear shape, a symmetrical curvilinear shape, a triangle, a square, a rectangle, a polygon, a right polygon, and an equilateral polygon.

Claim 31

Dependent Claim 15 words

The method as described in claim 28 , wherein said equilateral polygon is a hexagon.

Claim 32

Dependent Claim 33 words

The method as described in claim 18 , wherein each of said plurality of solid shapes in said array is nested with each said adjacent shape in said array in a tile-like pattern.

Claim 33

Dependent Claim 29 words

The method as described in claim 18 , wherein said predetermined spacing comprises an equal distance apart from and with respect to each said adjacent shape in said array.

Claim 34

Dependent Claim 19 words

The method as described in claim 31 , wherein said predetermined spacing is a distance of about 1 mm.

Claim 35

Dependent Claim 18 words

The method as described in claim 18 , wherein said predetermined size is about 4 mm in width.

Claim 36

Dependent Claim 14 words

The method as described in claim 18 , wherein said substrate is microwave transparent.

Claim 37

Dependent Claim 25 words

The method as described in claim 18 , wherein said substrate is selected from a group of substrates comprising: paper, paperboard, plastic, glass, and ceramic.

Claim 38

Dependent Claim 38 words

The method as described in claim 22 , wherein said microwave packaging material reflects between 80 and 85 percent of microwave energy incident upon said packaging material when said packaging material is placed in said operating microwave oven.

Claim 39

Dependent Claim 144 words

An abuse-tolerant microwave shielding material comprising: a substrate; an array of uniform solid shapes of microwave reflective material supported upon said substrate; wherein each of said solid shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said solid shapes in said array is spaced apart from each adjacent solid shape by an equal distance with respect to each adjacent solid shape; and a susceptor film supported upon said substrate; wherein said abuse-tolerant microwave shielding material reflects between 80 and 85 percent of microwave energy incident upon said shielding material when said shielding material is placed in an operating microwave oven; and wherein a combination of said predetermined shape, said predetermined size, and said spacing provides substantial resistance to arcing by or burning of said abuse-tolerant microwave shielding material under abusive cooking conditions in said operating microwave oven.

Claim 40

Dependent Claim 144 words

An abuse-tolerant microwave shielding material comprising: a substrate; an array of uniform solid shapes of microwave reflective material supported upon said substrate; wherein each of said solid shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said solid shapes in said array is spaced apart from each adjacent solid shape by an equal distance with respect to each adjacent solid shape; and a susceptor film supported upon said substrate; wherein said abuse-tolerant microwave shielding material reflects between 80 and 85 percent of microwave energy incident upon said shielding material when said shielding material is placed in an operating microwave oven; and wherein a combination of said predetermined shape, said predetermined size, and said spacing provides substantial resistance to arcing by or burning of said abuse-tolerant microwave shielding material under abusive cooking conditions in said operating microwave oven.

Claim 41

Dependent Claim 49 words

The abuse-tolerant microwave shielding material of claim 37 , wherein said predetermined shape comprises a shape selected from the group of shapes comprising: a circle, an oval, a curvilinear shape, a symmetrical curvilinear shape, a triangle, a square, a rectangle, a polygon, a right polygon, and an equilateral polygon.

Claim 42

Dependent Claim 18 words

The abuse-tolerant microwave shielding material as described in claim 38 , wherein said equilateral polygon is a hexagon.

Claim 43

Dependent Claim 26 words

The abuse-tolerant microwave shielding material as described in claim 37 , wherein said substrate is selected from the group comprising: paper, paperboard, plastic, glass, and ceramic.

Claim 44

Dependent Claim 166 words

An improvement to reusable, microwave-safe cookware, the improvement comprising: an abuse-tolerant microwave shielding material further comprising a substrate; an array of uniform solid shapes of microwave reflective material supported upon said substrate; wherein each of said solid shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said solid shapes in said array is spaced apart from each adjacent solid shape by an equal distance with respect to each adjacent solid shape; and a susceptor film supported upon said substrate; wherein said abuse-tolerant microwave shielding material is applied to said reusable cookware; wherein said abuse-tolerant microwave shielding material reflects between 80 and 85 percent of microwave energy incident upon said shielding material when said microwave-safe cookware is placed in an operating microwave oven; and wherein a combination of said predetermined shape, said predetermined size, and said spacing provides substantial resistance to arcing by or burning of said abuse-tolerant microwave shielding material under abusive cooking conditions in said operating microwave oven.

Claim 45

Dependent Claim 166 words

An improvement to reusable, microwave-safe cookware, the improvement comprising: an abuse-tolerant microwave shielding material further comprising a substrate; an array of uniform solid shapes of microwave reflective material supported upon said substrate; wherein each of said solid shapes further comprises: a respective predetermined shape; and a respective predetermined size; and wherein each of said solid shapes in said array is spaced apart from each adjacent solid shape by an equal distance with respect to each adjacent solid shape; and a susceptor film supported upon said substrate; wherein said abuse-tolerant microwave shielding material is applied to said reusable cookware; wherein said abuse-tolerant microwave shielding material reflects between 80 and 85 percent of microwave energy incident upon said shielding material when said microwave-safe cookware is placed in an operating microwave oven; and wherein a combination of said predetermined shape, said predetermined size, and said spacing provides substantial resistance to arcing by or burning of said abuse-tolerant microwave shielding material under abusive cooking conditions in said operating microwave oven.

Claim 46

Dependent Claim 19 words

The improvement as described in claim 41 , further comprising a microwave interactive material layer supported by said substrate.

Claim 47

Dependent Claim 15 words

The improvement as described in claim 41 , wherein said reusable cookware comprises ceramic cookware.

Claim 48

Dependent Claim 15 words

The improvement as described in claim 41 , wherein the reusable cookware comprises glass cookware.

Claim 49

Dependent Claim 48 words

The improvement as described in claim 44 , wherein: said glass cookware is further comprised of: a first layer of glass; and a second layer of glass; and wherein said abuse-tolerant microwave shielding material is sandwiched between said first layer of glass and said second layer of glass.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2007-01-12	2007-07-14	2008-01-13	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2011-01-12	2011-07-14	2012-01-13	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2015-01-12	2015-07-14	2016-01-13	$7700.00	Window Closed / Lapsed

Abuse-tolerant metallic pattern arrays for microwave packaging materials

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