CONVERTIBLE CONTAINER

Abstract

The convertible container, carton, or tray and method of use for microwave ovens including a cooking portion and a base portion. The cooking portion defines a quadrilateral panel which may include a susceptor material, the cooking portion including at least one diagonal fold line defining at least one corner tab. The base portion is configured to support the cooking portion in an elevated position. The base portion includes at least one invertible corner configured to transition from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the convertible container to enable rotation within the confines of a microwave.

Claims

1. A convertible container, comprising: a cooking portion defining a quadrilateral panel, the cooking portion including at least one diagonal fold line defining at least one corner tab; and a base portion configured to support the cooking portion in an elevated position, wherein the base portion includes at least one invertible corner configured to transition from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the convertible container.

2. The convertible container of claim 1, wherein the base portion comprises a first wall and a second wall oriented at a near-orthogonal angle relative to one another and which converge at a corner intersection.

3. The convertible container of claim 2, wherein the at least one invertible corner is defined by a first fold line positioned along the first wall and a second fold line positioned along the second wall, with the first fold line and the second fold line positioned on opposite sides of the corner intersection.

4. The convertible container of claim 3, wherein the first fold line defines a first segment of the first wall positioned between the first fold line and the corner intersection, and the second fold line defines a second segment of the second wall positioned between the second fold line and the corner intersection.

5. The convertible container of claim 4, wherein the first fold line and the second fold line act as hinges enabling the first segment and the second segment to pivot relative to other portions of the first wall and the second wall to affect the transition of at least one invertible corner from the first configuration to the second configuration.

6. The convertible container of claim 1, wherein the cooking portion and the base portion are constructed of a paperboard material.

7. The convertible container of claim 1, wherein the base portion comprises four near-orthogonal walls defining an interior portion configured to house a food item having an external dimension of at least four inches.

8. The convertible container of claim 1, wherein the base portion comprises an interior configured to receive a food item having a diameter of at least four inches, and the cooking portion defines a lid hingedly coupled to the base portion along one edge.

9. The convertible container of claim 8, wherein the lid is separatable from the base portion.

10. A method of using a convertible tray, the convertible tray initially in a form of a flat panel, including a cooking portion at least partially surrounded by four base panels, the method comprising: forming the flat panel into a quadrilateral tray by folding the four base panels to a near-orthogonal angle relative to the cooking portion along predefined lines, and securing respective ends of the four base panels to one another to form four corner intersections, wherein each of the four corner intersections defines a near-orthogonal external angle; separating at least one corner tab defined by the cooking portion from an adjacent one or more of the four base panels, wherein the at least one corner tab is positioned at a corner of the cooking portion adjacent to a first corner intersection of the four corner intersections; and inverting the first corner intersection from a first configuration in which the first corner intersection defines the near-orthogonal external angle, to a second configuration in which the first corner intersection defines a near-orthogonal internal angle to reduce a diagonal dimension of the convertible tray.

11. The method of claim 10, wherein the ends of the four base panels are secured to one another with at least one of tabs, slots, or glue to form the four corner intersections.

12. The method of claim 10, further comprising bending the at least one corner tab along respective diagonal fold lines to reduce the diagonal dimension of the cooking portion.

13. The method of claim 10, wherein the first corner intersection is defined by a first fold line positioned along one base panel and a second fold line positioned along another base panel, with the first fold line and the second fold line positioned on opposite sides of the first corner intersection, wherein the first fold line and the second fold line act as hinges enabling transition of the first corner intersection from the first configuration to the second configuration.

14. The method of claim 10, further comprising positioning a food item on the cooking portion.

15. A method of using a convertible container, the convertible container comprising a base portion and a cooking portion, the cooking portion serving as a lid hingedly coupled to the base portion along at least one edge, the cooking portion including at least one diagonal fold line defining at least one corner tab, and the base portion including at least one invertible corner, the method comprising: opening the lid of the convertible container to access an interior of the base portion; removing a food item from the interior of the base portion; pivoting the lid around the hinged coupling to an inverted state; inverting at least one corner of the base portion from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the base portion; bending at least one corner tab of the cooking portion along the at least one diagonal fold line to reduce the diagonal dimension of the cooking portion; and positioning the food item on the cooking portion, with a susceptor material facing upward and the food item positioned on the susceptor material.

16. The method of claim 15, wherein the convertible container is a microwavable container.

17. The method of claim 15, wherein the cooking portion includes the susceptor material.

18. The method of claim 15, further comprising pivoting the susceptor material around the hinged coupling to face away from the base portion.

19. The method of claim 15, further comprising separating the lid from the base portion.

20. The method of claim 19, further comprising positioning the susceptor material to face away from the base portion.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:

[0030] FIG. 1 is a perspective view depicting a microwavable container, in accordance with an embodiment of the disclosure.

[0031] FIG. 2 is a profile view depicting the microwavable container of FIG. 1.

[0032] FIG. 3 is a top plan view depicting the microwavable container of FIG. 1.

[0033] FIG. 4 is a plan view of a microwavable container in an initial flat-panel configuration, in accordance with an embodiment of the disclosure.

[0034] FIG. 4A is a close up, plan view of an interlocking assembly of a microwavable container, in accordance with an embodiment of the disclosure.

[0035] FIG. 5 is a perspective view depicting a microwavable container folded into a quadrilateral tray configuration, in accordance with an embodiment of the disclosure.

[0036] FIG. 6 is a perspective view highlighting an invertible corner of the microwavable container of FIG. 5, wherein the invertible corner is in a first configuration defining a near orthogonal external angle between adjacent walls of a base portion.

[0037] FIG. 6A is a perspective view highlighting an invertible corner of an interlocking microwavable container in the first configuration, in accordance with an embodiment of the disclosure.

[0038] FIG. 7 is a perspective view depicting the invertible corner of FIG. 6 in a transition state between the first configuration and a second configuration.

[0039] FIG. 8 is a perspective view depicting the invertible corner of FIG. 6 in the second configuration, defining a near-orthogonal internal angle between adjacent walls of the base portion.

[0040] FIG. 9 is a perspective view depicting the invertible corner of FIG. 6, in which a corner tab is bent upward, away from the base portion.

[0041] FIG. 9A is a perspective view highlighting the invertible corner of FIG. 6A, with the invertible corner in the second configuration, with a corner tab bend upward, away from the base portion, in accordance with an embodiment of the disclosure.

[0042] FIG. 10 is a perspective view depicting the microwavable container of FIG. 5, including four invertible corners in the second configuration, with four corresponding corner tabs bent upward, away from the base portion to reduce a diagonal dimension of the microwavable container.

[0043] FIG. 11 is a top plan view depicting relative dimensions of a microwavable container, in accordance with an embodiment of the disclosure.

[0044] FIG. 12 is a perspective view depicting a microwavable container configured to transition from a food storage container to a cooking platform having a reduced diagonal dimension, in accordance with an embodiment of the disclosure.

[0045] FIG. 13 is a perspective view highlighting an invertible corner of the microwavable container of FIG. 12, wherein the invertible corner is in a first configuration defining a near orthogonal external angle between adjacent walls of a base portion.

[0046] FIG. 14 is a perspective view depicting the invertible corner of FIG. 12 in the second configuration, defining a near-orthogonal internal angle between adjacent walls of the base portion.

[0047] FIG. 15 is a perspective view depicting the invertible corner of FIG. 13 in which a base portion is further manipulated to reduce a diagonal dimension of the microwavable container.

[0048] FIG. 16 is a perspective view depicting further folding of the microwavable container of FIG. 12, including modification of corner tabs of the lid to reduce a diagonal dimension of the cooking portion.

[0049] FIG. 17 is a perspective view depicting the microwavable container of FIG. 12, including four invertible corners in the second configuration, with eight corresponding corner tabs bent upward, away from the base portion to reduce a diagonal dimension of the microwavable container.

DETAILED DESCRIPTION

[0050] In the realm of microwavable food packaging, particularly for larger items such as food items having a major dimension of at least four inches or more, existing arrangements encounter limitations in cooking. One notable problem is that quadrilateral containers, cartons, and trays large enough to accommodate the food item cannot rotate on the microwave's turntable due to spatial constraints within most standard microwave ovens. This lack of rotation leads to uneven cooking, as the microwave energy is not uniformly distributed throughout the food item. Consequently, certain areas of the food item may be overcooked or undercooked, compromising the overall quality and enjoyment of the food item.

[0051] One solution to this problem has been to use round or pressed containers, however the use of round and pressed containers introduces another set of challenges. Round or pressed containers, while potentially capable of rotating freely within the microwave, are markedly more expensive to manufacture. Increased production costs stem from complexities involved in manufacturing pressed and formed package shapes, as well as increased waste in cutaway portions of the original stock material. Additionally, round and pressed containers are typically shipped fully formed which reduces shipping density, and thus is more expensive.

[0052] Embodiments of the present disclosure address these challenges through the incorporation of invertible corners and bendable corner tabs configured to reduce a diagonal dimension of an otherwise quadrilateral microwavable container. Although specific examples of square or quadrilateral containers are depicted, the concepts as disclosed herein are suitable to other polynomial shapes, including, but not limited to, rectangles, triangles, trapezoids, hexagons, octagons, or any other polygonal shape.

[0053] Although the present disclosure exemplifies a microwave oven equipped with a turntable or rotating device/rotating mechanism as a typical cooking appliance for demonstrating the utility of the disclosed containers, it should be understood that the inventive concepts herein are not limited solely to microwave ovens. The disclosed convertible containers are equally applicable to a variety of other cooking or heating appliances that feature a confined interior space equipped with a rotating mechanism. The disclosed convertible containers are also equally applicable to a variety of other cooking appliances that feature a confined interior space without a rotating mechanism. Such appliances include, but are not limited to, toaster ovens, pizza ovens, air fryers, holding cabinets, and other specialty devices designed for the preparation or holding of food products. These appliances, like microwave ovens, benefit from the ability of the containers to adapt to spatial constraints while facilitating even cooking or heating, thereby enhancing the versatility and utility of the disclosed solutions across different culinary technologies.

[0054] As used herein, a container can refer to any receptacle or enclosure designed to hold, store, transport, or protect items, including food products. Containers can vary widely in size, shape, material, and functionality, catering to the specific needs of the contents they hold. The materials used for containers are often chosen for properties that best suit the item's requirements, such as durability, protection, and environmental conditions. Features of containers may include airtight seals, handles for easy transportation, and mechanisms for controlled dispensing.

[0055] A carton can refer to a type of packaging container designed to hold, protect, and preserve items during storage, transportation, display, preparation, and consumption, including food products. Cartons can vary in size, shape, and functionality depending on the specific product they are intended for. A carton may include features such as folding closures, perforations for easy opening, cooking surfaces, and coatings or laminates to provide barrier properties against moisture, oxygen, and other environmental factors that could affect the product's quality and freshness.

[0056] A tray can refer to a shallow platform designed for the carrying, holding, cooking, or presenting of various items, including food products. Trays can vary in size, shape, material, and design, tailored to the specific application or aesthetic preference. The materials used for trays are often selected for properties that complement the tray's intended use, such as lightweight durability, ease of cleaning, or decorative appeal. Features of trays may include raised edges to prevent items from sliding off, compartments for organizing contents, and handles or grips for easy carrying. In some embodiments, a tray and food product may be contained within a carton.

[0057] Additionally, a container can function as both a carton and a tray. Typically, a carton is defined as a six-sided enclosure providing comprehensive protection and containment, while a tray is described as an open, five-sided platform designed for ease of access and presentation. In some embodiments, the removal of a lid or cover from a carton can transform it into a tray, offering a versatile solution that accommodates both the secure enclosure of products and their convenient display or access when desired.

[0058] Packaging refers to any material or structure designed for the enclosing or protection of items, particularly food products, during their storage, transportation, display, preparation, and consumption. This broad definition encompasses containers, cartons, and trays, each serving specific roles within the realm of packaging but united in their purpose to safeguard and maintain the quality of the contents they hold. Packaging materials and designs can be chosen based on the needs of the product, considering factors like durability, environmental conditions, and the preservation of freshness and quality.

[0059] Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0060] Referring to FIGS. 1-3, a microwavable container 100 is depicted in accordance with an embodiment of the disclosure. In one embodiment, the microwavable container 100 can include a cooking portion 102 and a base portion 104.

[0061] The cooking portion 102 can be defined as a quadrilateral panel which can include a susceptor material 106. The cooking portion 102 can include one or more diagonal fold lines 108A-D defining one or more corresponding corner tabs 110A-D, which can be bent at an angle relative to a cooking surface 112 defined by the cooking portion 102.

[0062] In some embodiments, each of the cooking surface 112 and the one or more corresponding corner tabs 110A-D can define a planar surface, wherein an orientation of the corner tabs 110A-D can be adjusted relative to the cooking surface 112 along the one or more diagonal fold lines 108A-D, such that the surfaces of the cooking surface 112 and the one or more corresponding corner tabs 110A-D are non-coplanar. For example, in some embodiments, the corner tabs 110A-D can be bent upward relative to the cooking surface 112, which can have a combined effect of reducing a diagonal dimension of the cooking portion 102, as well as providing a lateral edge as an aid in maintaining the position of a food item positioned thereon.

[0063] Additionally, it should be noted that although FIGS. 1-3 depicts the corner tabs 110A-D as extending upwardly generally away from the base portion 104, in other embodiments, the corner tabs 110A-D can be bent downwardly toward the base portion 104, having the effect of reducing an overall diagonal dimension of the microwavable container 100. In other embodiments, the corner tabs 110A-D are substantially coplanar with the cooking surface 112 and cooking portion 102. In other embodiments, the corner tabs 110A-D may be entirely removed from the microwavable container 100, such as by tearing off the corner tabs 110A-D, for example by way of perforations positioned along the diagonal fold lines 108A-D.

[0064] The base portion 104 can comprise a plurality of base panels 114A-D, arranged as walls configured to support the cooking portion 102 in an elevated position, in order to raise the cooking surface 112 off the bottom surface of the interior of the microwave to reduce a heat sink effect which can negatively affect the cooking of the food item within the microwave.

[0065] In order to reduce an overall diagonal dimension of the microwavable container 100, in some embodiments, the base portion 104 can define one or more invertible corners 116A-D configured to transition from a first configuration, defining a near orthogonal external angle (e.g., as depicted in FIG. 5), to a second configuration, defining a near orthogonal internal angle (as depicted in FIG. 10), thereby reducing a diagonal dimension of the microwavable container 100 to enable unimpeded rotation within a microwave oven equipped with a turntable. With additional reference to FIG. 4, a plan view of a microwavable container 100 in an initial flat-panel 118 configuration is shown. As depicted, the panel 118 can include a cooking portion 102, which can include a susceptor material 106 affixed thereto. Further, in some embodiments, the cooking portion 102 can be divided into a cooking surface 112 and one or more corner tabs 110A-D delineated by corresponding diagonal fold lines 108A-D. In some embodiments, the cooking surface 112 and the one or more corner tabs 110A-D are included as distinct and separate parts of the cooking portion 102, although any susceptor material 106 positioned on the cooking surface 112 may (or may not) extend to the one or more corner tabs 110A-D.

[0066] The cooking portion 102 can be at least partially surrounded by a plurality of base panels 114A-D, collectively representing the base portion 104. As depicted, in some embodiments, the base panels (e.g., second base panel 114B, etc.) can include a tab 120 configured to couple to an adjacent base panel (e.g., first base panel 114A, third base panel 114C, etc.) to form a corner intersection 122 between base panels (e.g., as depicted in FIG. 5). In some embodiments, the plurality of base panels 114A-D can be delineated from the cooking portion 102 along fold lines 124. Additionally, the tab 120 can be delineated from the base panel 114 via a fold line 121. Fold lines 124 can generally be defined as a score line or a bend.

[0067] Additionally, in some embodiments, portions of the fold lines 124 can be defined by a precut score line 127, thereby enabling separation between the first portion 132A and the corner tab 110A, and the second portion 132B and the corner tab 110A. In some embodiments, each precut score line 127 extends directly to the corner where, for example, the first portion 132A and the second portion 132B meet. In some embodiments, precut score line 127 is a cut line that does not comprise scoring and instead defines a cut line that permanently separates, for example, the first portion 132A and second portion 132B both from the one or more corner tabs 110A-D.

[0068] A score line in the context of a container, carton, or tray, is thin, straight path defining a predefined cut or line of reduced thickness or structural integrity. Score lines facilitate precise folding, bending, or separation of the material along the defined path. Score lines can be implemented through various methods such as exerting pressure, or employing cutting techniques, chosen based on the material type and the desired outcome. The primary purpose of a score line is to create a line of weakness in an otherwise sturdy material to aid in manipulation of the container, carton, or tray for functions like folding, bending, opening, assembling, or collapsing the structure.

[0069] A bend refers to pre-formed curves or angles in the material that facilitate the shaping, assembly, or structural integrity of the packaging. These are intentional deformations made in the packaging material to create corners, edges, or folds without breaking or cutting the material. Bends are positioned to help the container, carton, or tray maintain its form or to assist in its construction and folding into the final shape required for use, and to allow for the efficient transformation of flat sheets of material into complex, three-dimensional structures that can hold, protect, and allow for preparation of products.

[0070] Perforations refer to small holes or series of holes punched or pressed into the material to facilitate specific actions or outcomes. These perforations create areas of reduced material integrity, making it easier to tear or separate the material along the line of perforations. In some instances, these perforations can be aligned with score lines or bends, enhancing the ease with which portions of the container, carton, or tray can be removed. Perforations can also be placed in locations independent of score lines to serve different functions. For example, perforations can be utilized to allow the passage of moisture or air through the layers of a food container, carton, or tray to ensure even cooking in microwaveable packages.

[0071] With additional reference to FIG. 5, the plurality base panels 114A-D can be bent relative to the cooking portion 102 at a near-orthogonal angle, with the plurality base panels 114A-D coupled to one another along respective ends 126A, 126B to form corner intersections 122 also defining near orthogonal external angles.

[0072] A near orthogonal external angle refers to an angle that is close to 90 degrees, but not exactly 90 degrees, from a perspective of a geometric shape or structure. In practical terms, when describing objects like containers or packaging, a near orthogonal external angle suggests that the angle between adjoining walls or panels is intended to closely approximate a right angle. In reality, because the walls or panels of containers and packaging are not perfectly flat, the intersecting angles are typically not exactly 90 degrees.

[0073] In most cases, a near orthogonal angle falls within plus or minus 5 degrees of a right angle however, in some cases, a near orthogonal angle can deviate from a right angle by about 10 degrees or more. Accordingly, a near orthogonal angle allows for slight deviations from the perfect right angle for manufacturing ease, flexibility, or to accommodate specific functionalities. Thus, the corner intersections 122 need not be perfect, geometric corners. Rather the corner intersections 122 can be rounded or have extra edges and curves provided the overall impression left to a person viewing is generally that of an orthogonal corner.

[0074] In some embodiments, to form the corner intersections 122, the tab 120 positioned in proximity to the second portion 132B of the second base panel 114B can be operably coupled to the first portion 132A of the first base panel 114A. For example, as depicted in FIG. 4A, in some embodiments, the tab 120 can be positioned into slot 125 (e.g., via an interlocking assembly), or the tab 120 can be adhered or otherwise affixed (e.g., ultrasonically fused, glued, etc.) to the first portion 132A of the first base panel 114A to form the corner intersection 122.

[0075] FIG. 4A depicts one example of an interlocking or click-lock assembly, illustrating the mechanism by which the tab 120 engages with the slot 125 to form a secure corner intersection 122. In this embodiment, the tab 120, designed with a barbed or tapered end 123, is inserted into a correspondingly shaped slot 125 located at the first portion 132A. Upon insertion, the inherent resiliency of the material allows the tab 120 to slightly deform and then resume to its original shape, effectively locking into place within the slot 125.

[0076] In embodiments, panel 118 can be constructed of a paperboard material, although the use of other materials including plastics and composites is also contemplated. In accordance with principles of this disclosure, the container 100 can include a susceptor material 106 to help to brown food products oriented in or on the container when exposed to microwave energy. Such susceptor materials are well known in the art, and examples are described in U.S. Pat. Nos. 4,833,007; 4,230,924; 4,267,420; and 5,107,089, the contents of which are hereby incorporated by reference herein. In some embodiments, the microwavable container 100 does not include a susceptor material. In some embodiments, the panel 118 can be cut to desired dimensions and shipped in a flat configuration for later assembly into a microwavable tray or other three-dimensional form.

[0077] In some embodiments, one or more vents (e.g., represented by score lines, perforations, holes, sipes, etc.) can be defined in the susceptor material 106 and/or the panel 118 and/or a lid 134 (as depicted in FIGS. 12-17) (e.g. including the cooking portion 102 and the base portion 104). Holes in the context of food containers, cartons, or trays refer to deliberate openings created within the material to serve purposes related to the storage, cooking, or serving of food products. In microwaveable food packaging, holes are often designed to manage the escape of steam, to aid in even cooking or reheating of a food item, as well as in the release of grease or moisture that may accumulate during the cooking process.

[0078] Sipes refer to thin, shallow cuts or grooves etched into the surface of the material. Sipes are not full perforations that create open holes, but rather finely incised lines that can improve the functionality of packaging, particularly in relation to cooking or reheating food products. In microwaveable food packaging, sipes may be positioned to direct steam and moisture flow to enhance the cooking process. For example, sipes can act to evenly distribute heat across the food item by facilitating a more uniform release of steam from inside the container. Additionally, sipes can help in managing the accumulation of moisture or grease, ensuring that the bottom of a food product remains crisp by subtly channeling excess liquids and vapors away from the cooking surface.

[0079] For example, in some embodiments, the one or more holes 128, and one or more sipes 129 (e.g., an array or arrangement of sipes) can be arranged to enable moisture to escape from the food item while cooking, as well as to allow for the draining (e.g., of moisture and grease) from the food item. Although the holes 128 and sipes 129 are depicted as being positioned on the susceptor material 106 and cooking portion 102 (e.g., in FIG. 4), in other embodiments, one or more of the base panels 114A-D of the base portion 104 can define a vent or other aperture, gap, break, or discontinuation to enable venting.

[0080] In certain embodiments, the perforations, holes, or sipes may be designed to extend through both the susceptor material 106 and the cooking portion 102 (which can be positioned on lid 134 as depicted in FIG. 17), especially in configurations where the susceptor material and the cooking portion are bonded or otherwise joined together. Alternatively, the perforations, holes, or sipes may be arranged to extend solely through either the susceptor material 106 or the cooking portion 102. In yet another embodiment, the susceptor material 106 can include no perforations, holes, or sipes.

[0081] FIGS. 6-9 depict a physical transformation of the invertible corner 116A and corner tab 110A, as the invertible corner 116A transitions from the first configuration having a near orthogonal external angle between adjacent base panels 114A, 114B of the base portion 104 (as depicted in FIG. 6) to the second configuration having a near orthogonal internal angle between adjacent base panels 114A, 114B (as depicted in FIG. 8). FIG. 7 depicts the invertible corner 116A in mid-transition between the first configuration and the second configuration. In some embodiments, the first configuration represents a first stable arrangement of the invertible corner 116A and the second configuration represents a second stable arrangement of the invertible corner 116A, with the configuration depicted in FIG. 7 being a non-stable transitional arrangement, wherein the material used to construct the flat panel 118 has a natural resiliency (e.g., tendency to maintain a substantially planar configuration) to generally urge the invertible corner 116A into either of the two stable arrangements.

[0082] The invertible corner 116A can be defined by a first fold line 130A positioned along the first base panel 114A, and a second fold line 130B positioned along the second base panel 114B. As depicted, the first fold line 130A and the second fold line 130B can be positioned on opposite sides of the corner intersection 122. For example, the first fold line 130A can define a first portion 132A of the first base panel 114A, and the second fold line 130B can define a second portion 132B of the second base panel 114B. Fold lines 130A, 130B may include scores, perforations, or bends in the material of the microwavable container 100.

[0083] To facilitate inversion, in some embodiments, the corner tab 110 can be lifted or otherwise separated from the invertible corner 116. For example, in some embodiments, a perforation or other separation line can be defined between the base panels 114 and the corner tabs 110, to enable ease in separation of the corner tabs 110 from the invertible corners 116. FIG. 6A depicts an example microwavable container having interlocking corners (like that depicted in FIG. 4A), in which the corner tab 110A is lifted or otherwise separated from the invertible corner 116, and the invertible corner is in the first configuration. In some embodiments, the corner tab 110 is separated from the invertible corner by a pre-cut line without any scores or perforations. In some embodiments, the corner tab 110 is separated from the invertible corner by pre-cut lines that extend directly from the point of intersection between the first and second fold lines 130A, 130B and diagonal fold line 108A, to the corner intersection 122.

[0084] Thereafter, the first and second fold lines 130A, 130B can act as hinges, enabling the first portion 132A and the second portion 132B of the invertible corner 116 to pivot relative to other portions of the base portion 104 to transition the invertible corner 116 from the first configuration to the second configuration.

[0085] As depicted in FIG. 9, the corner tab 110 can be bent upwardly, away from the base portion 104, thereby serving to reduce a diagonal dimension of the microwavable container 100. FIG. 10 depicts an orthogonal microwavable container having a reduced diagonal dimension through the incorporation of four invertible corners 116 and four corner tabs 110. FIG. 9A depicts the invertible corner 116 of FIG. 6A in the second configuration, with a corner tab 110A bend upward, away from the base portion 104.

[0086] With additional reference to FIG. 11, for improved clarity in understanding relative angles and dimensions of the microwavable container 100, a top plan view depicting relative dimensions of a microwavable container 100 is depicted in accordance with an embodiment of the disclosure. The dimensions represented in FIG. 11 are applicable in embodiments where the microwavable container 100 is a substantially square shape. However, in embodiments of the present disclosure where microwavable container 100 is not a square shape, the following dimensions may not apply.

[0087] As depicted, D1 can represent a length or width of the microwavable container 100. For example, one embodiment contemplates the use of the microwavable container 100 to serve as a container for a 10-inch round pizza, and then be converted to reduce a diagonal dimension enabling the microwavable container 100 to serve as a platform for cooking the 10-inch pizza within the confines of a microwave oven.

[0088] As depicted, D1 is the dimension that a microwavable container 100, requires to contain the food item, and thus, is typically predetermined or known. In embodiments, D1 can range from about four inches to about fourteen inches; for example, D1 can be about 4 inches, about 5 inches, about 6 inches, about 7 inches, about 8 inches, about 9 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, or about 14 inches. Other sizes of D1 are also contemplated.

[0089] Dimension D2 represents the diagonal distance between opposite corners of the microwavable container 100. For a container 100 that is substantially square, D2 can be calculated using the equation:

[00001]$D2=D{1}_{}\sqrt{2}$

[0090] The diagonal dimension, D3, facilitates the rotation of the container within the microwave, ensuring even heating of the food item.

[0091] In some embodiments, the diagonal dimension D2 can be reduced to D3 through the incorporation of invertible corners 116 and folding corner tabs 110. In some embodiments, the reduced dimension D3 is dependent on S1, which represents a straight line distance between first and second fold lines 130A, 130B defining the invertible corner 116, or the position and length of the diagonal fold lines 108 positioned on the cooking portion 102.

[0092] In embodiments, distance S1 can be adjusted to accommodate the dimensions of the food item. For example, distance S1 can range from zero (or near zero), in which angle 1, representing an angle between first and second fold lines 130A, 130B or ends of the diagonal fold line 108, measures approximately 0, to S1.sub.max. As depicted angle 1 measures approximately 45; however, in other embodiments, 1 can measure less than 45. For example, a rectangular product (e.g., French bread, etc.), which might not require the full diagonal reduction that a 45 angle provides, could be accommodated using an angle 1 of approximately 30.

[0093] In some embodiments, S1.sub.max can be determined according to the following formula:

[00002]$S{1}_{\max }=\frac{D1}{1+\sqrt{2}}$

[0094] Thereafter, D3 can be determined according to the following formula:

[00003]$D3=S1\sqrt{\left(4+2\sqrt{2}\right)}$

[0095] Accordingly, in some embodiments, a diagonal dimension of the microwavable container 100 can be reduced from an initial dimension D2 to a reduced diagonal dimension D3, through the use of invertible corners 116 and folding corner tabs 110 having a length S1, thereby enabling uninhibited rotation of the microwavable container 100 within the confines of a microwave.

[0096] FIGS. 12-17 depict an alternative embodiment of a microwavable container 100, configured to transition from a six-sided container suitable for containing a food item 50, such as a 10-inch pizza, to a cooking platform. This embodiment includes a base portion 104 and a cooking portion 102, with the cooking portion 102 doubling as a lid 134 that is hingedly attached to the base portion 104 via a hinge mechanism 136. In another embodiment, the lid 134 can be removed from the base portion 104. These configurations allow the lid 134 to function both as a protective cover for the base portion 104 in its storage mode, as shown in FIG. 12, and as a cooking surface in its cooking mode, as depicted in FIG. 17.

[0097] For example, as depicted in FIGS. 12 and 15, the cooking portion 102 can include a first major surface represented as an initially exterior facing surface, and an opposing second major surface represented as an initially internal facing surface, which can optionally serve as a cooking surface 112. In some embodiments, a susceptor material 106, which can be represented as a thin sheet of energy interactive material, can be affixed to or otherwise coupled to the cooking surface 112.

[0098] The base portion 104 can be constructed with multiple base panels 114A-D affixed to a bottom surface 115. As depicted in FIG. 12, these base panels 114A-D are bent at near right angles relative to the bottom surface 115 and are interconnected at their ends to form corner intersections 122, creating nearly right-angled external vertices. Utilization of the microwavable container 100 involves opening the lid 134 to access the interior 138 of the base portion 104. In its storage configuration, the container's corners 116A-D adopt a first configuration, where the corner intersections 122 exhibit external near right angles.

[0099] FIGS. 13-15 detail the process of transitioning from storage configuration to cooking configuration. Opening the lid 134 permits removal of the stored food item 50 from the interior 138. The corners 116 (i.e., 116A-116D) can then be inverted from their first configuration to a second configuration, effectively narrowing the base portion's 104 diagonal dimension. This is achieved by detaching each corner 116A from the bottom surface 115 along a precut score line or perforation line 117, and then transitioning the corner 116A to a cooking configuration where the corner intersection 122 forms an internal near orthogonal angle. This adjustment not only modifies the shape but can also enhance the strength and support of the cooking surface 112 by reinforcing the corners 116. FIGS. 14-15 depict the invertible corner 116A being folded to define a triangular bottom surface tab 113, which upon bending along bend line 119 further reduces the diagonal dimension of the microwaveable container 100. In alternative embodiments, the bottom surface tab 113 may be removed to decrease its diagonal dimension. In another embodiment, the lid 134 may be removed, for example along hinge mechanism 136 or other precut score line or perforation line, and positioned on the base portion 104.

[0100] FIG. 16 depicts the lid 134, equipped with susceptor material 106 on its inner surface, being rotated about the hinge mechanism 136 to an inverted position, ensuring the susceptor material 106 faces away from the base portion 104. In yet another configuration (not depicted), the susceptor material 106 may be placed on the underside of the bottom surface 115. In another embodiment (not depicted), the microwavable container 100 can be folded into a pocket, creating top and bottom cooking surfaces on opposite sides of the food item. As depicted in FIG. 16, the bottom surface tabs 113 can be bent to substantially conform to the corner tabs 110 of the cooking portion, such that all eight tabs (including four corner tabs 110 and four bottom surface tabs 113) can be bent upwardly away from the base portion 104.

[0101] FIG. 16 also illustrates, where applicable, the bending of corner tabs 110 of the cooking portion 102 along diagonal fold lines 108 to diminish the cooking portion's 102 diagonal dimension. As shown in FIG. 17, the food item 50 is placed on the cooking portion 102, with the susceptor material 106 oriented upwards, facilitating direct contact between the food item 50 and the susceptor material 106 during cooking. In embodiments, the cooking portion 102 and/or the susceptor material 106 can optionally include one or more perforations, holes, or sipes, which can pass to the cooking portion 102, the susceptor material 106, or both the cooking portion 102 and the susceptor material 106. In other embodiments, the susceptor material 106 can be substantially free of perforations, holes or sipes.

[0102] It should be understood that the individual steps used in the methods of the present teachings may be performed in any order and/or simultaneously, as long as the teaching remains operable. Furthermore, it should be understood that the apparatus and methods of the present teachings can include any number, or all, of the described embodiments, as long as the teaching remains operable.

[0103] Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto.

Aspects:

[0104] Aspect 1: A convertible container, comprising: a cooking portion defining a quadrilateral panel, the cooking portion including at least one diagonal fold line defining at least one corner tab; and a base portion configured to support the cooking portion in an elevated position, wherein the base portion includes at least one invertible corner configured to transition from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the convertible container.

[0105] Aspect 2: The convertible container of aspect 1, wherein the base portion comprises a first wall and a second wall oriented at a near-orthogonal angle relative to one another and which converge at a corner intersection.

[0106] Aspect 3: The convertible container of aspect 2, wherein the at least one invertible corner is defined by a first fold line positioned along the first wall and a second fold line positioned along the second wall, with the first fold line and the second fold line positioned on opposite sides of the corner intersection.

[0107] Aspect 4: The convertible container of aspect 3, wherein the first fold line defines a first segment of the first wall positioned between the first fold line and the corner intersection, and the second fold line defines a second segment of the second wall positioned between the second fold line and the corner intersection.

[0108] Aspect 5: The convertible container of aspect 4, wherein the first fold line and the second fold line act as hinges enabling the first segment and the second segment to pivot relative to other portions of the first wall and the second wall to affect the transition of at least one invertible corner from the first configuration to the second configuration.

[0109] Aspect 6: The convertible container of aspect 1, wherein the cooking portion and the base portion are constructed of a paperboard material.

[0110] Aspect 7: The convertible container of aspect 1, wherein the cooking portion defines one or more vent apertures.

[0111] Aspect 8: The convertible container of aspect 1, wherein the base portion defines at least one wall having a length of at least four inches in the first configuration.

[0112] Aspect 9: The convertible container of aspect 1, wherein the base portion comprises four near-orthogonal walls defining an interior portion configured to house a food item having an external dimension of at least four inches.

[0113] Aspect 10: The convertible container of aspect 1, wherein the base portion comprises an interior configured to receive a food item having a diameter of at least four inches, and the cooking portion defines a lid hingedly coupled to the base portion along one edge.

[0114] Aspect 11: The convertible container of aspect 10, wherein the lid is separatable from the base portion.

[0115] Aspect 12: The convertible container of aspect 1, further comprising a susceptor material.

[0116] Aspect 13: The convertible container of aspect 1, wherein the convertible container is a microwavable container.

[0117] Aspect 14: A method of using a convertible tray, the convertible tray initially in a form of a flat panel, including a cooking portion at least partially surrounded by four base panels, the method comprising: forming the flat panel into a quadrilateral tray by folding the four base panels to a near-orthogonal angle relative to the cooking portion along predefined lines, and securing respective ends of the four base panels to one another to form four corner intersections, wherein each of the four corner intersections defines a near-orthogonal external angle; separating at least one corner tab defined by the cooking portion from an adjacent one or more of the four base panels, wherein the at least one corner tab is positioned at a corner of the cooking portion adjacent to a first corner intersection of the four corner intersections; and inverting the first corner intersection from a first configuration in which the first corner intersection defines the near-orthogonal external angle, to a second configuration in which the first corner intersection defines a near-orthogonal internal angle to reduce a diagonal dimension of the convertible tray.

[0118] Aspect 15: The method of aspect 14, wherein the ends of the four base panels are secured to one another with at least one of tabs, slots, or glue to form the four corner intersections.

[0119] Aspect 16: The method of aspect 14, further comprising bending the at least one corner tab along respective diagonal fold lines to reduce the diagonal dimension of the cooking portion.

[0120] Aspect 17: The method of aspect 14, wherein the first corner intersection is defined by a first fold line positioned along one base panel and a second fold line positioned along another base panel, with the first fold line and the second fold line positioned on opposite sides of the first corner intersection, wherein the first fold line and the second fold line act as hinges enabling transition of the first corner intersection from the first configuration to the second configuration.

[0121] Aspect 18: The method of aspect 14, further comprising positioning a food item on the cooking portion.

[0122] Aspect 19: The method of aspect 18, wherein a susceptor material is operably coupled to the cooking portion, and the food item positioned on the susceptor material.

[0123] Aspect 20: The method of aspect 14, wherein the convertible tray is a microwavable container.

[0124] Aspect 21: A method of using a convertible container, the convertible container comprising a base portion and a cooking portion, the cooking portion serving as a lid hingedly coupled to the base portion along at least one edge, the cooking portion including at least one diagonal fold line defining at least one corner tab, and the base portion including at least one invertible corner, the method comprising: opening the lid of the convertible container to access an interior of the base portion; removing a food item from the interior of the base portion; pivoting the lid around the hinged coupling to an inverted state; inverting at least one corner of the base portion from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the base portion; bending at least one corner tab of the cooking portion along the at least one diagonal fold line to reduce the diagonal dimension of the cooking portion; and positioning the food item on the cooking portion, with a susceptor material facing upward and the food item positioned on the susceptor material.

[0125] Aspect 22: The method of aspect 21, wherein the convertible container is a microwavable container.

[0126] Aspect 23: The method of aspect 21, wherein the cooking portion includes the susceptor material.

[0127] Aspect 24: The method of aspect 21, further comprising pivoting the susceptor material around the hinged coupling to face away from the base portion.

[0128] Aspect 25: The method of aspect 21, wherein the base portion comprises an interior configured to receive the food item having a diameter of at least four inches.

[0129] Aspect 26: The method of aspect 21, further comprising separating the lid from the base portion.

[0130] Aspect 27: The method of aspect 26, further comprising positioning the susceptor material to face away from the base portion.

[0131] Aspect 28: A packaged food item comprising: a food item; a convertible container comprising a cooking portion and a base portion configured to support the cooking portion in an elevated position, wherein the base portion includes at least one invertible corner configured to transition from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the convertible container; and an outer packaging enclosing the food item and the convertible container.

[0132] Aspect 29: A convertible container comprising: a lid hingedly connected to a base portion via a hinge mechanism, the lid defining a cooking portion on a first major surface of the lid, wherein the base portion includes at least one invertible corner configured to transition from a first configuration defining a near-orthogonal external angle, to a second configuration defining a near-orthogonal internal angle to reduce a diagonal dimension of the convertible container.