대표
청구항
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1. A method of assembling a container for microwave heating of a food product, comprising:providing a mandrel having an exterior surface, a body portion, and a top portion, the top portion of the mandrel defining a recess and the exterior surface of the mandrel defining a plurality of bores in at least a portion of the top portion and at least a portion of the body portion; providing a sheet of barrier material having a first side and a second side; draping the first side of the sheet on the mandrel over the top portion and at least a portion of the body...
1. A method of assembling a container for microwave heating of a food product, comprising:providing a mandrel having an exterior surface, a body portion, and a top portion, the top portion of the mandrel defining a recess and the exterior surface of the mandrel defining a plurality of bores in at least a portion of the top portion and at least a portion of the body portion; providing a sheet of barrier material having a first side and a second side; draping the first side of the sheet on the mandrel over the top portion and at least a portion of the body portion thereof; applying a vacuum to the bores of the mandrel to hold at least a portion of the sheet about a portion of the mandrel and to define a pocket in a portion of the at least a portion of the sheet being held within the pocket of the mandrel; depositing a quantity of the food product within the pocket; providing a tub assembly having a mouth, a floor, at least one elongate wall panel, and an interior surface, the floor having an interior face and an exterior face; positioning the mouth of the tub assembly in overlying orientation with the mandrel and the quantity of food product such that the pocket is substantially closed by the interior face of the floor; and sealing a portion of the second side of the barrier material to the interior surface of the tub assembly about the pocket to encapsulate the quantity of food product between the barrier material and the interior face of the floor of the tub assembly. 2. The method of claim 1, wherein the sealing step comprises heat sealing the second side of the barrier material to the interior face of the floor of the tub assembly so that a least a partial peripheral outer portion is formed to separate the food product from the at least one wall panel.3. The method of claim 2, wherein the sealing step further comprises heat sealing the second side of the barrier material to the at least one wall panel of the tub assembly.4. The method of claim 1, wherein the sealing step comprises heat sealing the second side of the barrier material to the at least one wall panel of the tub assembly.5. The method of claim 4, wherein the step of heat sealing the barrier material to the at least one wall panel of the tub assembly comprises forming a first heat sealed attachment between the barrier material and the wall panel approximately mid-height along the tub assembly.6. The method of claim 5, wherein the step of heat sealing the barrier material to the at least one wall panel of the tub assembly comprises forming a second heat sealed attachment between the barrier material and the wall panel adjacent the mouth of the tub assembly.7. The method of claim 1, wherein the step of providing a tub assembly further comprises fabricating the tub assembly by folding at least one blank to form the floor and the at least one wall panel.8. The method of claim 7, wherein the fabricating step comprises:providing a wall panel blank having a first edge surface, an opposed second edge surface and defining a plurality of wall panels extending therebetween, said wall panels being hingedly connected along separate scored fold lines; folding the wall panel blank about the fold lines to position the first edge surface and second edge surface in at least partial overlapping registration; then connecting at least a portion of the first edge surface to at least a portion of the second edge surface to form a blank structure; erecting the blank structure to form a sidewall structure having a plurality of sidewalls; providing a bottom panel blank defining a base and a plurality of edge panels extending away from and being hingedly connected to the base of the bottom blank along seperate scored fold lines; folding the edge panels of the bottom panel blank about the respective fold lines therein to form a bottom structure in which the edge panels are oriented substantially perpendicular to the base; placing the sidewall structure over the bottom structure; and connecting a least a portion of the edge panels of the bottom structure to a portion of the sidewalls of the sidewall structure adjacent a bottom edge of the sidewall structure. 9. The method of claim 8, wherein the step of connecting at least a portion of the first edge surface to the second edge surface comprises activating an adhesive positioned along at least a portion of the first edge surface.10. The method of claim 8, wherein the step of connecting at least a portion of the edge panels of the bottom structure to a portion of the sidewalls of the sidewall structure comprises activating an adhesive positioned along a portion of the sidewalls and between the portion of the edge panels and the portion of the sidewalls.11. The method of claim 8, further comprising providing a mandrel having a top surface and a base, and wherein the step of placing the sidewall structure over the bottom structure comprises:positioning the bottom structure on the top surface of the mandrel such that the edge panels are directed toward the base of the mandrel; and passing the sidewall structure over both the mandrel and the bottom structure such that the floor of the tub assembly is formed. 12. The method of claim 1, wherein the exterior surface of the mandrel defines a plurality of corners, and wherein, in the vacuum application step, a plurality of flaps in the sheet are defined, one such flap being defined adjacent each respective corner of the mandrel, and each such flap being formed from overlapping portions of the first side of the sheet.13. The method of claim 12, further comprising attaching each flap to a portion of the second side of the sheet.14. The method of claim 13, wherein the step of attaching each flap to the portion of the second side of the sheet comprises forming a third attachment between each flap and the portion of the second side of the sheet.15. The method of claim 14, wherein the forming step comprises heat fusing each flap to the portion of the second side of the sheet.16. A machine for assembling a container for microwave heating of a food product, comprising:a) a tub assembly fabrication subassembly having a means for fabricating a plurality of tub assemblies and a first transfer mechanism for conveying the tub assemblies, each tub assembly having a mouth, a floor, at least one elongate wall panel, and an interior surface, the floor having an interior face and an exterior face; b) a container integration subassembly comprising: a frame structure; a sheet of a barrier material, the sheet having a first side and an opposed second side; a transfer station carried on said frame structure and having a first plurality of mandrels and a means for conveying the mandrels along a generally linear transfer path, each mandrel having an exterior surface, a body portion, and a top portion, the top portion of the mandrel defining a recess and the exterior surface of the mandrel defining a plurality of bores in at least a portion of the top portion and at least a portion of the body portion; a sheet receiving station in communication with a vacuum source for receiving and positioning the first side of the sheet on the mandrel on the top portion and about at least a portion of the body portion of the mandrel, the bores of the mandrel being in fluid communication with the vacuum source to hold at least a portion of the sheet about the mandrel and to define a pocket in a portion of the at least a portion of the sheet being held within the recess of the mandrel; a food product station having a means for depositing a predetermined quantity of food product within the pocket, the depositing means being positioned proximate the pocket; a container erection station in communication with the first transfer mechanism, the container erection station being positioned with respect to the mandrels and having a means for positioning the mouth of one of the tub assemblies in overlying orientation with one of the mandrels and the quantity of food product such that the pocket is substantially closed by the interior face of the floor; and a means for sealing the second side of the barrier material to the interior surface of the tub assembly about the pocket to encapsulate the quantity of food product between the barrier material and the interior face of the floor of the tub assembly. 17. The machine of claim 16, wherein the second side of the barrier material is heat sealed to the interior face of the floor of the tub assembly so that a least a partial peripheral outer portion is formed to separate the food product from the at least one wall panel.18. The machine of claim 17, wherein each of the first plurality of mandrels has a longitudinal axis, and wherein the sealing means comprises a heated ram positioned above the mandrels for movement along a generally linear ram stroke path between a raised position and a lowered position in which a portion of the heated ram is in contact with a portion of the exterior face of the floor of the tub assembly such that the pocket is substantially closed by the interior face of the floor, the ram stroke path being generally co-axial with the longitudinal axis of the mandrel, the heated ram having a heating element that heat seals the barrier material to the interior floor of the tub assembly.19. The machine of claim 18, wherein the sealing means further comprises a sleeve member being positioned above the mandrels for movement along a generally linear sleeve stroke path between a raised position and a lowered position in which portions of the sleeve member are in contact with portions of the at least one wall panel of the tub assembly, the sleeve stroke path being generally co-axial with the longitudinal axis of the mandrel, the sleeve member having at least one heating element for attaching the barrier material to the at least one wall panel of the tub assembly.20. The machine of claim 16, wherein the sealing means comprises a sleeve member being positioned above the mandrels for movement along a generally linear sleeve stroke path between a raised position and a lowered position in which portions of the sleeve member are in contact with portions of the at least one wall panel of the tub assembly, the sleeve stroke path being generally co-axial with the longitudinal axis of the mandrel, the sleeve member having at least one heating element for attaching the barrier material to the at least one wall panel of the tub assembly.21. The machine of claim 16, wherein the exterior surface of the mandrel defines a plurality of corners and a plurality of side surfaces extending therebetween, and wherein a plurality of extending flaps in the sheet are defined as the at least a portion of the sheet is being held about a portion of the mandrel, one such flap being defined adjacent each corner of the mandrel, and each such flap being formed from overlapping portions of the first side of the sheet.22. The machine of claim 21, wherein the sheet receiving station further comprises a first static arm member, a second static arm member, a plow member, and a pair of heat elements, the first static arm member being positioned along a first side of the linear transfer path of the conveying means so that a portion of the first static arm member engages a portion of one of the flaps and pushes the flap into contact with a portion of the second side of the sheet as the mandrel moves along the transfer path, the second static arm member opposed to the first static arm member and positioned along a second side of the linear transfer path of the conveying means so that a portion of the second static arm member engages a portion of a second one of the flaps and pushes the flap into contact with a portion of the second side of the sheet as the mandrel moves along the transfer path, the first and second flaps being positioned on-opposite sides of the mandrel, wherein the plow member has a pair of opposing planar plow elements, the plow member being positioned above the mandrels for pivotal movement between a raised position and a contact position, in which each respective plow element engages and folds one of a third one of the flaps or a fourth one of the flaps, respectively, into contact with a portion of the second side of the sheet such that the first flap and the third flap are positioned on the same side of the mandrel and the second flap and the fourth flap are positioned on the opposite side of the mandrel, and wherein each heat element of the pair of heat elements being positioned along one of respective first and second sides of the linear transfer path for movement along a linear heat element stoke path between a non-engaged position and an engaged position in which a heat element contacts and heat welds a portion of the respective flaps to the respective portions of the second side of the sheet.23. The machine of claim 16, wherein the means for fabricating a plurality of tub assemblies comprises:a supply of wall panel blanks, each wall panel blank having a first edge surface, an opposed second edge surface, a bottom edge extending therebetween, and defining a plurality of wall panels extending therebetween, said wall panels hingedly connected along separate score lines, wherein at least a portion of the first edge surface has a heat-sensitive adhesive disposed thereon, and wherein at least a portion of the wall panel blank proximate the bottom edge of the wall panel blank has a heat-sensitive adhesive disposed thereon; a supply of bottom structures having a plurality of substantially upright edge panels; a second frame structure; a blank infeed station mounted on the second frame structure for receiving the blank and having a third transfer mechanism for conveying the blank along a second transfer path, the blank defining a plane as the blank moves along the second transfer path; a blank receiving station mounted on the second frame structure for receiving the wall panel blank from the blank infeed station, a portion of the blank receiving station defining a frame opening extending beneath and substantially co-planer to the plane defined by the blank moving along the transfer path; a plunge ram being positioned above the blank receiving station for movement along a generally linear plunge stroke path between a raised position and a lowered position, the plunge stroke path being generally perpendicular to and extending through the plane defined by the blank moving along the transfer path, wherein the plunge ram passes through the frame opening to bend a first wall panel with the first edge surface and an opposing second wall panel with the second edge surface of the blank along the respective score lines; a first pivot arm and a second pivot arm, each pivot arm constructed and arranged on the second frame member for pivotal movement between an raised position and an engaged position, in which a portion of the first pivot arm contacts a portion of the first wall panel and a portion of the second pivot arm contacts a portion of the second wall panel so that the first edge surface is positioned in at least partial overlapping registration with the second edge surface; a means for applying heat to the adhesive disposed on the first edge surface to connect at least a portion of the first edge surface and a portion of the second edge surface to define a blank structure; an erection station having a suction ram having a means for selectively grasping a portion of the blank structure, the suction ram constructed and arranged on the second frame structure above the second transfer path for movement along a generally linear suction ram stroke path between a lowered position, in which an end of the suction ram grasps a portion of one wall panel of the blank structure, and a raised position, in which the end of the suction ram grasping the portion of the one wall panel is withdrawn along the suction ram stoke path to form a sidewall structure in which the adjoining respective wall panels are at approximate right angles with respect to each other, the erection station further having a plow transfer member being positioned above the transfer path for generally linear movement along a plow stroke path; and a fabrication station having a turntable rotatable about an axis substantially perpendicular to the transfer path, the turntable having a plurality of turntable mandrels constructed and arranged about a peripherial edge of the turntable, each turntable mandrel having a base, an opposed end, which is sized and shaped for complementary receipt of one bottom structure, and a body portion sized and shaped for complementary receipt of one sidewall structure, the fabrication station having means for positioning the bottom structure on the end of the turntable mandrel so that the edge panels extend toward the base of the turntable mandrel, wherein, as the turntable rotates, one turntable mandrel having one bottom structure positioned thereon is positioned with respect to the plow stroke path of the erection station so that one sidewall structure is pushed onto the mandrel and over the bottom structure as the plow transfer member extends along the plow stroke path such that at least a portion of the sidewall structure proximate the bottom edge of the panel blank contacts a portion of the edge panels of the bottom structure, wherein the fabrication station further comprises a means for applying heat to the adhesive disposed on the bottom edge of the panel blank to connect at least a portion of the wall panels to at least a portion of the edge panels to form one tub assembly.24. The machine of claim 23, wherein the erection station further includes a pair of opposing sidewall squaring plates constructed and arranged to engage opposing wall panels of the wall structure as the suction ram is raised.25. The machine of claim 23, further comprising:a supply of bottom panel blanks, each bottom panel blank having a base and a plurality of edge panels being hingedly connected to the base of the bottom blank along scored fold lines; a foot plunger having a foot sized and shaped for complementary receipt with the base of the bottom panel, the foot plunger constructed and arranged for movement along a generally linear path from a raised position to a lowered position, in which the foot of the foot plunger cooperates with one bottom panel blank so that the edge panels of the bottom panel blank are folded about the fold lines therein to form the bottom structure. 26. A machine for assembling a container for microwave heating of a food product, comprising:a) a supply of pre-erected tub assemblies, each tub assembly having a mouth, a floor, at least one elongate wall panel, and an interior surface, the floor having an interior face and an exterior face; b) a container integration subassembly comprising: a frame structure; a sheet of a barrier material, the sheet having a first side and an opposed second side; a transfer station carried on said frame structure and having a first plurality of mandrels and a means for conveying the mandrels along a generally linear transfer path, each mandrel having an exterior surface, a body portion, and a top portion, the top portion of the mandrel defining a recess and the exterior surface of the mandrel defining a plurality of bores in at least a portion of the top portion and at least a portion of the body portion; a sheet receiving station in communication with a vacuum source for receiving and positioning the first side of the sheet on the mandrel on the top portion and about at least a portion of the body portion of the mandrel, the bores of the mandrel being in fluid communication with the vacuum source to hold at least a portion of the sheet about the mandrel and to define a pocket in a portion of the at least a portion of the sheet being held within the recess of the mandrel; a food product station having a means for depositing a predetermined quantity of food product within the pocket, the depositing means being positioned proximate the pocket; a container erection station in communication with the supply of pre-erected tub assemblies, the container erection station being positioned with respect to the mandrels and having a means for positioning the mouth of one of the tub assemblies in overlying orientation with one of the mandrels and the quantity of food product such that the pocket is substantially closed by the interior face of the floor; and a means for sealing the second side of the barrier material to the interior surface of the tub assembly about the pocket to encapsulate the quantity of food product between the barrier material and the interior face of the floor of the tub assembly. 27. The machine of claim 26, wherein the second side of the barrier material is heat sealed to the interior face of the floor of the tub assembly so that a least a partial peripheral outer portion is formed to separate the food product from the at least one wall panel.28. The machine of claim 27, wherein each of the first plurality of mandrels has a longitudinal axis, and wherein the sealing means comprises a heated ram positioned above the mandrels for movement along a generally linear ram stroke path between a raised position and a lowered position in which a portion of the heated ram is in contact with a portion of the exterior face of the floor of the tub assembly such that the pocket is substantially closed by the interior face of the floor, the ram stroke path being generally co-axial with the longitudinal axis of the mandrel, the heated ram having a heating element that heat seals the barrier material to the interior floor of the tub assembly.29. The machine of claim 28, wherein the sealing means further comprises a sleeve member being positioned above the mandrels for movement along a generally linear sleeve stroke path between a raised position and a lowered position in which portions of the sleeve member are in contact with portions of the at least one wall panel of the tub assembly, the sleeve stroke path being generally co-axial with the longitudinal axis of the mandrel, the sleeve member having at least one heating element for attaching the barrier material to the at least one wall panel of the tub assembly.30. The machine of claim 26, wherein the sealing means comprises a sleeve member being positioned above the mandrels for movement along a generally linear sleeve stroke path between a raised position and a lowered position in which portions of the sleeve member are in contact with portions of the at least one wall panel of the tub assembly, the sleeve stroke path being generally co-axial with the longitudinal axis of the mandrel, the sleeve member having at least one heating element for attaching the barrier material to the at least one wall panel of the tub assembly.
