Tray assembly and methods

Abstract

A single-use tray is useable to impart aromatic material to food upon the application of heat. The tray assembly is pre-filled with aromatic material, such as wood chips, spices, herbs, or natural or artificial flavorings. The tray assembly includes a first tray with a base and a second tray non-removably secured to the first tray over the base and over the volume of aromatic material. The second tray has a cooking surface defining an aperture arrangement to permit the flow of gases from the aromatic material through the cooking surface upon application of heat. A packaged food product includes the tray assembly with prepackaged food and an outer protective covering or wrapper. Methods of making a tray, packaging food, and using are provided.

1 . A single-use pre-filled tray assembly comprising: 
 (a) a first tray having a base with a heating surface and a surrounding wall;    (b) a volume of an aromatic material positioned on the base of the first tray; and    (c) a second tray non-removably secured to the first tray over the base and the volume of aromatic material; 
 (i) the second tray having a cooking surface; and  
 (ii) the cooking surface defining an aperture arrangement to permit the flow of gases from the aromatic material through the cooking surface upon application of heat to the heating surface of the first tray.  
   
   
   
       2 . A tray assembly according to  claim 1  wherein the second tray includes a wall surrounding the cooking surface; the second tray being nested within the first tray.  
   
   
       3 . A tray assembly according to  claim 2  wherein the second tray wall is non-removably connected to the surrounding wall of the first tray.  
   
   
       4 . A tray assembly according to  claim 3  wherein the second tray wall is crimped to the surrounding wall of the first tray.  
   
   
       5 . A tray assembly according to  claim 2  wherein the second tray wall is non-orthogonally angled relative to the cooking surface.  
   
   
       6 . A tray assembly according to  claim 1  wherein the aromatic material comprises wood chips.  
   
   
       7 . A tray assembly according to  claim 1  wherein the aromatic material comprises spices or herbs or mixtures thereof.  
   
   
       8 . A tray assembly according to  claim 1  wherein the aromatic material comprises natural or artificial flavorings or mixtures thereof.  
   
   
       9 . A tray assembly according to  claim 1  wherein the aperture arrangement in the second tray includes a plurality of spaced holes in the cooking surface.  
   
   
       10 . A tray assembly according to  claim 1  wherein the tray assembly is disposable, with the first tray and second tray each comprising foil trays.  
   
   
       11 . A tray assembly according to  claim 1  further comprising: 
 (a) a food product oriented on the cooking surface of the second tray; and    (b) a removable packaging cover trapping the food product on the second tray.    
   
   
       12 . A tray assembly according to  claim 1  wherein the first tray is non-porous.  
   
   
       13 . A packaged food product comprising: 
 (a) a first tray;    (b) a volume of an aromatic material positioned in the first tray;    (c) a second tray non-removably secured to the first tray over the volume of aromatic material; 
 (i) the second tray having a cooking surface;  
 (ii) the cooking surface defining an aperture arrangement to permit the flow of gases from the aromatic material through the cooking surface upon application of heat to the first tray;  
   (d) a food product oriented on the cooking surface of the second tray; and    (e) a removable packaging cover trapping the food product on the second tray.    
   
   
       14 . A packaged food product according to  claim 13  wherein: 
 (a) the first tray includes a base and a surrounding wall;    (b) the second tray includes a wall extending from the cooking surface; and    (c) the second tray is nested within the first tray.    
   
   
       15 . A packaged food product according to  claim 13  wherein the aromatic material comprises wood chips.  
   
   
       16 . A packaged food product according to  claim 13  wherein the aromatic material comprises spices or herbs or mixtures thereof.  
   
   
       17 . A packaged food product according to  claim 13  wherein the aromatic material comprises natural or artificial flavorings or mixtures thereof.  
   
   
       18 . A packaged food product according to  claim 13  wherein the food product includes any one of vegetables, proteins, and combinations thereof.  
   
   
       19 . A method of making a tray assembly; the method comprising: 
 (a) placing an aromatic material in a first tray;    (b) orienting a second tray over the aromatic material in the first tray; the second tray having a cooking surface defining an aperture arrangement therein; and    (c) securing the second tray to the first tray to ensure the first tray and second tray are non-separable.    
   
   
       20 . A method according to  claim 19  wherein the step of securing includes crimping together a sidewall of the first tray and a sidewall of the second tray.  
   
   
       21 . A method according to  claim 19  wherein the step of placing an aromatic material includes placing wood chips in the first tray.  
   
   
       22 . A method according to  claim 19  wherein the step of placing an aromatic material includes placing spices or herbs or mixtures thereof in the first tray.  
   
   
       23 . A method according to  claim 19  wherein the step of placing an aromatic material includes placing artificial or natural flavorings or mixtures thereof in the first tray.  
   
   
       24 . A method of packaging a food product; the method comprising: 
 (a) placing an aromatic material in a first tray;    (b) orienting a second tray over the aromatic material in the first tray; the second tray having a cooking surface defining an aperture arrangement therein;    (c) securing the second tray and first tray together;    (d) orienting a food product on the cooking surface of the second tray; and    (e) orienting a removable and disposable cover over the food product to trap the food product against the cooking surface.    
   
   
       25 . A method according to  claim 24  wherein the step of placing an aromatic material in the first tray includes placing wood chips in the first tray.  
   
   
       26 . A method according to  claim 24  wherein the step of placing an aromatic material in the first tray includes placing spices or herbs or mixtures thereof in the first tray.  
   
   
       27 . A method according to  claim 24  wherein the step of placing an aromatic material in the first tray includes placing artificial or natural flavorings or mixtures thereof in the first tray.  
   
   
       28 . A method of flavoring a food product; the method including: 
 (a) placing a food product onto a cooking surface of a single-use tray assembly; the cooking surface defining an aperture arrangement therethrough; the tray assembly including a base arrangement under the cooking surface and an aromatic material being within the base arrangement;    (b) heating the tray assembly to heat the aromatic material and cause the aromatic material to give off fumes;    (c) allowing the fumes to flow through the aperture arrangement in the cooking surface to the food product on the cooking surface;    (d) removing the food product from the cooking surface; and    (e) discarding the single-use tray assembly.