Thermally activatable microwave interactive materials

1. A heat stabilized microwave energy interactive insulating material comprising: a susceptor film comprising a substantially continuous layer of microwave energy interactive material supported on a first polymer film, the microwave energy interactive material being operative for generating heat in response to microwave energy; a second polymer film joined to the layer of microwave energy interactive material in a predetermined pattern that defines at least one closed cell between the layer of microwave energy interactive material and the second polymer film; and a water-providing reagent disposed between the layer of microwave energy interactive material and the second polymer film, the water-providing reagent being operative for releasing water vapor and inflating the closed cell in response to heat from the microwave energy interactive material, wherein the heat stabilized microwave energy interactive insulating material is devoid of paper, such that the water-providing reagent is not bound within paper.

2. The insulating material of claim 1 , wherein the microwave energy interactive material comprises indium tin oxide.

3. The insulating material of claim 1 , wherein the microwave energy interactive material comprises aluminum.

4. The insulating material of claim 1 , wherein the water-providing reagent is a hydrated solid, an occluded water material, an encapsulated water material, a water glass, or any combination thereof.

5. The insulating material of claim 1 , wherein the second polymer film is joined to the non-paper based layer using thermal bonding.

6. The insulating material of claim 1 , wherein the second polymer film is joined to the non-paper based layer using adhesive bonding.

7. A durably expandable microwave interactive insulating material comprising: a microwave energy interactive material supported on a first polymer film layer, the microwave energy interactive material being operative for generating heat in response to microwave energy; a second polymer film layer joined to the microwave energy interactive material in a predetermined pattern, thereby forming at least one closed cell between the microwave energy interactive material and the second polymer film layer; and a gas-releasing reagent overlying at least a portion of at least one of the microwave energy interactive material and the second polymer film layer adjacent to the closed cell, the gas-releasing reagent being operative for releasing a gas in response to heat from the microwave energy interactive material, the gas being for inflating the closed cell, wherein the gas-releasing reagent is not bound within a layer of paper, wherein at least one of the first polymer film and the second polymer film comprises a barrier material adapted to maintain the closed cell in an inflated condition after exposure to microwave energy has ceased.

8. The insulating material of claim 7 , wherein the gas-releasing reagent comprises at least one blowing agent.

9. The insulating material of claim 8 , wherein the blowing agent is p-p′-oxybis(benzenesulphonylhydrazide), azodicarbonamide, p-toluenesulfonylsemicarbazide, or any combination thereof.

10. The insulating material of claim 7 , wherein the first polymer film and the second polymer film each comprise a barrier material.

11. The insulating material of claim 10 , wherein the barrier material is selected from the group consisting of ethylene vinyl alcohol, a barrier nylon, polyvinylidene chloride, a barrier fluoropolymer, nylon 6, nylon 6,6, coextruded nylon 6/EVOH/nylon 6, silicon oxide coated film, barrier polyethylene terephthalate, and any combination thereof.

12. The insulating material of claim 7 , wherein the closed cell remains substantially inflated for at least about 1 minute after the application of microwave energy has ceased.

13. The insulating material of claim 12 , wherein the closed cell remains substantially inflated for at least about 5 minutes after the application of microwave energy has ceased.

14. The insulating material of claim 7 , wherein the microwave energy interactive material is selected from the group consisting of aluminum and indium tin oxide.

15. A durably expandable microwave interactive insulating material comprising: a susceptor film comprising a substantially continuous layer of microwave energy interactive material supported on a first polymer film, the microwave energy interactive material being operative for converting at least a portion of impinging microwave energy into heat; a support layer joined to the layer of microwave energy interactive material; a second polymer film joined to the support layer in a predetermined pattern, thereby forming at least one closed cell between the support layer and the second polymer film; and a gas-generating coating overlying at least one of the support layer the second polymer film, the gas-generating coating being operative for generating a gas in response to heat from the microwave energy interactive material, the gas being for inflating the closed cell, wherein the gas-generating coating is not bound within a layer of paper, wherein at least one of the first polymer film and the second polymer film comprises a barrier material adapted to maintain the closed cell in an inflated condition after exposure to microwave energy has ceased.

16. The insulating material of claim 15 , wherein the first polymer film and the second polymer film each comprise a barrier material.

17. The insulating material of claim 15 , wherein the barrier material is selected from the group consisting of ethylene vinyl alcohol, a barrier nylon, polyvinylidene chloride, a barrier fluoropolymer, nylon 6, nylon 6,6, coextruded nylon 6/EVOH/nylon 6, silicon oxide coated film, barrier polyethylene terephthalate, and any combination thereof.

18. The insulating material of claim 15 , wherein the gas is carbon dioxide.

19. The insulating material of claim 15 , wherein the closed cell remains substantially inflated for at least about 1 minute after the application of microwave energy has ceased.

20. The insulating material of claim 15 , wherein the closed cell remains substantially inflated for at least about 5 minutes after the application of microwave energy has ceased.

21. The insulating material of claim 1 , wherein the water-providing reagent is selected from the group consisting of a hydrated mineral, a crystalline inorganic chemical with water of hydration, a natural mineral with water of hydration, and any combination thereof.

22. The insulating material of claim 1 , wherein the water-providing reagent is selected from the group consisting of hydrates of magnesium orthophosphates, calcium sulfate, aluminum hydroxide, calcium carbonate, silica gel, bentonites, gypsum, barium citrate, calcium citrate, and magnesium citrate, and any combination thereof.

23. The insulating material of claim 1 , wherein the water-providing reagent is selected from the group consisting of Mg 3 (PO 4 ) 2 .22H 2 O, MgHPO 4 .3H 2 O, Al(OH) 3 .3H 2 O, CaCO 3 .6H 2 O, Ba(C 6 H 5 O 7 ) 2 .7H 2 O, Ca(C 6 H 5 O 7 ) 2 .4H 2 O, and Mg(C 6 H 5 O 7 ) 2 .5H 2 O.

24. The insulating material of claim 1 , wherein the water-providing reagent comprises an occluded water material selected from the group consisting of silica gels, clathrates, and any combination thereof.

25. The insulating material of claim 1 , wherein the water-providing reagent comprises a water glass having the formula:

(Na 2 O x SiO 2 x=3-5),

where x is from about 3 to about 5.

26. The insulating material of claim 1 , wherein the water-providing reagent comprises one or more substances that combine to generate a gas upon exposure to heat.

27. The insulating material of claim 26 , wherein the substances comprise sodium bicarbonate and an acid.