CA1233436A - Popcorn package - Google Patents
Popcorn packageInfo
- Publication number
- CA1233436A CA1233436A CA000465534A CA465534A CA1233436A CA 1233436 A CA1233436 A CA 1233436A CA 000465534 A CA000465534 A CA 000465534A CA 465534 A CA465534 A CA 465534A CA 1233436 A CA1233436 A CA 1233436A
- Authority
- CA
- Canada
- Prior art keywords
- bag
- charge
- sheet
- package
- microwave
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/34—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within the package
- B65D81/3446—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within the package specially adapted to be heated by microwaves
- B65D81/3461—Flexible containers, e.g. bags, pouches, envelopes
- B65D81/3469—Pop-corn bags
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2581/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D2581/34—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
- B65D2581/3401—Cooking or heating method specially adapted to the contents of the package
- B65D2581/3402—Cooking or heating method specially adapted to the contents of the package characterised by the type of product to be heated or cooked
- B65D2581/3421—Cooking pop-corn
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Food Science & Technology (AREA)
- Mechanical Engineering (AREA)
- Package Specialized In Special Use (AREA)
- Grain Derivatives (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A popcorn package for shipping and popping pop-corn is described. The package includes a bag formed from flexible sheet material having a pair of face panels and infolded gussets extending between them. Top and bottom seals extend transversely at the ends of the bag and a charge of popcorn and fat is positioned within the bag between the gussets and one of the panels which is placed on the floor of a microwave oven when the corn is to be popped within the bag. Between the charge and the lower surface of the pakcage is bonded a flexible and foldable inductive microwave pickup sheet that can be composed of a plastic film upon which a thin layer of metal has been deposited. During heating the in-ductive microwave pickup sheet absorbs heat from the microwave energy and transfers it by conduction to the overlying charge of popcorn thereby increasing the volume of the popped corn.
A popcorn package for shipping and popping pop-corn is described. The package includes a bag formed from flexible sheet material having a pair of face panels and infolded gussets extending between them. Top and bottom seals extend transversely at the ends of the bag and a charge of popcorn and fat is positioned within the bag between the gussets and one of the panels which is placed on the floor of a microwave oven when the corn is to be popped within the bag. Between the charge and the lower surface of the pakcage is bonded a flexible and foldable inductive microwave pickup sheet that can be composed of a plastic film upon which a thin layer of metal has been deposited. During heating the in-ductive microwave pickup sheet absorbs heat from the microwave energy and transfers it by conduction to the overlying charge of popcorn thereby increasing the volume of the popped corn.
Description
~33436 The present invention relates to packaged foods and more particularly to a package or popping corn in a microwave oven.
In recent years manufacturers have begun distribut-\ ing popcorn ln gusseted paper bags. The corn is popped by \ placing the entire bag in a microwave oven. In this way, the\ corn is heated by microwave energy while it remains in the \ bag. As the corn pops, the bag expands to accommodate the popcorn kernels.
` One shortcoming of commercial products is the prob-lem of maintaining the best possible volumetric yields. The volumetric yield is measured by popping a standard quantity of corn in its package within a microwave oven, pouring the popped kernels into a graduate and noting the total volume.
The resulting final volumes have not always been satisfactory and all too often a disappointingly high number of kernels remain unpopped. Moreover, those that do pop are often less than maximum volume.
U.S. Patents Nos. 3,973,045 and 3,835,280 are repre-sentative of the prior art. The packages described in the patent do not, when heated, achieve maximum potential volumet-ric yield.
In view of these shortcomings the present invention provides a package for improving the volumetric yield of pop-corn dlstributed and popped in flexible bags. The present invention also achieves the improved yields while in no way interferring with the flexibility of the bag or substantially increasing its cost. The present invention again provides a way to relate to the charge of popcorn and fat in a package to a microwave inductive member to maximize heating of the pickup member and the transEer of the heat efficiently to the popcorn while allowing the package to be collapsed to a very small oh . - 1 -33~36 volume for shipment and yet the pickup means will permit free expansion during heating to a large enough volume to accommo-date the popped kernels while the pickup sheet remains throughout heating efficiently thermally coupled to the pop-corn.
According to the present invention there is provided a popcorn package suited for shipment in a collapsed state and for heating in a microwave oven to accomplish popping of pop-corn kernels within the package comprising, a collapsible bag formed from flexible sheet material transparent to microwave energy, said bag having a food heating compartment therein containing a charge of popcorn and fat and having a bottom surface during heating that includes a flexible sheet of paper, a flexible and foldable microwave concentrating induc-tive pickup sheet only on the bottom of the compartment con-taining the charge, said inductive sheet being composed of a base material in sheet form having a flexible microwave induc-tor material thereon characterized by becoming hot to effect concentrated heating of a localized portion of the charge when exposed to microwave energy, the pickup sheet being substan-tially flat and being bonded to said paper sheet for dimen-sional support to prevent shriveling and scorching during localized heating of a food and defining a substantially flat flexible bottom for the food heating compartment containing the charge of fat and popcorn, the pickup sheet being in heat transfer relationship with the charge contained in the com-partment and being flexible enough while bonded to the paper to permit the bag to bend freely during shipment and during popping while the bag expands from a collap5ed state to an expanded state, the portlons of the package other than the bottom surface being freè from microwave receptive material to Eacilitate locallzed absorption of microwave energy my -the . - 2 -:~Z33~36 pickup shee-t to thereby concentrate absorbed microwave energy at the bottom of the charge.
In one embodiment of the present invention the charge of popcorn and fat is spread out lat:erally so that ls presents a broad face resting on the flexible inductive sheet and the lower bag panel adjacent the floor portion of the microwave oven during popping whereby microwave energy is absorbed by the inductive pickup sheet and transferred to the popcorn and fat above it. Suitably the microwave inductive lo pickup sheet comprises a film of plastic resinous material having a microwave inductive metal electrodeposited thereon as a thin layer. Desirably the electrodeposited layer is trans-parent to light.
In a particular embodiment of the present invention said bag is folded transversely into three sections of approx-imately equal size including a central section and two end sections, each end section being empty and being folded cen-trally to a position in proximity to the charge contained in the central section of the bag, said transverse folding defin-ing a means as a part of the bag to temporarily restrain thecharge at the center of the bag and in only one tube and said microwave inductive sheet material being located at least within the central section of the bag below said charge.
The present invention thus provides a popcorn pack-age for shipping and popping popcorn within a microwave oven.
The bag is formed from flexible sheet material transparent to microwave energy and includes two opposed face panels of the same width or of different widths. Sections of extensible interconnectlng folded sheet materlal define centrally pro-eating gussets that extend between the s:lde edges oE thefirst and second panels Jo allow the bag to expand as the corn pops. One panel of the bag deflnes .Lower wall of the bag ~33~6 which is placed downwardly when the corn is popped. A fle-xible and foldable inductive microwave pickup sheet is pro-vided. The sheet is paper or plastic film having a microwave receptive pickup material thereon characterized by becoming hot when exposed to microwave energy. The pickup shee-t is present at least in the part of the bag where the charge of popcorn and fat is located and is in heat transfer relation-ship therewith. The pickup sheet is bonded to the lower wall of the bag and is supported thereby so that it remains in place beneath the charge to thus substantially line the pool of hot fat during the cookiny operation. The pickup sheet in this way substantially surrounds the lower aspect of the entire pool of hot fat and because of its flexibility can be folded or flexed upwardly around the sides and edges of the pool as the bag is folded. The popcorn and fat contained in the bag is positioned intermediate the ends of the bag and is spaced apart from the ends. The charge is also located between the centrally projecting gussets and the lower face panel. The centrally projecting gussets approach each other tending to divide the bag into a pair of collateral tubes.
The charge of popcorn and fat is confined substantially entirely in -the lower tube. The tubes are in communication with each other between the gussets so that the popcorn can pass from the lower tube to the upper tube during popping. In addition, the charge of popcorn and fat is spread out later-ally, that is to say, from side to side so that it presents a broad face resting on the inductive sheet and bag panel ad;a-cent the floor portlon of the microwave oven during popping whereby microwave energy i9 absorbed by the inductive pickup sheet and transEerred to the popcorn and fat above it.
The present in~entlon will now be described by way of examp:le with rcEerence -to -the accompanylng drawlngs, in 23343Çi which:--Figure 1 is a perspectlve view of the packaye inaccordance with the invention fllled wlth a charge of popcorn and fat;
Figure 2 is a transverse cross-sectional view taken on line 2-2 of Figure l;
Figure 3 is a perspective view of the package in accordance with another form of the invention prior to fill-ing;
Figure 4 is a partial side elevational view of the bag shown in Figure 3 as it appears in a flattened condition prior to filling;
Figure 5 is a perspective view of the package of Figures 3 and 4 after being filled and folded for shipment;
Figure 6 is a perspective view of the package of Figure 5 after being unfolded and properly oriented in a microwave oven preparatory to cooking;
Figure 7 is a transverse cross-sectional view taken on line 7-7 of Figure 6;
Figure 8 is a view similar to Figure 7 as it appears when the popcorn begins to pop;
Figure 9 is a view similar to Figure 8 in a later stage in the popping cycle;
Figure 10 is a diagrammatic perspective view of one method of filling the bags in accordance with the invention;
and figure 11 is a highly magnified semidiagramatic cross-sectional view of the induc-tive pickup sheet and under-lying bag wall.
Figures 1 and 2 illustrate a form of the lnventlon ln whlch a paclcage l employed havlng face panels oE equal size. The embodimen-t of figures 1 and 2 comprises a package ~L~33~3~i 10 composed of a bag 12 formed from flexible sheet material such as paper whlch is of collateral tubular configuration, that is to say, being composed of a pair of parallel longi-tudinally extending tubes 14 and 16 which communicate with one ano-ther along a central longitudinal opening 18. The two parallel tubes 14 and 16 are separated by longitudinally extending side indentions 20 and 22. When the package com-prises a paper bag, the bag can be composed of upper and lower face panels 24 and 2G, respectively of equal size, and the indentions 20 and 22 comprise gussets. The bag shown in Figure 1 has bottom seal 28. After being filled, the top 30 is also sealed conventionally by means of heat or a suitable adhesive.
As best seen in Figure 2, a food product 32 comprising a mixture of popcorn and fat is placed in the collateral - 5a -~23;~36 tube 16 while the tube 14 is maintained substantially free from the charge of popcorn and fit.
When the package is heated to pop the corn, tube 16 containing the charge 32 is placed downwardly in the microwave oven. In this position panel 26 adjacent the charge 32 faces downwardly and contacts the bottom wall of the cooking chamber of the microwave oven as will be described in more detail below. It will also be noted that the charge 32 is located approximately centrally with respect to the ends of the bag that is to say, approximately halfway between the top 30 and the bottom seal 28.
Positioned adjacent to the panel 26 which serves as the lower or bottom panel during the heating opera-tion is a microwave pickup sheet 27. Sheet 27 is flexible and foldable and is composed of a plastic film having a microwave receptive metallic material 29 thereon (Figure 11). The microwave receptive material 29 is characterized by becoming hot when exposed to microwave energy. The sheet 27 and metallic layer 29 may, if desired, be bonded to a paper backing 31 which serves as a support and the entire laminate composed of the film , the metallic layer 29 and the paper backing 31 is secured preferably by ad-hesive bonding to the lower wall panel 26 of the bag as shown in Figures 2, 7, 8 and 9. The inductive sheet 27-29 is present at least in the portion of the bag where the charge of fat and corn 32 is located and is in heat transfer relatiQnship thcrewith. l`he sheet 27-29 is bonded to the lower wall 26 ox the ba~3 ancl is supported thereby to remain in place and to s~lbstantially line the pool of hot ~Z3~3~i fat in which the corn is suspended during the cooking operation. In this way, the microwave inductive sheet substantially surrounds the entire lower surface of the pool of hot fat andr owing to its flexibility,can be folded i.e., curved upwardly around the sizes and edges of the heated fat 52 shown in Figures 8 and 9.
The metal coating 29 is usually very~thin, transparent or semitransparent but partially reflective of light. It can be formed, for example, by vacuum metali~ing a plastic film-such as a polyester film. Various metals can be used such as aluminum, copper, gold and various ferrous materials.
Other suitable inductor sheet materials can be obtained from Jomergin, Inc. of St. Albans, Vermont, and Camvac International of Brewster, New York. It should be under-stood that layer 29 is not a continuous uninterrupted metal which is a good conductor of electricity. It is instead thin enough to be transparent to light.
Thus, the microwave inductive heat pickup sheet absorbs the microwave energy signals generated in the microwave oven and becomes extremely hot, probably due to internal losses in the metal layer 29 which causes it to heat up rapidly to a much higher temperature than an equivalent quantity of water, fat or other common food substance and this heat is transferred by conduction to the food.
It is important to note that the product rests in heat transfer relationship with the underlying inductive sheet 27 and that the hot layer of flexible sheet material 27-29 substantially surrounds the entire lower surface of the pool of hot fat. Moreover, because of its flexibility, it can be transferred through all of the bag forming operations without damage and without requirement for additional forming or handling operations. In addition, when the bag is folded it will, if large enough, follow con-tours of the bag and will fold upwardly if desired around the side edges of the pool 52 of fat which forms at the bottom ox the bag as the popcorn is heated. While the inductive sheet has been shown laminated to a paper backing 31 in Figure 11, it should be understood that the paper backing is optional, provided, however, the plastic sheet 27 is in some way supported dimensionally, for example,by bonding it directly to the wall 26 of the bag. The microwave inductive pickup sheet 27 can be of various shapes, rectangular, round or in strip form. In any event, it should be bonded to the wall 26 of the bag because if it is not held in place, it will tend to float away from the wall 26 and may become charred be-cause heat is not conducted efficiently to the charge of food present in the bag. While the sheet 27 can be spot bonded to the bag, it is particularly important to bond at least the edges to the bag wall 26 to provide dimensional stability. If it is not supported firmly as, for example, by bonding at -the edges or over its entire area, it will -tend to shrink to a small size and will overheat.
Refer now to Figures 3 through 9 which illustrate another form of the invention and in which the same numbers refer to corresponding parts. As sllown best in Figllres 3 and I, a packaye on is providecl comprising a bag forrned from flexible sheet materials s-lch as ~33~3~
paper preferably with a greaseproof paper liner of suitable known construction and including first and second parallel collateral tubes 42 and 44 both of which cxtend longitudinally and comm~lnicate with one another along midline at 46. The bag is sealecl by means of a bottom seal 48 and prior to filling is open at the top 50 such that a charge of popcorn and fat 52 can be introduced as shown in Figure 5. After the charge has been introduced, the top 50 is sealed as shown at 50a in Figure 6. It can be seen in Figures 3 and 4 that the collateral tubes 42 and 44 are separated by indentations 54 and 56 and although not essential to the invention, the indentations are conveniently formed by construct-ing the bag with longitudinally extending centrally projecting gussets at 54 and 56. The bag after being constructed will usually be flattened to the condition shown in Figure 4 with the innermost aspect of the gussets 54 and 56 comprising folds indicated by dotted lines 54a and 56a. The bag is in this case provided with two longitudinally extending face panels; panel 58 and panel 60 which is smaller in width and area than face panel 58. While size is not critical, it is pre-ferred that the panel 60 be about 18% to 50% smaller in area than the panel 58. Consequently, tube 44 is smaller in cross-section than tube 42. The term "cross-section" herein has reference to the tubes when fully expanded to circular configuration as shown in Figure 3.
The bag illustrated is a tube type bag, that is, a bag ormed from a continuous tube of paper manufacturecl on a so-called bag tuber and cut transversely at: uniform ~33~36 intervals to define the top and bottom ends 50 and 48.
the bag can, however, be of the pasted bottom type with folding panels at the top and bottom of the bag which are pasted shut after the bag is filled. It should be noted that the charge 52 is placed approximately inter-mediate to the ends of the bag as shown in Figures 5 and 6. After filling and sealing the top 50 at 50a, the bag is folded transversely at 62 and 64 to divide -the bag roughly into three equal sections for convenient shipment with the charge 52 in approximately the center of the bag as best seen in Figure 6.
The charge 52 is placed in the tube 60 of smaller cross-section, that is to say, laterally of the midline of the bag. The larger tube 42 is maintained substantially free of the charge of popped corn fat.
When the corn is to be popped, the package 40 is positioned horizontally and placed in a microwave oven 68 with the panel 60 facing downward. The~charge 52 is thus located adjacent the sheet 27 which is adjacent the floor 69 of the cooking chamber 72 within oven 68.
The microwave oven 68 which is itself entirely conven-tional, includes the usual oven controls 70, cooking chamber 72 and door 74. After the door 74 is closed, microwave energy will heat the charge 52 causing the fat to melt as shown in Figure 8 and some of the popcorn will pop while steam is generated filling the first relatively large tubular section 42 with a combination of steam and popped corn. As cooking continues, rnore and more of the chance 52 will pop and the package wil:L
become filled with popped kernels 7~. The invention result.s in a substantial increase in volumetric yields as sllown in Tables L and 2.
~233~36 FINAL VOLIJME OF POPPED CORN5' Control Bag 4 3" 4"x8'~" 3" With No Square Square Strip Circle Inductive Pickup Pickup Pickup Pickup Pickup go 1040 840 1150 730 4~2 % increase135% 90~ 160~ 65% -0-FINAL VOLUME OF POPPED CORN
4" Square 4" Square Control Pickup Pickup (Same Bag Metalized Aluminized With No Film 1 Mylar Inductive 0.5 Mil 0. 5 Mil Pickup) __ c.c.2 1550 1250 860 increase over control 80~ 45% -0-536 gm. of corn and 16 gms. of fat heated in a 400 watt mierowave oven for 3.5 minutes. Bags were yusseted paper bags measuring 4" wide and 9~" long (gusse-ts were 1.5"
deep with bag collapsed). Panels were of equal size (Figures 1 and 2).
6Average of 5 runs.
7In all samples, the inductive piekup was composed of metalized plastic sheet 0.5 mil bonded to paper backing, product from James River Corp. of Kalamazoo, Michigan.
Pickup was bonded to inside of the lower surface of the bag.
372 gm. of eorn and 25 gm. fat heated in 400 watt microwave oven for 5 minutes. Bags were gusseted paper baqs mea~ur-ing 5~" wide x 11~" tall with panels of unequal w:idth (Figures 3~10). The smaller panel was 4 3/4" wide.
lProduct obtained Erom James River Corp. of Kalamazoo, Mich.
2Averaqe of 5 rulls.
~;~33~3~
present invention. Depending upon circumstances, the improvement may range from a volume increase of between about 45% and 160%. It appears that not only more of the popcorn kernels popped, but in addition the average volume of the popped kernels is greater with the present inven-tion.
Many variations of the invention within the scope of the appended claims will be apparent to those skilled in the art. For example, the term "metallic material" may include metal compounds such as iron oxide, tin oxide, etc.
and the pickup shee-t can be loose in the bag and held in by the weight of the product or bonded between plies or to the outside of the bag.
In recent years manufacturers have begun distribut-\ ing popcorn ln gusseted paper bags. The corn is popped by \ placing the entire bag in a microwave oven. In this way, the\ corn is heated by microwave energy while it remains in the \ bag. As the corn pops, the bag expands to accommodate the popcorn kernels.
` One shortcoming of commercial products is the prob-lem of maintaining the best possible volumetric yields. The volumetric yield is measured by popping a standard quantity of corn in its package within a microwave oven, pouring the popped kernels into a graduate and noting the total volume.
The resulting final volumes have not always been satisfactory and all too often a disappointingly high number of kernels remain unpopped. Moreover, those that do pop are often less than maximum volume.
U.S. Patents Nos. 3,973,045 and 3,835,280 are repre-sentative of the prior art. The packages described in the patent do not, when heated, achieve maximum potential volumet-ric yield.
In view of these shortcomings the present invention provides a package for improving the volumetric yield of pop-corn dlstributed and popped in flexible bags. The present invention also achieves the improved yields while in no way interferring with the flexibility of the bag or substantially increasing its cost. The present invention again provides a way to relate to the charge of popcorn and fat in a package to a microwave inductive member to maximize heating of the pickup member and the transEer of the heat efficiently to the popcorn while allowing the package to be collapsed to a very small oh . - 1 -33~36 volume for shipment and yet the pickup means will permit free expansion during heating to a large enough volume to accommo-date the popped kernels while the pickup sheet remains throughout heating efficiently thermally coupled to the pop-corn.
According to the present invention there is provided a popcorn package suited for shipment in a collapsed state and for heating in a microwave oven to accomplish popping of pop-corn kernels within the package comprising, a collapsible bag formed from flexible sheet material transparent to microwave energy, said bag having a food heating compartment therein containing a charge of popcorn and fat and having a bottom surface during heating that includes a flexible sheet of paper, a flexible and foldable microwave concentrating induc-tive pickup sheet only on the bottom of the compartment con-taining the charge, said inductive sheet being composed of a base material in sheet form having a flexible microwave induc-tor material thereon characterized by becoming hot to effect concentrated heating of a localized portion of the charge when exposed to microwave energy, the pickup sheet being substan-tially flat and being bonded to said paper sheet for dimen-sional support to prevent shriveling and scorching during localized heating of a food and defining a substantially flat flexible bottom for the food heating compartment containing the charge of fat and popcorn, the pickup sheet being in heat transfer relationship with the charge contained in the com-partment and being flexible enough while bonded to the paper to permit the bag to bend freely during shipment and during popping while the bag expands from a collap5ed state to an expanded state, the portlons of the package other than the bottom surface being freè from microwave receptive material to Eacilitate locallzed absorption of microwave energy my -the . - 2 -:~Z33~36 pickup shee-t to thereby concentrate absorbed microwave energy at the bottom of the charge.
In one embodiment of the present invention the charge of popcorn and fat is spread out lat:erally so that ls presents a broad face resting on the flexible inductive sheet and the lower bag panel adjacent the floor portion of the microwave oven during popping whereby microwave energy is absorbed by the inductive pickup sheet and transferred to the popcorn and fat above it. Suitably the microwave inductive lo pickup sheet comprises a film of plastic resinous material having a microwave inductive metal electrodeposited thereon as a thin layer. Desirably the electrodeposited layer is trans-parent to light.
In a particular embodiment of the present invention said bag is folded transversely into three sections of approx-imately equal size including a central section and two end sections, each end section being empty and being folded cen-trally to a position in proximity to the charge contained in the central section of the bag, said transverse folding defin-ing a means as a part of the bag to temporarily restrain thecharge at the center of the bag and in only one tube and said microwave inductive sheet material being located at least within the central section of the bag below said charge.
The present invention thus provides a popcorn pack-age for shipping and popping popcorn within a microwave oven.
The bag is formed from flexible sheet material transparent to microwave energy and includes two opposed face panels of the same width or of different widths. Sections of extensible interconnectlng folded sheet materlal define centrally pro-eating gussets that extend between the s:lde edges oE thefirst and second panels Jo allow the bag to expand as the corn pops. One panel of the bag deflnes .Lower wall of the bag ~33~6 which is placed downwardly when the corn is popped. A fle-xible and foldable inductive microwave pickup sheet is pro-vided. The sheet is paper or plastic film having a microwave receptive pickup material thereon characterized by becoming hot when exposed to microwave energy. The pickup shee-t is present at least in the part of the bag where the charge of popcorn and fat is located and is in heat transfer relation-ship therewith. The pickup sheet is bonded to the lower wall of the bag and is supported thereby so that it remains in place beneath the charge to thus substantially line the pool of hot fat during the cookiny operation. The pickup sheet in this way substantially surrounds the lower aspect of the entire pool of hot fat and because of its flexibility can be folded or flexed upwardly around the sides and edges of the pool as the bag is folded. The popcorn and fat contained in the bag is positioned intermediate the ends of the bag and is spaced apart from the ends. The charge is also located between the centrally projecting gussets and the lower face panel. The centrally projecting gussets approach each other tending to divide the bag into a pair of collateral tubes.
The charge of popcorn and fat is confined substantially entirely in -the lower tube. The tubes are in communication with each other between the gussets so that the popcorn can pass from the lower tube to the upper tube during popping. In addition, the charge of popcorn and fat is spread out later-ally, that is to say, from side to side so that it presents a broad face resting on the inductive sheet and bag panel ad;a-cent the floor portlon of the microwave oven during popping whereby microwave energy i9 absorbed by the inductive pickup sheet and transEerred to the popcorn and fat above it.
The present in~entlon will now be described by way of examp:le with rcEerence -to -the accompanylng drawlngs, in 23343Çi which:--Figure 1 is a perspectlve view of the packaye inaccordance with the invention fllled wlth a charge of popcorn and fat;
Figure 2 is a transverse cross-sectional view taken on line 2-2 of Figure l;
Figure 3 is a perspective view of the package in accordance with another form of the invention prior to fill-ing;
Figure 4 is a partial side elevational view of the bag shown in Figure 3 as it appears in a flattened condition prior to filling;
Figure 5 is a perspective view of the package of Figures 3 and 4 after being filled and folded for shipment;
Figure 6 is a perspective view of the package of Figure 5 after being unfolded and properly oriented in a microwave oven preparatory to cooking;
Figure 7 is a transverse cross-sectional view taken on line 7-7 of Figure 6;
Figure 8 is a view similar to Figure 7 as it appears when the popcorn begins to pop;
Figure 9 is a view similar to Figure 8 in a later stage in the popping cycle;
Figure 10 is a diagrammatic perspective view of one method of filling the bags in accordance with the invention;
and figure 11 is a highly magnified semidiagramatic cross-sectional view of the induc-tive pickup sheet and under-lying bag wall.
Figures 1 and 2 illustrate a form of the lnventlon ln whlch a paclcage l employed havlng face panels oE equal size. The embodimen-t of figures 1 and 2 comprises a package ~L~33~3~i 10 composed of a bag 12 formed from flexible sheet material such as paper whlch is of collateral tubular configuration, that is to say, being composed of a pair of parallel longi-tudinally extending tubes 14 and 16 which communicate with one ano-ther along a central longitudinal opening 18. The two parallel tubes 14 and 16 are separated by longitudinally extending side indentions 20 and 22. When the package com-prises a paper bag, the bag can be composed of upper and lower face panels 24 and 2G, respectively of equal size, and the indentions 20 and 22 comprise gussets. The bag shown in Figure 1 has bottom seal 28. After being filled, the top 30 is also sealed conventionally by means of heat or a suitable adhesive.
As best seen in Figure 2, a food product 32 comprising a mixture of popcorn and fat is placed in the collateral - 5a -~23;~36 tube 16 while the tube 14 is maintained substantially free from the charge of popcorn and fit.
When the package is heated to pop the corn, tube 16 containing the charge 32 is placed downwardly in the microwave oven. In this position panel 26 adjacent the charge 32 faces downwardly and contacts the bottom wall of the cooking chamber of the microwave oven as will be described in more detail below. It will also be noted that the charge 32 is located approximately centrally with respect to the ends of the bag that is to say, approximately halfway between the top 30 and the bottom seal 28.
Positioned adjacent to the panel 26 which serves as the lower or bottom panel during the heating opera-tion is a microwave pickup sheet 27. Sheet 27 is flexible and foldable and is composed of a plastic film having a microwave receptive metallic material 29 thereon (Figure 11). The microwave receptive material 29 is characterized by becoming hot when exposed to microwave energy. The sheet 27 and metallic layer 29 may, if desired, be bonded to a paper backing 31 which serves as a support and the entire laminate composed of the film , the metallic layer 29 and the paper backing 31 is secured preferably by ad-hesive bonding to the lower wall panel 26 of the bag as shown in Figures 2, 7, 8 and 9. The inductive sheet 27-29 is present at least in the portion of the bag where the charge of fat and corn 32 is located and is in heat transfer relatiQnship thcrewith. l`he sheet 27-29 is bonded to the lower wall 26 ox the ba~3 ancl is supported thereby to remain in place and to s~lbstantially line the pool of hot ~Z3~3~i fat in which the corn is suspended during the cooking operation. In this way, the microwave inductive sheet substantially surrounds the entire lower surface of the pool of hot fat andr owing to its flexibility,can be folded i.e., curved upwardly around the sizes and edges of the heated fat 52 shown in Figures 8 and 9.
The metal coating 29 is usually very~thin, transparent or semitransparent but partially reflective of light. It can be formed, for example, by vacuum metali~ing a plastic film-such as a polyester film. Various metals can be used such as aluminum, copper, gold and various ferrous materials.
Other suitable inductor sheet materials can be obtained from Jomergin, Inc. of St. Albans, Vermont, and Camvac International of Brewster, New York. It should be under-stood that layer 29 is not a continuous uninterrupted metal which is a good conductor of electricity. It is instead thin enough to be transparent to light.
Thus, the microwave inductive heat pickup sheet absorbs the microwave energy signals generated in the microwave oven and becomes extremely hot, probably due to internal losses in the metal layer 29 which causes it to heat up rapidly to a much higher temperature than an equivalent quantity of water, fat or other common food substance and this heat is transferred by conduction to the food.
It is important to note that the product rests in heat transfer relationship with the underlying inductive sheet 27 and that the hot layer of flexible sheet material 27-29 substantially surrounds the entire lower surface of the pool of hot fat. Moreover, because of its flexibility, it can be transferred through all of the bag forming operations without damage and without requirement for additional forming or handling operations. In addition, when the bag is folded it will, if large enough, follow con-tours of the bag and will fold upwardly if desired around the side edges of the pool 52 of fat which forms at the bottom ox the bag as the popcorn is heated. While the inductive sheet has been shown laminated to a paper backing 31 in Figure 11, it should be understood that the paper backing is optional, provided, however, the plastic sheet 27 is in some way supported dimensionally, for example,by bonding it directly to the wall 26 of the bag. The microwave inductive pickup sheet 27 can be of various shapes, rectangular, round or in strip form. In any event, it should be bonded to the wall 26 of the bag because if it is not held in place, it will tend to float away from the wall 26 and may become charred be-cause heat is not conducted efficiently to the charge of food present in the bag. While the sheet 27 can be spot bonded to the bag, it is particularly important to bond at least the edges to the bag wall 26 to provide dimensional stability. If it is not supported firmly as, for example, by bonding at -the edges or over its entire area, it will -tend to shrink to a small size and will overheat.
Refer now to Figures 3 through 9 which illustrate another form of the invention and in which the same numbers refer to corresponding parts. As sllown best in Figllres 3 and I, a packaye on is providecl comprising a bag forrned from flexible sheet materials s-lch as ~33~3~
paper preferably with a greaseproof paper liner of suitable known construction and including first and second parallel collateral tubes 42 and 44 both of which cxtend longitudinally and comm~lnicate with one another along midline at 46. The bag is sealecl by means of a bottom seal 48 and prior to filling is open at the top 50 such that a charge of popcorn and fat 52 can be introduced as shown in Figure 5. After the charge has been introduced, the top 50 is sealed as shown at 50a in Figure 6. It can be seen in Figures 3 and 4 that the collateral tubes 42 and 44 are separated by indentations 54 and 56 and although not essential to the invention, the indentations are conveniently formed by construct-ing the bag with longitudinally extending centrally projecting gussets at 54 and 56. The bag after being constructed will usually be flattened to the condition shown in Figure 4 with the innermost aspect of the gussets 54 and 56 comprising folds indicated by dotted lines 54a and 56a. The bag is in this case provided with two longitudinally extending face panels; panel 58 and panel 60 which is smaller in width and area than face panel 58. While size is not critical, it is pre-ferred that the panel 60 be about 18% to 50% smaller in area than the panel 58. Consequently, tube 44 is smaller in cross-section than tube 42. The term "cross-section" herein has reference to the tubes when fully expanded to circular configuration as shown in Figure 3.
The bag illustrated is a tube type bag, that is, a bag ormed from a continuous tube of paper manufacturecl on a so-called bag tuber and cut transversely at: uniform ~33~36 intervals to define the top and bottom ends 50 and 48.
the bag can, however, be of the pasted bottom type with folding panels at the top and bottom of the bag which are pasted shut after the bag is filled. It should be noted that the charge 52 is placed approximately inter-mediate to the ends of the bag as shown in Figures 5 and 6. After filling and sealing the top 50 at 50a, the bag is folded transversely at 62 and 64 to divide -the bag roughly into three equal sections for convenient shipment with the charge 52 in approximately the center of the bag as best seen in Figure 6.
The charge 52 is placed in the tube 60 of smaller cross-section, that is to say, laterally of the midline of the bag. The larger tube 42 is maintained substantially free of the charge of popped corn fat.
When the corn is to be popped, the package 40 is positioned horizontally and placed in a microwave oven 68 with the panel 60 facing downward. The~charge 52 is thus located adjacent the sheet 27 which is adjacent the floor 69 of the cooking chamber 72 within oven 68.
The microwave oven 68 which is itself entirely conven-tional, includes the usual oven controls 70, cooking chamber 72 and door 74. After the door 74 is closed, microwave energy will heat the charge 52 causing the fat to melt as shown in Figure 8 and some of the popcorn will pop while steam is generated filling the first relatively large tubular section 42 with a combination of steam and popped corn. As cooking continues, rnore and more of the chance 52 will pop and the package wil:L
become filled with popped kernels 7~. The invention result.s in a substantial increase in volumetric yields as sllown in Tables L and 2.
~233~36 FINAL VOLIJME OF POPPED CORN5' Control Bag 4 3" 4"x8'~" 3" With No Square Square Strip Circle Inductive Pickup Pickup Pickup Pickup Pickup go 1040 840 1150 730 4~2 % increase135% 90~ 160~ 65% -0-FINAL VOLUME OF POPPED CORN
4" Square 4" Square Control Pickup Pickup (Same Bag Metalized Aluminized With No Film 1 Mylar Inductive 0.5 Mil 0. 5 Mil Pickup) __ c.c.2 1550 1250 860 increase over control 80~ 45% -0-536 gm. of corn and 16 gms. of fat heated in a 400 watt mierowave oven for 3.5 minutes. Bags were yusseted paper bags measuring 4" wide and 9~" long (gusse-ts were 1.5"
deep with bag collapsed). Panels were of equal size (Figures 1 and 2).
6Average of 5 runs.
7In all samples, the inductive piekup was composed of metalized plastic sheet 0.5 mil bonded to paper backing, product from James River Corp. of Kalamazoo, Michigan.
Pickup was bonded to inside of the lower surface of the bag.
372 gm. of eorn and 25 gm. fat heated in 400 watt microwave oven for 5 minutes. Bags were gusseted paper baqs mea~ur-ing 5~" wide x 11~" tall with panels of unequal w:idth (Figures 3~10). The smaller panel was 4 3/4" wide.
lProduct obtained Erom James River Corp. of Kalamazoo, Mich.
2Averaqe of 5 rulls.
~;~33~3~
present invention. Depending upon circumstances, the improvement may range from a volume increase of between about 45% and 160%. It appears that not only more of the popcorn kernels popped, but in addition the average volume of the popped kernels is greater with the present inven-tion.
Many variations of the invention within the scope of the appended claims will be apparent to those skilled in the art. For example, the term "metallic material" may include metal compounds such as iron oxide, tin oxide, etc.
and the pickup shee-t can be loose in the bag and held in by the weight of the product or bonded between plies or to the outside of the bag.
Claims (12)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A popcorn package suited for shipment in a col-lapsed state and for heating in a microwave oven to accomplish popping of popcorn kernels within the package comprising, a collapsible bag formed from flexible sheet material transpar-ent to microwave energy, said bag having a food heating com-partment therein containing a charge of popcorn and fat and having a bottom surface during heating that includes a fle-xible sheet of paper, a flexible and foldable microwave con-centrating inductive pickup sheet only on the bottom of the compartment containing the charge, said inductive sheet being composed of a base material in sheet form having a flexible microwave inductor material thereon characterized by becoming hot to effect concentrated heating of a localized portion of the charge when exposed to microwave energy, the pickup sheet being substantially flat and being bonded to said paper sheet for dimensional support to prevent shriveling and scorching during localized heating of a food and defining a substan-tially flat flexible bottom for the food heating compartment containing the charge of fat and popcorn, the pickup sheet being in heat transfer relationship with the charge contained in the compartment and being flexible enough while bonded to the paper to permit the bag to bend freely during shipment and during popping while the bag expands from a collapsed state to an expanded state, the portions of the package other than the bottom surface being free from microwave receptive material to facilitate localized absorption of microwave energy by the pickup sheet to thereby concentrate absorbed microwave energy at the bottom of the charge.
2. The package of Claim 1 wherein the charge of popcorn and fat is spread out laterally so that it presents a broad face resting on the flexible inductive sheet and the lower bag panel adjacent the floor portion of the microwave oven during popping whereby micro-wave energy is absorbed by the inductive pickup sheet and transferred to the popcorn and fat above it.
3. The package of Claim 2 wherein the microwave inductive pickup sheet comprises a film of plastic resinous material having a microwave inductive metal electro-deposited thereon as a thin layer.
4. The package of Claim 3 wherein the electrodeposited layer is transparent to light.
5. The package of Claim 3 wherein the metallic layer com-prises aluminum.
6. The package of Claim 3 wherein the metallic layer comprises a ferrous material.
7. The package of Claim 1 wherein the flexible inductive sheet material comprises an elongated strip bonded to the lower panel of the bag and extending longitudinally thereof between the top and bottom edges of the panels.
8. The package of Claim 1 wherein said flexible and foldable inductive microwave pickup sheet comprises a laminate composed of a layer of plastic resinous film material having a thin metallic layer deposited thereon and a paper backing sheet bonded thereto, said laminate being adhesively bonded to the lower wall panel in heat conductive relationship to the adjacent overlying charge of popcorn and fat.
9. The package of Claim 8 wherein the metallic layer is a transparent layer of electrodeposited metal.
10. The package according to Claim 1 wherein there is provided a means as a part of the bag to temporarily restrain the charge of popcorn and fat at the center of the bag and in only one tube.
11. The package according to Claim 10 wherein said means as a part of the bag to temporarily restrain the charge comprises a pair of transversely extending folds in the bag on each side of the charge to form a pair of flaps adapted to extend upwardly when the bag is placed on the lower face panel for popping.
12. The package of Claim 1 wherein said bag is folded transversely into three sections of approximately equal size including a central section and two end sections, each end section being empty and being folded centrally to a position in proximity to the charge contained in the central section of the bag, said transverse folding defining a means as a part of the bag to temporarily restrain the charge at the center of the bag and in only one tube and said microwave inductive sheet material being located at least within the central section of the bag below said charge.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US61272384A | 1984-05-21 | 1984-05-21 | |
| US612,723 | 1984-05-21 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1233436A true CA1233436A (en) | 1988-03-01 |
Family
ID=24454393
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000465534A Expired CA1233436A (en) | 1984-05-21 | 1984-10-16 | Popcorn package |
Country Status (2)
| Country | Link |
|---|---|
| JP (3) | JPS60251059A (en) |
| CA (1) | CA1233436A (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6312479A (en) * | 1986-06-30 | 1988-01-19 | 凸版印刷株式会社 | Food vessel with microwave heating element |
| JPS6312478A (en) * | 1986-06-30 | 1988-01-19 | 凸版印刷株式会社 | Food vessel with microwave heating element |
| JPS6321279U (en) * | 1986-07-25 | 1988-02-12 | ||
| JPS6370970U (en) * | 1986-10-25 | 1988-05-12 | ||
| JPS642608A (en) * | 1987-06-25 | 1989-01-06 | Oji Paper Co Ltd | Heating promotion material for microwave cooking |
| JPH0543705Y2 (en) * | 1987-07-03 | 1993-11-04 | ||
| TW440425B (en) * | 1999-07-14 | 2001-06-16 | Shimano Kk | Rotor drive for spinning reel and spinning reel |
| KR100905448B1 (en) * | 2007-08-09 | 2009-06-30 | 이주석 | Instant food manufacturing method |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3973045A (en) * | 1973-05-14 | 1976-08-03 | The Pillsbury Company | Popcorn package for microwave popping |
| US4292332A (en) * | 1976-05-10 | 1981-09-29 | Mcham David E | Container for prepackaging, popping and serving popcorn |
| US4190757A (en) * | 1976-10-08 | 1980-02-26 | The Pillsbury Company | Microwave heating package and method |
| US4230924A (en) * | 1978-10-12 | 1980-10-28 | General Mills, Inc. | Method and material for prepackaging food to achieve microwave browning |
| CA1153069A (en) * | 1979-03-16 | 1983-08-30 | Oscar E. Seiferth | Food receptacle for microwave cooking |
-
1984
- 1984-10-16 CA CA000465534A patent/CA1233436A/en not_active Expired
- 1984-12-14 JP JP59263140A patent/JPS60251059A/en active Granted
-
1993
- 1993-02-01 JP JP5014663A patent/JPH0780504B2/en not_active Expired - Lifetime
-
1996
- 1996-08-20 JP JP8218524A patent/JPH09193971A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0624473A (en) | 1994-02-01 |
| JPS60251059A (en) | 1985-12-11 |
| JPH0541513B2 (en) | 1993-06-23 |
| JPH0780504B2 (en) | 1995-08-30 |
| JPH09193971A (en) | 1997-07-29 |
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| MKEX | Expiry |