Not applicable to this application.
Not applicable to this application.
The described example embodiments in general relate to a construct and microwave susceptor for heating a food item in a microwave oven, and more particularly a popcorn bag and microwave susceptor for popping popcorn in a microwave oven.
A construct for heating a food item in a microwave oven, such as a microwave popcorn bag, can be constructed of a fibrous material such as a paper product. The construct generally includes a microwave susceptor for converting microwave energy generated by a microwave source, e.g., the oven, to thermal energy. The thermal energy in turn heats a food item contained in the construct, such as kernels of popcorn in a bag, in order to cook the food item or, in the case of popcorn kernels, to cause them to pop. The construct may also contain a flavored or non-flavored cooking oil-producing substance which liquifies as it is heated with the food item. In the case of popcorn kernels, the heated liquified cooking oil helps cause the kernels to pop and helps the popped corn stay moist and resist burning. Other food items also may produce oil-containing and/or other juices as it cooks.
After manufacture, a microwave popcorn bag or other microwave food construct can spend a considerable amount of time in transit and/or in storage prior to being used. As a result, oil and/or grease from the popcorn or other food item, and/or from an oil-producing substance, in the bag or other construct can spend a considerable amount of time in contact with the fibrous material of the bag or other construct. With such extended contact, there is a substantial risk of the oil and/or grease penetrating into and even through the fibrous material. In addition, while the bag or other construct is in use and as the popcorn or other food item in the bag or other construct is heated, liquified cooking oil and/or oil-containing juices can penetrate into and through the fibrous material. Penetration of oil, grease, and/or other juices into the fibrous material can stain the bag or other construct, which is unattractive to consumers. In addition, leakage through the fibrous material can result in a mess inside and outside of the bag or other construct, including inside a microwave.
To prevent penetration and leakage, the fibrous material may be sprayed or otherwise treated with certain chemical substances that resist penetration of the oil and/or other juices into and through the fibrous material. For example, the fibrous material can be treated with certain fluorocarbon (FC)-containing substances which penetrate and permeate the fibrous material. When applied to fibrous materials, such FC-containing substances are generally effective at repelling oil and oil-containing liquids. However, some FC-containing substances may include PFAS (per-and polyfluoroalkyl substances) and for various reasons some retail and wholesale customers desire not to use fibrous packaging containing PFAS. In addition, some manufacturers of some of the FC-containing substances are discontinuing the use of FC-based grease proof coatings and chemistries.
Accordingly, there is a need to address the problem of oil, grease, and/or other oil-containing juices penetrating into and through microwave food constructs in general, and more specifically microwave popcorn bags, that are made of fibrous materials such as paper products, but without using FC-containing chemical substances that may include PFAS. As described and claimed below, the present invention provides a unique microwave food construct and microwave susceptor, specifically a microwave popcorn bag and microwave susceptor, that addresses this need as well as others.
The various example embodiments of the present disclosure relate to a construct and a microwave susceptor film for heating a microwave food item, in particular microwave popcorn. The construct is comprised of a fibrous material and includes the microwave susceptor film for heating kernels of the popcorn in a microwave oven. The microwave susceptor film also effectively resists the penetration of oil, grease, and/or other juices through the fibrous material without the need to treat the fibrous material with potentially undesired chemical substances.
According to an example embodiment, the construct includes an interior space with an interior volume, a first panel (e.g., base panel) with a surface for supporting the popcorn kernels in the interior space, and a second panel (e.g., first side panel) that is adjacent to the first panel for containing the popcorn kernels in the interior space. The microwave susceptor film extends across the first panel and into the second panel to resist oil penetrating through the fibrous material of the construct.
According to one aspect of the example embodiment, the second panel has an expandable portion with a fold area near the base panel, and the microwave susceptor film extends into the fold area. According to another aspect, the fibrous material comprises a laminate having an inner layer and an outer layer, and the microwave susceptor film is present between the inner layer and the outer layer. According to another aspect, the oil-resistant material of the microwave susceptor film comprises a biodegradable cellulose material. According to yet another aspect, the microwave susceptor film has a microwave interactive material that is present only in the first panel.
According to yet another aspect of the example embodiment, the construct includes a third panel (e.g., second side panel) that is adjacent to the first panel for containing the popcorn kernels and that is substantially opposite the second panel, and the microwave susceptor film extends across the first panel into the second and third panels. According to yet another aspect, the third panel has an expandable portion with a fold area near the base panel, and the microwave susceptor film extends into the fold area.
According to yet another aspect of the example embodiment, the construct has a first end portion and a second end portion that is substantially opposite the first end portion, the second panel extends substantially the entire distance between the first end portion and the second end portion, and the microwave susceptor film extends along the second panel substantially the entire distance between the first end portion and the second end portion. According to yet another aspect, the third panel extends substantially the entire distance between the first end portion and the second end portion, and the microwave susceptor film extends along the third panel substantially the entire distance between the first end portion and the second end portion. According to yet another aspect, when the expandable portion of each of the second panel and the third panel is expanded, the microwave susceptor film forms a tray structure with a bottom on the first panel and opposed sides along the second panel and the third panel.
According to another example embodiment, the construct has a base panel with a surface for supporting popcorn kernels to be heated, a top panel substantially opposite to the base panel, a first side panel between the base panel and the top panel for containing the popcorn kernels, and a second side panel between the base panel and the top panel for containing the popcorn kernels that is substantially opposite to the first side panel. The first side panel comprises a first gusset with a first fold area and the second side panel comprises a second gusset with a second fold area. The first gusset is expandable in the first fold area and the second gusset is expandable in the second fold area. The microwave susceptor film comprises an oil-resistant film with a microwave interactive material, and the oil-resistant film extends across the base panel into the first fold area and the second fold area to resist oil penetrating through the fibrous material. The microwave interactive material is present only in the base panel.
According to an aspect of the example embodiment, the microwave interactive material has a first side substantially facing the first side panel and a second side substantially facing the second side panel, the first side is tapered toward the base panel until no microwave interactive material is present at the first side panel, and the second side is tapered toward the base panel until no microwave interactive material is present at the second side panel. According to another aspect, the oil-resistant film extends into the first side panel substantially the entire distance between the base panel and the top panel. According to another aspect, the oil-resistant film extends into the second side panel substantially the entire distance between the base panel and the top panel. According to yet another aspect, the first side panel extends along the base panel substantially the entire distance between a first end portion and a second end portion of the construct, and the oil-resistant film extends along the first side panel substantially the entire distance between the first end portion and the second end portion. According to yet another aspect, the second side panel also extends along the base panel substantially the entire distance between the first end portion and the second end portion, and the oil-resistant film extends along the second side panel substantially the entire distance between the first end portion and the second end portion.
According to another example embodiment, a microwave susceptor film is configured for use in a construct for heating a microwave food item. The construct is comprised of a fibrous material and has a first panel for supporting the food item and second and third panels adjacent to the first panel for containing the food item. The microwave susceptor film has an oil-resistant film and a microwave interactive material on the oil-resistant film, and is configured so that the oil-resistant film is able to extend across the first panel into the second and third panels to resist oil penetrating the fibrous material, and the microwave interactive material is confined entirely to the first panel.
There has thus been outlined, rather broadly, some of the embodiments of the present disclosure in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional embodiments of that will be described hereinafter and that will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment in detail, it is to be understood that the various embodiments are not limited in its application to the details of construction or to the arrangements of the components set forth in the following description or illustrated in the drawings. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.
To better understand the nature and advantages of the present disclosure, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present disclosure. Also, as a general rule, and unless it is evidence to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose.
A. Overview.
As shown in
The microwave susceptor film 50 comprises an oil-resistant film, a portion of which comprises a microwave interactive material 52. The film 50 is laminated between the outer layer 62 and the inner layer 64 of the fibrous material. The portion comprising the microwave interactive material 52 is contained entirely in the base panel 34 while the oil-resistant film extends laterally across the base panel 34, across the first and second fold lines 26 that are adjacent to the base panel 34, and into the respective first and second fold areas 24 of the first and second side panels 22. Depending on the embodiment, the oil-resistant film may extend across some or all of the fold areas 24 and fold lines 26 comprising the opposing first and second side panels 22 and substantially all the way to the top panel 28 to resist penetration of oil and/or grease through the fibrous material.
As constructed, and prior to use, the construct 10 has a relatively flat profile with the top panel 28 and base panel 34 being spaced relatively close together and the first and second fold areas 24 of the side panels 22 being folded in on themselves along the fold lines 26. In this state, the volume of the interior space 38 is relatively small but is sufficient to contain the popcorn kernels 44 and the optional oil-producing substance 46 (or another microwave food item) to be heated. Such items are introduced into a lower portion of the interior space 38 of the construct 10 adjacent to and in contact with the base panel 34 and potentially the first and second fold areas 24 of the respective first and second side panels 22 during the manufacturing process.
In use, the construct 10 is placed on a platform in a microwave oven with the base panel 34 and microwave susceptor in contact with and supported on the platform. The popcorn kernels 44 and optional oil-producing substance 46 (or other microwave food item) to be heated are in contact with and are supported on portions of the interior surface 40 of the inner layer 64 of the construct 10 that correspond to the base panel 34 and the microwave susceptor film 50. They may also be in contact with portions of the interior surface 40 that correspond to either or both of the first and/or second side panels 22 that are adjacent to the base panel 34, e.g., first and second fold areas 24 and first and second fold lines 26. As the microwave susceptor applies heat to the popcorn kernels 44 and the optional oil-producing substance 46, the kernels begin to pop, releasing gases and filling the interior space 38. This causes the construct 10, including the side panels 22, to expand outwardly and the fold areas 24 to unfold along the fold lines 26.
As the fold areas 24 unfold along the fold lines 26, the oil-resistant microwave susceptor film 50 forms an elongated substantially U-shaped tray structure. The bottom of the tray lies on the base panel 34 and extends between the opposed first and second side panels 22. The bottom of the tray comprises the oil-resistant film and the microwave interactive material 52. The opposed sides or legs of the tray comprise only the oil-resistant film and extend across the first and second fold lines 26 that are adjacent to the base panel 34 and upwardly into and along the first and second fold areas 24 of the respective first and second side panels 22 that are adjacent to the base panel 34. Any oil, grease or other juices that may result from the heating process enter and are collected in the tray structure. The microwave susceptor film 50 thus helps prevent the oil, grease, or other juices from coming in contact with and potentially penetrating through the fibrous material of the construct 10 in the fold areas 24 and along the fold lines 26, which are the areas that are most susceptible to such penetration and leakage.
B. Microwave Food Construct.
With reference primarily to
The example microwave food construct 10 is configured to contain a microwave food item 44 such as popcorn kernels (or another microwave food item, e.g., pork rinds, puff pellets, etc.) and optionally a cooking oil-producing substance 46 for heating in a microwave oven. While the optional cooking oil- producing substance 46 is helpful to include with certain food items 44 like popcorn kernels to help cause the kernels to pop and the popped kernels to stay moist and resist burning, the substance 46 may or may not be needed or helpful with other types of food items 44. Some food items 44 also may themselves produce oil, oil-containing liquids, and/or other juices as they are heated. If used, the cooking oil-producing substance 46 can comprise a semi-solid cooking grease or fat that can be melted or liquified upon application of heat to produce a liquid cooking oil substance. The substance 46 can also include flavoring components such as butter, salt, etc.
The example microwave food construct 10 in the form of a microwave popcorn bag is preferably constructed of a single piece of fibrous material or more preferably of a single piece of a multi-layer laminate of fibrous material in a manner further described herein. As shown in
The first and second side panels 22 are arranged to be substantially opposed to each other. Each of the first and second side panels 22 extends substantially completely between and joins together the top panel 28 and the base panel 34, preferably at or near opposite outer edges of the top panel 28 and base panel 34 respectively. Each of the first and second side portions 22 also extends substantially completely along the opposite outer edges of the top panel 28 and the base panel 34 between the first end portion 12 and the second end portion 18 including the first end portion seal 14 and the second end portion seal 20.
The top panel 28, the base panel 34, the first and second side portions 22, and the first and second end portion seals 14, 20 are arranged so that the construct 10 defines an interior space 38 that has an interior volume. The construct 10 also has an interior surface 40 and an exterior surface 42 that is opposite of the interior surface 40. The interior space 38 is configured and adapted to contain the food item 44, e.g., popcorn, after the construct 10 is manufactured, during transit and storage, and while and after the food item is heated. The interior space 38 is also configured and adapted to contain the optional oil-producing substance 46 and/or other oils or juices that may be produced when the food item 44 is heated.
In the example embodiment, the interior surface 40 of the construct 10 is comprised of an interior surface of the inner layer 64 of the laminated fibrous material of which the construct 10 is made. The interior surface 40 is exposed to and may come in contact with the food item 44, optional oil-producing substance 46, and various other oils, grease, juices, etc. in various locations during transit, storage, and use of the construct 10. More specifically, and as will become apparent from the description herein, the interior surface 40 is particularly likely to come in contact with the food item 44, optional oil-producing substance 46, and/or various other oil-containing liquids, juices, etc. in areas that correspond to the base panel 34 and at least parts of the first and second side panels 22 that are adjacent to the base panel 34. These areas are thus particularly at risk for penetration by the oil and/or various other liquids into and through the laminated fibrous material.
Also in the example embodiment, the exterior surface 42 of the construct 10 is comprised of an exterior surface of the outer layer 62 of the laminated fibrous material of which the construct 10 is made. The exterior surface 42 is exposed to the environment external to the construct 10 and is not directly exposed to or in contact with the food item 44, optional oil-producing substance 46, and/or other oils, juices, etc. contained in the interior space 38. The exterior surface is readily visible to users. Accordingly, indicia can be provided on the exterior surface 42 preferably in areas corresponding to the locations of the top panel 28 and the base panel 34. For example, various indicia can identify the food item 44 contained in the construct 10, provide instructions for proper use of the construct 10, and/or provide heating instructions for the food item 44.
As shown in
When the popcorn kernels or other food item 44 are to be heated, the construct 10 is placed on a platform in a microwave oven and is oriented with the base panel 34 and microwave susceptor film 50 supported on the platform and the popcorn kernels and optional oil-producing substance supported on the base panel 34, including the microwave susceptor film 50. The microwave susceptor film 50 is functional to receive microwave energy from the microwave oven and to apply heat to the popcorn kernels or other food item 44 and the optional oil-producing substance 46 in the construct 10. As the popcorn kernels are heated and pop, gases are generated in the interior space 38 of the construct 10. The popped kernels also increase in volume and begin to fill the interior space 38. Accordingly, as shown in
The example construct 10 and the volume of the interior space 38 are made expandable by having each of the first and second side panels 22 of the construct 10 comprise a foldable and expandable gusset structure. As shown in
As shown in
As the popcorn kernels or other food item 44 and the optional oil- producing substance 46 are heated in a microwave, the kernels pop, gases are generated, and the popped kernels begin to expand and fill the interior space 38. As shown in
It will be appreciated that while one example of a suitable gusset structure is described, smaller or larger gusset structures comprising fewer or more fold areas 24 and fold lines 26 may be used depending on the degree to which it is desired for the construct 10 to be expandable. Further, the gusset structures may occupy a greater or smaller portion of the first and second side panels 22. Still further, the gusset structures may be included in both the first and second side panels 22 or only in one of the side panels 22. All such variations are contemplated and are thus intended to be included within the scope of the present disclosure.
It also will be appreciated that during the heating process, at least a portion of the popcorn kernels or other food item 44, the oil-producing substance 46 if present, and/or other oils, oil-containing liquids, and/or juices resulting from heating the food item 44 are likely to remain or come in contact with areas of the interior surface 40 that correspond to the base panel 34 and the gussets of the side panels 22 that are adjacent to the base panel 34, including one or more fold areas 24 and fold lines 26. Accordingly, these areas are at increased risk of being penetrated and of leakage occurring. As described further below, the microwave susceptor film 50 is preferably configured and arranged in the base panel 34 and areas of the side panels 22 that are near or adjacent to the base panel 34 to resist penetration into and through the fibrous material of the construct 10 by such oils, liquids, and/or other juices in these locations.
As shown in
Accordingly, during the manufacturing process of the construct 10, the first end portion seal 14 initially may be adhered closed continuously or discontinuously across all or a portion of the distance it extends between the first and second side panels 22 with an appropriate non-toxic food grade sealant. In at least one portion of the seal 14, the sealant will preferably be thinner or otherwise less adherent so that as the popcorn kernels pop and the bag expands, the forces acting to pull the seal 14 open will overcome the sealing force of the temporary sealant and produce or expand the top opening 16 in the seal 14 to allow the gases to escape. The sealing force provided by the temporary sealant to the remainder of the seal 14 is preferably weak enough so that when the heating process is completed, a consumer can easily expand the top opening 16 and open the seal 14 to gain access to the contents of the construct 10.
In contrast to the first end portion seal 14, the second end portion seal 20 is preferably permanently sealed with a suitable non-toxic food grade sealant. It will be appreciated however that instead of the first end portion seal 14 being provided with a first end portion opening 16 for venting gases and accessing the contents of the construct 10, the second end portion seal 20 may be provided with an opening in the same manner and for the same uses. Both variations are contemplated and are considered to be within the scope of the disclosure herein.
For the reasons explained herein, the fibrous material from which the construct 10 is made preferably is not treated with a fluorocarbon (FC)-containing chemical to provide resistance to oil and grease penetration. However, one or more surfaces of the fibrous material can be treated, coated, or otherwise provided with a thin layer or coating of a non-toxic oil-resistant substance such as a wax or waxy substance in one or more selected areas 32 to help resist oil and grease penetration in those areas.
For example, a coating of such a substance can be applied to the interior surface 40 of the inner layer 64 of fibrous material in one or more selected areas 32, e.g., areas that correspond to the fold areas 24 and fold lines 26 in side panels 22, that may be more susceptible to oil and grease penetration than other areas. If used, the substance is preferably provided in areas 32 where the microwave susceptor film 50 is not present. The substance thus provides protection against penetration of the fibrous material in these areas in addition to the microwave susceptor film 50 as described herein. For example,
As further shown in
It will be appreciated that while the example embodiment of the construct 10 has a generally box-like configuration with four substantially rectangular panels, other configurations are also possible and will benefit from the features disclosed herein. For example, an alternative configuration could have a substantially circular or otherwise rounded base panel 34 with a single continuous side panel 22 that extends substantially around the periphery the base panel 34. The side panel 22 could be non-expandable, expandable with a plurality of defined fold areas 24, or even expandable without defined fold areas 24. This and other alternative configurations that are consistent with and can employ one or more of the various features described herein are contemplated and considered to be within the scope of the disclosure.
C. Microwave Susceptor Film.
As shown in
The microwave susceptor film 50 preferably comprises a thin film of non-toxic food grade material that is resistant to penetration by oil, grease, and other oil-containing juices and liquids. In addition, the microwave susceptor film 50 preferably comprises an environmentally friendly, biodegradable cellulosic material, most preferably a thin cellophane film. Other thin film materials are also suitable, including thermoplastic polymers such as polyethylene terephthalate (also known as PET or polyester), various other polyesters, and the like, however these materials are less preferred because they are not as environmentally friendly or biodegradable as cellulose-based thin films like cellophane.
The microwave susceptor film 50 has a first surface and a second surface that is arranged opposite to the first surface. A microwave interactive material 52 is present on one of the first and second surfaces. When the microwave susceptor film 50 is laminated with the fibrous material, the microwave interactive material 52 preferably is adjacent to and in contact with the inner layer 64 of the fibrous material. As described further herein, the microwave interactive material 52 occupies only a portion of one of the first and second surfaces and not the entire area of the surface.
The microwave interactive material 52 preferably comprises a thin coating of aluminum or another suitable metal. Alternatively, the microwave interactive material 52 can comprise certain ceramic or other materials that are capable of converting microwave energy to thermal energy. In the case of a metal material, such as aluminum, the microwave interactive material 52 can be applied directly to a surface of the microwave susceptor film 50 by spray coating, vacuum deposition, direct printing, or another suitable process. Such processes may also include de-metallization processes. Although in the present example embodiment such processes are less preferred, it is contemplated that such processes may be more useful in other embodiments and therefore both direct application processes and de-metallization processes are intended to be encompassed within the scope of the present disclosure.
Similarly, in the present example embodiment, i.e., a microwave popcorn bag, the microwave interactive material 52 need not be patterned. However, it is contemplated that a patterned microwave interactive material 52 could be useful in other applications involving other types of food items 44 and other types of constructs 10. Accordingly, both unpatterned and patterned microwave interactive material 52 is intended to be encompassed within the scope of the present disclosure.
The microwave interactive material 52 functions to receive microwaves from a microwave source, e.g., a microwave oven, and to convert the microwave energy to heat. Accordingly, the construct 10 can be placed in a microwave oven with the base panel 34 supported on a platform in the oven and the popcorn kernels or other food item 44 and optional oil-producing substance 46 to be heated supported on and in contact with the base panel 34 above the microwave susceptor film 50 as described herein. When the microwave source is activated, the microwave interactive material 52 absorbs the microwave energy, converts it to heat, and applies the heat to the popcorn kernels or other food item 44 and to the optional oil-producing substance 46.
The microwave susceptor film 50 also functions to resist oils, grease, etc. from the popcorn or other food item 44 and the optional oil-producing substance 46 that are contained in the construct 10, as well as oils, juices, etc. that may be produced during a heating process, from penetrating into and through the fibrous material of the construct 10 during transit, storage, and use of the construct 10. Accordingly, as described further herein, the microwave susceptor film 50 is preferably configured to be present in the areas of the construct 10 in which such oils, grease, etc. are likely to be in contact with the fibrous material and where the fibrous material is more susceptible to penetration and leakage, e.g., the base panel 34 and portions of the side panels 22 that are near or adjacent to the base panel 34.
As shown generally in
Also as described generally above and as shown in detail in
The portion of the microwave susceptor film 50 that includes the microwave interactive material 52 is contained completely in the base panel 34. The microwave interactive material 52 does not cross any fold lines 26 and does not extend into the side panels 22 of the construct 10. The reason is that the presence of microwave interactive material 52 in folded or creased areas of the construct 10 could concentrate too much heat in those areas which could result in burning of the popcorn or other food item 44 in those areas and possible charring or burning of the fibrous material. However, it is preferred to maximize the distance the microwave interactive material 52 extends laterally in the base panel 34 between the first and second side panels 22 without crossing the fold lines 26 between the base panel 34 and first and second side panels 22. That is preferably accomplished by tapering, fading or thinning the microwave interactive material 52 on the surface of the microwave susceptor film 50 at or near its opposite first and second side edges until no microwave interactive material remains near or at the fold lines 26. In other words, only the oil-resistant material, e.g., cellophane, of the microwave susceptor film 50 remains in those areas.
In the example embodiment of
Also, in the example embodiment shown in
As described above, in use the base panel 34 of the construct 10 is supported on a platform in a microwave oven. As the microwave interactive material 52 of the microwave susceptor film 50 receives microwaves and applies heat to the popcorn or other food item 44 and optionally to the oil-producing substance 46 in the construct 10, the fold areas 24 of the gussets in the opposed first and second side panels 22 of the construct 10 begin to unfold outward along the fold lines 26 as the construct 10 expands. As the fold areas 24 fold outward, the microwave susceptor film 50 forms an elongated substantially U-shaped tray structure within the construct 10 as best shown in
It will be appreciated that although a particular example embodiment of the microwave susceptor film 50 is described, the microwave susceptor film 50 and its components can have different shapes and sizes than described, and can have different orientations and arrangements in the construct 10 than described provided that they are consistent with performing the functions and achieving the objectives described herein. All such variations are thus intended to be encompassed within the scope of the present disclosure.
D. Roll Stock.
As described above, the example construct 10 in the form of a microwave popcorn bag or shell is preferably constructed of a single piece of laminated fibrous material. As shown in
All of the components for constructing a single construct 10 are contained in a substantially planar blank 11 as shown in
Cut lines 68 are present at spaced intervals in the continuous roll stock 60 between sequential spaced areas that correspond to blanks 11 for single constructs 10. The roll stock 60 can be unwound from a reel or roller or can be fed otherwise. The sequential spaced areas that correspond to blanks 11 for individual constructs 10 are cut from the continuous roll at the cut lines 68, and the resulting single pieces of laminated material corresponding to individual constructs 10 can then be fed to an assembly line or to one or more individual work stations where the individual constructs 10 can be constructed.
As shown in
It will be appreciated that while the inner and outer layers 62, 64 of fibrous material preferably will be continuous, the microwave susceptor film 50 may or may not be continuous.
Once a piece of the multi-layer laminate material corresponding to a single construct 10 is cut from the continuous roll stock 60, it can be used to make a finished construct 10. For example, referring to
Opposing surfaces of the top panel 28 and the base panel 34 near or at the second end portion 18 of the construct 10 are brought together to form the second end portion seal 20 and are permanently adhered at adhesive areas 66 with a suitable non-toxic food grade permanent adhesive. The popcorn kernels or other food item 44 and optional oil producing substance 46 are introduced into the interior space 38 through the open first end portion 12 of the construct 10 and are preferably placed on the interior surface 40 of the base panel 34 of the construct atop the microwave susceptor film 50 as shown in
The opposing surfaces of the top panel 28 and the base panel 34 near or at the first end portion 12 of the construct 10 are then brought together to form the first end portion seal 14 and potentially a first end opening 16 and are temporarily adhered at adhesive areas 66 along all or a portion of the length of the seal with a suitable non-toxic food grade temporary adhesive. With the first end portion 12 sealed, the construct 10 is complete and the interior space 38 and the contents of the construct 10 are isolated from the external environment. If desired, the first end portion 12 and the second end portion 18 of the completed construct 10 may be folded inwardly over the top panel 28 or the base panel 34, for example along the horizontal dashed fold lines shown in
E. Operation of Preferred Embodiment.
In describing an example use of an example embodiment of the construct 10, it is assumed that the construct 10 is in the form of a microwave popcorn bag and that construction of the construct 10 has been previously completed as described above. To the extent the construct 10 has been folded into a more compact form as described above, the construct 10 is first unfolded into substantially the form shown in
While the microwave oven is activated, the microwave interactive material 52 of the microwave susceptor film 50 receives microwave energy, converts the microwave energy to heat, and applies the heat to the popcorn kernels and oil-producing substance 46 in the interior space 38 of the construct 10. As the popcorn kernels and oil-producing substance 46 heat up, the kernels begin to pop, producing gases in the interior space 38 of the construct 10 and filling the interior space 38. The gases are allowed to vent at least partially through the first end portion opening 16 in the first end portion seal 14 and the outward forces produced in the interior space 38 cause the folding areas 24 of the gussets of the first and second side panels 22 to unfold outwardly and the construct 10 to expand as described herein and as shown in
As the construct 10 expands, the microwave susceptor film 50 forms a substantially U-shaped tray on the base panel 34 and along portions of the first and second side panels 22 as shown in
The microwave oven can remain activated for a period of time suitable to cause substantially all of the popcorn kernels to pop. Upon completion of the heating process, the first end portion opening 16 can be expanded and the popcorn can be accessed and removed from the interior space 38 if desired for consumption.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar to or equivalent to those described herein can be used in the practice or testing of the various embodiments of the present disclosure, suitable methods and materials are described above. All patent applications, patents, and printed publications cited herein are incorporated herein by reference in their entireties, except for any definitions, subject matter disclaimers or disavowals, and except to the extent that the incorporated material is inconsistent with the express disclosure herein, in which case the language in this disclosure controls. The various embodiments of the present disclosure may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the various embodiments in the present disclosure be considered in all respects as illustrative and not restrictive. Any headings utilized within the description are for convenience only and have no legal or limiting effect.
Number | Name | Date | Kind |
---|---|---|---|
3066844 | Moore | Dec 1962 | A |
4015085 | Woods | Mar 1977 | A |
4036423 | Gordon | Jul 1977 | A |
4038425 | Brandberg | Jul 1977 | A |
4210674 | Mitchell | Jul 1980 | A |
4268738 | Flautt, Jr. | May 1981 | A |
4279933 | Austin | Jul 1981 | A |
4448309 | Roccaforte | May 1984 | A |
4553010 | Bohrer | Nov 1985 | A |
4641005 | Seiferth | Mar 1987 | A |
4678882 | Bohrer | Jul 1987 | A |
4734288 | Engstrom | Mar 1988 | A |
4825025 | Seiferth | Apr 1989 | A |
4861958 | Bohrer | Aug 1989 | A |
5008024 | Watkins | Apr 1991 | A |
5097107 | Watkins | Mar 1992 | A |
5214257 | Riskey | May 1993 | A |
5334820 | Risch | Aug 1994 | A |
5871790 | Monier | Feb 1999 | A |
6320172 | Watkins | Nov 2001 | B1 |
6586715 | Watkins | Jul 2003 | B2 |
7022955 | Watkins | Apr 2006 | B2 |
10589918 | DeVerney | Mar 2020 | B2 |
20090061053 | Gaylor | Mar 2009 | A1 |
20200115139 | Birchmeier | Apr 2020 | A1 |
20210086976 | France | Mar 2021 | A1 |
20210387788 | Gorman | Dec 2021 | A1 |
Number | Date | Country |
---|---|---|
0320294 | Jun 1989 | EP |
0205304 | Mar 1991 | EP |
0451530 | Oct 1991 | EP |
0317203 | Feb 1993 | EP |
1399151 | Apr 1965 | FR |
841015 | Jul 1960 | GB |
2046060 | Nov 1980 | GB |
9115096 | Oct 1991 | WO |
9636546 | Nov 1996 | WO |