CA1239129A - Method for increasing the volumetric yield of microwave cooked popcorn - Google Patents
Method for increasing the volumetric yield of microwave cooked popcornInfo
- Publication number
- CA1239129A CA1239129A CA000465535A CA465535A CA1239129A CA 1239129 A CA1239129 A CA 1239129A CA 000465535 A CA000465535 A CA 000465535A CA 465535 A CA465535 A CA 465535A CA 1239129 A CA1239129 A CA 1239129A
- Authority
- CA
- Canada
- Prior art keywords
- tube
- bag
- charge
- popcorn
- tubes
- 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
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- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Food Science & Technology (AREA)
- Mechanical Engineering (AREA)
- Grain Derivatives (AREA)
- Package Specialized In Special Use (AREA)
Abstract
Abstract of the Disclosure A method is described of filling and sealing a popcorn package. A
flexible bag is provided which may be formed from flexible sheet material such as paper having longitudinally extending gussets in which the in-folded portions of the gussets approach each other closely to divide the bag into a pair of collateral tubes communicating together along a central line. The bag is held in an upright position with one of the tubes in a collapsed state while the other is expanded. The expanded tube has a smaller cross section than the other tube. A charge of fat and corn is introduced into the tube of smaller cross section through its open top. Preferably, a means is provided for collapsing the tube of smaller cross section transversely at a point below the center of the bag but above the bottom end of the bag to maintain the charge at the center of the bag and in the smaller tube. The bag is then sealed. During popping in a microwave oven, microwave energy is absorbed efficiently to achieve a popped volume about 10% to 15% greater than an equivalent package with tubes of equal cross section. The popcorn passes during heating from the smaller tube to the larger tube as the bag expands during the popping operation.
flexible bag is provided which may be formed from flexible sheet material such as paper having longitudinally extending gussets in which the in-folded portions of the gussets approach each other closely to divide the bag into a pair of collateral tubes communicating together along a central line. The bag is held in an upright position with one of the tubes in a collapsed state while the other is expanded. The expanded tube has a smaller cross section than the other tube. A charge of fat and corn is introduced into the tube of smaller cross section through its open top. Preferably, a means is provided for collapsing the tube of smaller cross section transversely at a point below the center of the bag but above the bottom end of the bag to maintain the charge at the center of the bag and in the smaller tube. The bag is then sealed. During popping in a microwave oven, microwave energy is absorbed efficiently to achieve a popped volume about 10% to 15% greater than an equivalent package with tubes of equal cross section. The popcorn passes during heating from the smaller tube to the larger tube as the bag expands during the popping operation.
Description
The invention relates to the cooking of packaged foods and to a method for popping popcorn with microwave energy.
In recent years several manufacturers have begun distributing popcorn in gusted paper bags. The corn is popped by placing the entire bag in a microwave oven. The corn is heated with microwave energy while it remains in the bag. As the corn pops, the bag expands to accommodate the popped kernels.
One of the shortcomings of commercial products has been the problem of maintaining the best possible volumetric yields. The 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 measuring the total volume.
These 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 of less than maximum volume. In work leading to the present invention it was discovered that the food product in the popping container Jan itself interfere ~,~ . ' with the bag expansion. U.S. patents 3,973,045 and 3,835,280 are representative of `. thy prior art. As shown, for example, in U.S. patent 3,973,045, Figures 2 and 3, the charge is distributed throughout the full cross-section of the bag. The same home- I:
eons distribution is shown in U.S. patent 3,835,280, Figures 3 and 4. These packages do not, when heated, achieve maximum potential volumetric yields.
The present invention provides a package and method for improving the volumetric yield of popcorn distributed and popped in containers of the type described.
he present invention also provides the above improvements without substantially increasing costs.
The invention again provides an effective way to reliably position a charge of corn and fat within a package :
so as to increase volumetric yields.
A
:
The present invention further provides a method of increasing volumetric yields of popped corn by positioning the charge of unpopped corn within the bag and oven in a new way.
The present invention again provides a bag of spew coal configuration that will improve volumetric yields and promote bag expansion when used as a container for popping popcorn within a microwave oven.
The invention further provides an improved package of unique configuration containing a charge of unpopped pop-corn and fat placed in a predetermined position within the package which cooperates with the package configuration to improve volumetric yields of microwave popped corn.
According to one aspect thereof the present invent lion provides a method of filling and sealing a popcorn bag comprising, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a rota-lively large *ace panel on one side, a narrower face panel on the other side and sections of interconnecting folded gusset I material projecting centrally between the side edges of the first and second panels with the centrally projecting gussets approaching each other closely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section, and the other relatively small in cross-sec-lion, placing a charge of fat and corn substantially entirely within the tube of smaller cross-section, and maintaining the other tube substantially free of fat and corn and sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller-cross section and centrally thereof, said tubes being in communique-lion with each other between the gussets whereby when the bag containing the popcorn is heated within a microwave oven by
In recent years several manufacturers have begun distributing popcorn in gusted paper bags. The corn is popped by placing the entire bag in a microwave oven. The corn is heated with microwave energy while it remains in the bag. As the corn pops, the bag expands to accommodate the popped kernels.
One of the shortcomings of commercial products has been the problem of maintaining the best possible volumetric yields. The 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 measuring the total volume.
These 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 of less than maximum volume. In work leading to the present invention it was discovered that the food product in the popping container Jan itself interfere ~,~ . ' with the bag expansion. U.S. patents 3,973,045 and 3,835,280 are representative of `. thy prior art. As shown, for example, in U.S. patent 3,973,045, Figures 2 and 3, the charge is distributed throughout the full cross-section of the bag. The same home- I:
eons distribution is shown in U.S. patent 3,835,280, Figures 3 and 4. These packages do not, when heated, achieve maximum potential volumetric yields.
The present invention provides a package and method for improving the volumetric yield of popcorn distributed and popped in containers of the type described.
he present invention also provides the above improvements without substantially increasing costs.
The invention again provides an effective way to reliably position a charge of corn and fat within a package :
so as to increase volumetric yields.
A
:
The present invention further provides a method of increasing volumetric yields of popped corn by positioning the charge of unpopped corn within the bag and oven in a new way.
The present invention again provides a bag of spew coal configuration that will improve volumetric yields and promote bag expansion when used as a container for popping popcorn within a microwave oven.
The invention further provides an improved package of unique configuration containing a charge of unpopped pop-corn and fat placed in a predetermined position within the package which cooperates with the package configuration to improve volumetric yields of microwave popped corn.
According to one aspect thereof the present invent lion provides a method of filling and sealing a popcorn bag comprising, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a rota-lively large *ace panel on one side, a narrower face panel on the other side and sections of interconnecting folded gusset I material projecting centrally between the side edges of the first and second panels with the centrally projecting gussets approaching each other closely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section, and the other relatively small in cross-sec-lion, placing a charge of fat and corn substantially entirely within the tube of smaller cross-section, and maintaining the other tube substantially free of fat and corn and sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller-cross section and centrally thereof, said tubes being in communique-lion with each other between the gussets whereby when the bag containing the popcorn is heated within a microwave oven by
- 2 -~7~3~
the application of microwave energy, the popcorn will pus from the smaller tube to the larger tube during popping within the bag as the bag expands to achieve a popped volume increase on the order of 10% to 15~ or more compared to an equivalent package with tubes of equal cross-section. Suitably prior to filling, one of said tubes is maintained in a collapsed condo lion while the other said tube is expanded to an open condo-lion and the charge is thereafter introduced into the open tube.
lo In another aspect thereof the present invention pro-vises a method of filling and sealing a popcorn bag comprise - in, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a relatively Jo large face panel on one side, a narrower face panel on the ` other side and sections of interconnecting folded gusset mate-fiat projecting centrally between the side edges of the first and second panels with the centrally projecting russets approaching each other closely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section and the other relatively small in cross-section, holding the bag in an upright position, opening the smaller tube at least at the top, inserting a charge of corn and fat into the smaller tube while in an open condition and maintain in the other tube substantially free of fat and corn and sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller cross-section and centrally thereof, said tubes being in communication with each other between the gussets whereby when the bag containing the popcorn is heated with a microwave oven by the application of microwave energy, the popcorn will pass from the smaller tube to the larger tube during popping
the application of microwave energy, the popcorn will pus from the smaller tube to the larger tube during popping within the bag as the bag expands to achieve a popped volume increase on the order of 10% to 15~ or more compared to an equivalent package with tubes of equal cross-section. Suitably prior to filling, one of said tubes is maintained in a collapsed condo lion while the other said tube is expanded to an open condo-lion and the charge is thereafter introduced into the open tube.
lo In another aspect thereof the present invention pro-vises a method of filling and sealing a popcorn bag comprise - in, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a relatively Jo large face panel on one side, a narrower face panel on the ` other side and sections of interconnecting folded gusset mate-fiat projecting centrally between the side edges of the first and second panels with the centrally projecting russets approaching each other closely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section and the other relatively small in cross-section, holding the bag in an upright position, opening the smaller tube at least at the top, inserting a charge of corn and fat into the smaller tube while in an open condition and maintain in the other tube substantially free of fat and corn and sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller cross-section and centrally thereof, said tubes being in communication with each other between the gussets whereby when the bag containing the popcorn is heated with a microwave oven by the application of microwave energy, the popcorn will pass from the smaller tube to the larger tube during popping
- 3 -3~3.'~
within the bag as the bag expands to achieve a pepped volume increase on the order of 10% to 15% or more compared to an equivalent package with tubes of equal cross-sectiorl. Suit-ably the smaller tube is cut shorter at one end than the larger tube, the bags are advanced continuously in an upright position and a means is provided to retain the large tube in a collapsed condition, the smaller tube is held open a its upper end and the food product is introduced into the open end of the small tube.
lo In a further aspect thereof the present invention provides a method of filling and sealing a popcorn bag come prosing, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a first rota-lively large face panel on one side, a second narrower face panel on the other side and sections ox interconnecting folded gusset material projecting centrally between the side edges of the first and second panels with the centrally projecting gust sets approaching each other closely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section and the other relatively small in cross-section, during the filling operation maintaining the tube of relatively large cross section in a collapsed condo-lion and the other tube in an expanded condition, holding the smaller tube in a collapsed condition transversely at a point below the center of the bag but spaced upwardly from the both Tom thereof, holding the bag in an upright position and inserting a charge of corn and fat into the smaller tube while the small tube is in an open condition with a portion thereof collapsed to thereby temporarily maintain the charge at the center of the bag during the filling operation and in only one tube, sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller cross-section and centrally thereof, the charge of popcorn and fat is thereby confined substantially entirely in the tube of smaller cross-section, said tubes being in comma-nication with each other between the gussets whereby when thy bag containing the popcorn is heated within a microwave oven by the application of microwave energy, the popcorn will pass from the smaller tube to the larger tube during popping within the bag as the bag expands to achieve a popped volume increase I on the order of 10% to 15% or more compared to an equivalent package with tubes of equal cross-section.
In another aspect thereof the present invention pro-vises a method of filling and sealing a popcorn bag comprise in: providing a bag for storing and shipping popcorn, said bag being formed from flexible sheet material transparent to microwave energy and having first and second rectangular face panels each having parallel transversely extending top and bottom edges and parallel vertically extending side edges, sections of interconnecting folded gusset material projecting I centrally between the side edges of the face panels with the centrally projecting gussets approaching each other closely enough to divide the bag into first and second collateral tubes, holding the bag in an upright position with the top edges of the panels uppermost, expanding the first tube to open said tube by drawing the first face panel away from the second collateral tube, maintaining the second collateral tube .
in a collapsed condition by keeping said second panel in con-tact with adjacent sections of gusset material, inserting a charge of popcorn and fat into the expanded tube by allowing the charge to fall into the tube from its open end by gravity, the close proximity of toe second panel of the bag and the gussets preventing transfer of the corn and fat during the .~''' .
filling operation into the collapsed tube, sealing the bag and maintaining the bag in a collapsed condition during shipment and storage to prevent expansion and outward folding of the gussets to thereby hold the charge of fat and corn sub Stan-tidally entirely within said first tube until the corn is popped, the tubes being in communication with each other between the gussets whereby when the bag containing the pop-corn is heated within a microwave oven by the application of microwave energy the popcorn will transfer from the first tube to the second tube during popping within the bag as the bag expands and the gussets move apart. Suitably the charge placed in said package comprises about 10 parts of corn for each 4 parts of fat and the package is sealed after the charge is inserted into the bag. Desirably the charge is dropped into the open tube and means is provided for preventing the charge from falling past a point located approximately inter-mediate top and bottom ends of the package. Suitably a fill-in spout which inserts said charge is provided and the fill-in spout is slid longitudinally of the bag into the open end I of said first tube. Preferably a suction cup is secured to said first tube and is moved in the direction proceeding away from the other tube to thereby open said first tube prior to filling. Suitably a bottom portion of said first tube is maintained in the collapsed position to thereby temporarily maintain the charge at the center ox the bag during the fill-in operation and in only the first tube, the charge of fat and corn thereby falling through the open end ox the first tube by gravity until striking the collapsed portion of the first tube whereby the charge is maintained intermediate the ends of the bag. Desirably a holding means is placed against said second tub suction cup means is engaged with the first panel and said suction cup is then moved away from the second - pa -, tube to expand the first tube while the second tube is kept in a collapsed condition by the holding means. Preferably a filling spout which inserts said charge is placed in proximity to the bag with its bottom end aligned with the upper free open end of said first tube. More preferably tabs are pro-voided on the filling spout and the tabs are engaged against the top edge of the gussets to hold them against the upper edge of said second tube.
Briefly, the invention provides a method for a pop-corn shipping package to be used for popping corn within a dual purpose shipping and popping container, e.g., a bag, with increased volumetric yields of popped corn. One aspect of the invention is the provision of a package formed from flexible sheet material of collateral tubular configuration, that is to say, comprising two parallel longitudinally extending sections communicating together at the center of the package. Sub Stan-tidally all of the charge of popcorn and fat is placed within one tubular section and the other is maintained free of pop-corn. The package filled in this manner is positioned with Jo the charge lowermost in the microwave oven. During popping the upper tubular section is free to expand as it fills with popcorn while the lower tubular section continues to hold unpopped corn and liquefied fat. Another aspect of the invent lion is the provision of a package as just described wherein one of the tubular bag sections is of a smaller cross-sec tonal size than the other. The charge of corn and fat is ; placed in the tubular section of the smallest diameter. In one practical embodiment of the invention the package come proses a gusted bag including a pair of face panels and interconnecting centrally projecting side gussets thereby defining the two tubular sections The first face panel is of greater width than the second face panel. Typically the area 5b -of the smaller face panel is about 18% to 50~ less than the area of the larger face panel.
The invention also discloses automated methods for filling packages in accordance with the invention in such a way as to properly locate the charge.
The present invention will be further illustrated by way of the accompanying drawings, in which:-Figure 1 is a perspective view of the package in accordance with the invention filled with 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-in;
Figure 4 is a partial side elevation Al view of the bag shown in Figure 3 as it appears in a flattened condition prior to willing;
Figure 5 is a perspective view of the package of I 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 ion a later stage in the popping cycle;
Figure 10 is a diagrammatic perspective view of one method of filling the bays in accordance with the invention;
Figure 11 is a partial perspective view of the top I; ' - 5c -I
of a modified form of bag in accordance with the invention showing another means of filling the bag;
Figure 12 is a vertical side elevation Al view of the filling operation illustrated in Figure 11;
Figure 13 is a perspective view of another method of filling the bags in accordance with the invention;
Figure 14 is a perspective view of another filling method;
Figure 15 is a horizontal cross-sectional view taken on line 15-15 of Figure 14;
Figure 16 is a perspective view illustrating still another method of filling bags in accordance with the invent lion; and Figure 17 is a graph relating the face areas to popped volume.
Figures 1 and 2 illustrate a form of the invention in which a package is employed having face panels of equal size. The embodiment of Figures 1 and 2 comprises a package 10 composed of a bag 12 formed from flexible sheet material such as paper and being of collateral tubular configuration, that is to say, being composed of a pair parallel longitude-natty extending tubes 14 and 16 which communicate with one another along a central longitudinal opening 18. The two par-allot tubes 14 and 16 are separated by longitudinally extend-in side indentions 20 and 22. When the package comprises a paper bag, the bag can be composed of first and second face panels 24 and 26, respectively of equal size, and the indent lions 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 comprise in a mixture of popcorn and fat is placed in the collateral a So -tube 16 while the tube 14 Is maintained subs~an~lally free from the charge ox popcorn and fat. By malntalnlng the charge sub-stantlally entirely In one of the collateral tubes, a surprising Increase In the volume of the popped corn will result. For exam-pie, In one test a volumetric of almost 10% was achieved. The placement of the charge can be thought of as being lateral, I.e.
closer to one face panel of the bag as opposed to the prior art In which the popcorn charge Is distributed homogeneously across the bag and usually Is divided almost equally between both tubes such that approximately half of the charge Boolean In tube 14 and half being In tube 16.
When the package Is heated to pop the corn, tube 16 containing the charge 32 Is preferably placed downwardly In the microwave oven. In to I s pus I lion panel 26 contacting the charge I faces downwardly and contacts the bottom wall of the cooking chamber of the microwave oven as will be described In more detail below In connection with Figure 6. 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.
Refer now to Table 1 which Illustrates the Improvement In volume of popped corn that can be achieved through the Invent 26 lion embodied In Figures 1 and 2. As can be seen, a volumetrlcIncrease In the popped corn of 9.4% was accomplished using the lateral placement of the charge as shown In Figures 1 and 2 come pared with the homogeneous or random placement of the charge throughout the entire cross section of the bag. It Is believed that even better results can be obtained than those shown In the table with optimum bag dimensions, corn varieties and popping conditions etc.
I
Popped Volume of Corn with Homoqenous : Placement vs. Lateral Placement of Kirk Homogeneous Placement (prior art) 1600 420cc Lateral Placement (Invention) 17~0 290cc volume Increase I
*700 watt microwave oven, cooking lime minutes, charge 3.5 oz.
at OF.
; Refer now to Figures 3 through 9 which Illustrate anon then form of the invention. As shown best In Figures 3 and 4, a package 40 Is provided comprising a bay formed From flexible sheet materials such as paper preferably with a greaseproof paper : 15 finer of suitable known construction and Including first and se a-on parallel collateral tubes 42 and 44 both of which extend ion-gltudlnally and communicate with one another along midline at 46.
:. The bag Is sealed by means of a bottom seal 48 and prior to fill-In Is open at the top I such that a charge of popcorn and fat I can be Introduced as shown In Flyer 5. After the charge has been Introduced, the top I Is sealed as shown at aye In Figure 6. It can be seen In Figures 3 and 4 that the collateral tubes 42 and 44 are separated by Indentations I and 56 and although . not essential to the Invention, the Indentations are conveniently formed by constructing the bag with longitudinally extending eon-tally projecting gussets at 54 and 56. The bag after being con-strutted will usually be flattened to the condition shown In Fig-: use 4 with the Innermost aspect of the gussets 54 and 56 compels-In folds Indicated by dotted fine aye and aye. Accordingly the bag Is provided with two lonyltudlnally extending face panels;
3 panel 58 and panel 60 which Is smaller In width and area than face panel I While size Is not critical It Is preferred that the panel 60 be about 18% to 50% smaller In area than the panel 58. Consequently tube 44 Is smaller In cross sections than tube 42. The term "cross section" heroin has reference to the tubes ,,~
I
' X ' .
I
when fur Ivy expanded to circular conFI0uratlon as shown In Figure 3. The bag Illustrated Is a tune type bag, that Is, a jag ore trot a continuous tube ox paper manufactured on a so called bag tuber and cut transversely at uniform In~ervais to define the top and bottom ends 50 and 48. The bag can however, be ox the pasted bottom type Wylie folding pane 15 at the top and bottom of the bag which are pasted shut aster the bag Is filled. It should be noted that the charge 52 Is placed approximately Intermediate to the ends of Tao bug as Stalin on Flyer S and 6. Al ton f I I I In and sealing the top 50 at soar the bag Is folder transversely at 62 and 64 to divide the bag roughly Into three equal sections For convenient shipment with the charge 52 In approximately the eon-ton 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 propped, the package I Is post-toned horizontally and placed In a microwave oven I with the panel 60 lacing downward. The charge 52 Is thus located adjacent the floor 69 of the cooking chamber 72 within oven 68. The microwave oven I which Is Itself entirely conventional, 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 F l guru 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, more and more of the charge 52 will pop and the package will become filled with popped kernels 74. The Invention results In a substantial Increase In volumetric yields as shown In Table 2 and Flogger 17.
A reduction of the bottom panel Jo to Z9.25 square Inches pro-dupes a 6X Increase In popped volume, a reduction to 24.75 square inches produces a 10% Increase and a reduction to 20.75 square Inches produces a 16% Increase in the popped volume of the corn.
This Is Illustrated graphically In Figure 7.
Popped Volume of Corn vs. Area of Bottom Face of Container Percent Reduction Percent awry of Faces Popped Volume of Bottom Face Increase In (sun. In.) of corn go Panel Area popped vol.
Top Bottom 35.75 35.75 1805 250 (None, both Panels equal) 35.7~ 2g.25 1920 220 I 6%
35.75 24.75 1990 190 31% 10%
35.7~ 20.75 2100 200 43% 16%
35.75 24.00 1980 210 33% 9%
Refer now to Figure 10 wherein the save numerals refer to correspondln~ parts Illustrated In Figures 3 through 9. As can be seen, the bags 60 have been foxed transversely along fine 62 and are located In an upright position during flown they are transferred laterally from left to fight In the figure using any of several well known filling machines that are commercially available. Thus the package 40 Is carried from left to rl~ht by means of a conveyor that is part of transfer and filling machine (not shown). In this form of the Invention the upper end of tube 44 Is shorter than tube 42. This Is accomplished by gutting off the top portion of tube 44 beginning at the marginal edges aye and aye ox the gussets 54 and 56. The upper edge of tube 42 slides within a downwardly opening U-shaped gulderall 76. This allows the tube 44 to be opened at the proper lime by means of a suction cup 78 which engages panels 60 and draws the panel away from panel I A flying spout 8 Is placed In proximity with each successl~e bag such that Its bottom end Is aligned with the upper open end of the small tube 44. As the bag passes beneath Lo f I I I In spout 80, a charge of popcorn and fat 52 Is Inserted and as can be seen, falls entirely within tube 44 so that the larger collateral tube 42 Is maintained substantially free of the charge of fat and popcorn. Tile transverse fold 62 maintains the charge 52 In approximately the center of the bag, that Is to say, Inter-mediate the ends 48 and I This function can be accomplished In other ways, e.g. with a clamp, placed on the bag. After filling, the top 50 the bag Is sealed In any conventional well known man-nor as by means of adhesive or heat sealing Refer now to F l gurus 1 1 and 12 which the same numbers refer to corresponding parts In the previous views. The package 40 Is the same as previously described expect that Instead of the entire upper end of tube 44 being sorter than tube 42, a cutout section 84 Is provided entirely within the panel 60. The cutout 84 may extend downwardly toward the bottom of the bag about 1/2 to 1 Inch to accommodate a filling spout 86 having tabs or lateral extensions 88 and 89 which engage the-uppermost edges of the gust sets 56 and 54 respectively as best seen In Figure 11 . The spout end Its extensions 88 and 89 hold the gussets on top of the bag against the upper edge of the larger tube 44 which Is In turn ` pressed against a ver$1cal plate or other surface which for sum-pllclty has not been shown In the figures. After the spout 86 nod the extensions engage the gussets, 54 and 56, the panel 60 Is pulled outwardly e.g. by a suction cup (not shown) to open tube 44. Once tube 44 Is opened, the charge of corn and fat Is dropped In the spout 86, and Is allowed to fall Into tube 44 thereby locating It In the desired position entirely within tube 44. The tube 42 which Is maintained In a flattened condition at this point will be substantially free of the food product.
Figure 13 Illustrates a similar flown method where the same numerals refer to corresponding parts. In this case a filling spout 90 Is used. Spout 90 Is not provided with tabs and I Is somewhat longer from top to bottom than spout 86. In this filling method, the lower open end 92 of the spout 90 Is Inserted ;
_ 10 --' Into tube 44 which us then drawn upwardly over the spout. As can be seen, this will open the tube I allowing the charge of corn and fat to be Introduced while the collateral tube 42 remains flattened and tree from any substantial quantity of the food product. It Is to be understood that In all of the embodiments of the Invention, Incldenta~ quantities of the food product may spill over Into the unfilled tube and that such Spy I lover which sometimes happens In high speed commercial production fines wow not depart from the spirit or scope ox the present Invention.
In Figures 14 and 15 a similar filling method Is shown except that no spout Is employed. In this case a pelf of penal-lot downwardly depending fixed retaining arms 94 and 96 supported from a stationary framework 98 hold the side edges of the flat-toned tube 42. A suction cup 100 enrages panel 60 and draws It away from panel 58 thereby expending the smaller collateral tube 44. The charge Is then dropped Into tube 44.
Flyer I shows a somewhat similar arrangement except that In this case panel I Is engaged by a stationary suction cupJ02 and a pelf of pincher arms 104 and 106 which enrage the 5 Ire edges of panel 60 are brought centrally towards one another In the direction shown by the arrows thereby.plnchlng the tube 44 to expand It for flailing. Once tube 44 has been expanded a shown In the Figure, the charge Is Introduced.
The charge 52 can be Introduced In many forms. For example the corn and fat can be Introduced separately or together and the fat may be either solid or heated till fluid. However, If solid, less transfer to the other tube will take place. One preferred form of the charge Is shown I n Figure 10. The charge Is composed of fat and corn generally In the shape of a doughnut lye. annular. It was found that the heat transfers to the food faster when It Is In this shape.
I
Bags may be manufactured by any known method but are preferably formed on a bag tuber. The folding shoes of the tuber should be arranged for all embodiments other than Figures 1 and 2 such that the gusset folds are formed In the prover location to make one face of the bag smaller than the other. The tube form-lung apparatus Is otherwise standard. A ~yplcal bag when folded flit no shown In Figures 1 through 9 may have Hewlett of 1Z~ and a width of l/2 n, Where panel 60 Is reduced In width It may be from about 4 to 4 1/2" wide. It was found that for each I
decrease In the area of one face the popped volume will Increase by about 3% (See Figure 17).
The charge 52 of popcorn and fat can have any known commercially acceptable formula preferably about 10 parts corn for each 4 parts of fat. One satisfactory formula used with the present Invention Is 68.5% corn, 27.6% Nat and 2.8% salt by weight. The fat comprises hydrogenated coconut oil having a molting point between about 80F to 130F. Packages are skipped f Rosen and maintained under reFrlDerated conditions prior to use.
Accorldngly It can be seen that the fat Is normally In solid form when below about 80F. The charge placed In the bag will there-fore remain In the position where It Is placed at the lime of filling.
While the reason for the success of the Invention In Improving volumetric yields Is not known with certainty, It Is believed that the lateral placement ox the charge described and the location of It adjacent to the bottom of the wall of the oven permits the bag to expand more easily as soon as gas and vapor Is ; 30 generated responsive to healing and even before the fat Is all melted. It Is also believed that the Invention as described In Figures other than 1 and 2 performs better than the prior art because the reduced panel size concentrates the charge and causes more of the corn to remain Immersed In the hot fat during the I cooking operation thereby promoting better heat transfer to the unpopped kernels. The narrower the smaller face panel Is made .
`
the greater will be the volume ox popped corn. Of course, the face dimensions cannot be reduced to such an extent that the package Is not capable of holding the volume of corn to be con-tanned In the package. Therefore reduction on the smaller panel area of less than 50% of the area of the large Panel Is not US-Al Ivy practical.
Many variations of the Invention within the scope of the appended claims will be apparent to those skilled In the art.
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within the bag as the bag expands to achieve a pepped volume increase on the order of 10% to 15% or more compared to an equivalent package with tubes of equal cross-sectiorl. Suit-ably the smaller tube is cut shorter at one end than the larger tube, the bags are advanced continuously in an upright position and a means is provided to retain the large tube in a collapsed condition, the smaller tube is held open a its upper end and the food product is introduced into the open end of the small tube.
lo In a further aspect thereof the present invention provides a method of filling and sealing a popcorn bag come prosing, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a first rota-lively large face panel on one side, a second narrower face panel on the other side and sections ox interconnecting folded gusset material projecting centrally between the side edges of the first and second panels with the centrally projecting gust sets approaching each other closely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section and the other relatively small in cross-section, during the filling operation maintaining the tube of relatively large cross section in a collapsed condo-lion and the other tube in an expanded condition, holding the smaller tube in a collapsed condition transversely at a point below the center of the bag but spaced upwardly from the both Tom thereof, holding the bag in an upright position and inserting a charge of corn and fat into the smaller tube while the small tube is in an open condition with a portion thereof collapsed to thereby temporarily maintain the charge at the center of the bag during the filling operation and in only one tube, sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller cross-section and centrally thereof, the charge of popcorn and fat is thereby confined substantially entirely in the tube of smaller cross-section, said tubes being in comma-nication with each other between the gussets whereby when thy bag containing the popcorn is heated within a microwave oven by the application of microwave energy, the popcorn will pass from the smaller tube to the larger tube during popping within the bag as the bag expands to achieve a popped volume increase I on the order of 10% to 15% or more compared to an equivalent package with tubes of equal cross-section.
In another aspect thereof the present invention pro-vises a method of filling and sealing a popcorn bag comprise in: providing a bag for storing and shipping popcorn, said bag being formed from flexible sheet material transparent to microwave energy and having first and second rectangular face panels each having parallel transversely extending top and bottom edges and parallel vertically extending side edges, sections of interconnecting folded gusset material projecting I centrally between the side edges of the face panels with the centrally projecting gussets approaching each other closely enough to divide the bag into first and second collateral tubes, holding the bag in an upright position with the top edges of the panels uppermost, expanding the first tube to open said tube by drawing the first face panel away from the second collateral tube, maintaining the second collateral tube .
in a collapsed condition by keeping said second panel in con-tact with adjacent sections of gusset material, inserting a charge of popcorn and fat into the expanded tube by allowing the charge to fall into the tube from its open end by gravity, the close proximity of toe second panel of the bag and the gussets preventing transfer of the corn and fat during the .~''' .
filling operation into the collapsed tube, sealing the bag and maintaining the bag in a collapsed condition during shipment and storage to prevent expansion and outward folding of the gussets to thereby hold the charge of fat and corn sub Stan-tidally entirely within said first tube until the corn is popped, the tubes being in communication with each other between the gussets whereby when the bag containing the pop-corn is heated within a microwave oven by the application of microwave energy the popcorn will transfer from the first tube to the second tube during popping within the bag as the bag expands and the gussets move apart. Suitably the charge placed in said package comprises about 10 parts of corn for each 4 parts of fat and the package is sealed after the charge is inserted into the bag. Desirably the charge is dropped into the open tube and means is provided for preventing the charge from falling past a point located approximately inter-mediate top and bottom ends of the package. Suitably a fill-in spout which inserts said charge is provided and the fill-in spout is slid longitudinally of the bag into the open end I of said first tube. Preferably a suction cup is secured to said first tube and is moved in the direction proceeding away from the other tube to thereby open said first tube prior to filling. Suitably a bottom portion of said first tube is maintained in the collapsed position to thereby temporarily maintain the charge at the center ox the bag during the fill-in operation and in only the first tube, the charge of fat and corn thereby falling through the open end ox the first tube by gravity until striking the collapsed portion of the first tube whereby the charge is maintained intermediate the ends of the bag. Desirably a holding means is placed against said second tub suction cup means is engaged with the first panel and said suction cup is then moved away from the second - pa -, tube to expand the first tube while the second tube is kept in a collapsed condition by the holding means. Preferably a filling spout which inserts said charge is placed in proximity to the bag with its bottom end aligned with the upper free open end of said first tube. More preferably tabs are pro-voided on the filling spout and the tabs are engaged against the top edge of the gussets to hold them against the upper edge of said second tube.
Briefly, the invention provides a method for a pop-corn shipping package to be used for popping corn within a dual purpose shipping and popping container, e.g., a bag, with increased volumetric yields of popped corn. One aspect of the invention is the provision of a package formed from flexible sheet material of collateral tubular configuration, that is to say, comprising two parallel longitudinally extending sections communicating together at the center of the package. Sub Stan-tidally all of the charge of popcorn and fat is placed within one tubular section and the other is maintained free of pop-corn. The package filled in this manner is positioned with Jo the charge lowermost in the microwave oven. During popping the upper tubular section is free to expand as it fills with popcorn while the lower tubular section continues to hold unpopped corn and liquefied fat. Another aspect of the invent lion is the provision of a package as just described wherein one of the tubular bag sections is of a smaller cross-sec tonal size than the other. The charge of corn and fat is ; placed in the tubular section of the smallest diameter. In one practical embodiment of the invention the package come proses a gusted bag including a pair of face panels and interconnecting centrally projecting side gussets thereby defining the two tubular sections The first face panel is of greater width than the second face panel. Typically the area 5b -of the smaller face panel is about 18% to 50~ less than the area of the larger face panel.
The invention also discloses automated methods for filling packages in accordance with the invention in such a way as to properly locate the charge.
The present invention will be further illustrated by way of the accompanying drawings, in which:-Figure 1 is a perspective view of the package in accordance with the invention filled with 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-in;
Figure 4 is a partial side elevation Al view of the bag shown in Figure 3 as it appears in a flattened condition prior to willing;
Figure 5 is a perspective view of the package of I 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 ion a later stage in the popping cycle;
Figure 10 is a diagrammatic perspective view of one method of filling the bays in accordance with the invention;
Figure 11 is a partial perspective view of the top I; ' - 5c -I
of a modified form of bag in accordance with the invention showing another means of filling the bag;
Figure 12 is a vertical side elevation Al view of the filling operation illustrated in Figure 11;
Figure 13 is a perspective view of another method of filling the bags in accordance with the invention;
Figure 14 is a perspective view of another filling method;
Figure 15 is a horizontal cross-sectional view taken on line 15-15 of Figure 14;
Figure 16 is a perspective view illustrating still another method of filling bags in accordance with the invent lion; and Figure 17 is a graph relating the face areas to popped volume.
Figures 1 and 2 illustrate a form of the invention in which a package is employed having face panels of equal size. The embodiment of Figures 1 and 2 comprises a package 10 composed of a bag 12 formed from flexible sheet material such as paper and being of collateral tubular configuration, that is to say, being composed of a pair parallel longitude-natty extending tubes 14 and 16 which communicate with one another along a central longitudinal opening 18. The two par-allot tubes 14 and 16 are separated by longitudinally extend-in side indentions 20 and 22. When the package comprises a paper bag, the bag can be composed of first and second face panels 24 and 26, respectively of equal size, and the indent lions 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 comprise in a mixture of popcorn and fat is placed in the collateral a So -tube 16 while the tube 14 Is maintained subs~an~lally free from the charge ox popcorn and fat. By malntalnlng the charge sub-stantlally entirely In one of the collateral tubes, a surprising Increase In the volume of the popped corn will result. For exam-pie, In one test a volumetric of almost 10% was achieved. The placement of the charge can be thought of as being lateral, I.e.
closer to one face panel of the bag as opposed to the prior art In which the popcorn charge Is distributed homogeneously across the bag and usually Is divided almost equally between both tubes such that approximately half of the charge Boolean In tube 14 and half being In tube 16.
When the package Is heated to pop the corn, tube 16 containing the charge 32 Is preferably placed downwardly In the microwave oven. In to I s pus I lion panel 26 contacting the charge I faces downwardly and contacts the bottom wall of the cooking chamber of the microwave oven as will be described In more detail below In connection with Figure 6. 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.
Refer now to Table 1 which Illustrates the Improvement In volume of popped corn that can be achieved through the Invent 26 lion embodied In Figures 1 and 2. As can be seen, a volumetrlcIncrease In the popped corn of 9.4% was accomplished using the lateral placement of the charge as shown In Figures 1 and 2 come pared with the homogeneous or random placement of the charge throughout the entire cross section of the bag. It Is believed that even better results can be obtained than those shown In the table with optimum bag dimensions, corn varieties and popping conditions etc.
I
Popped Volume of Corn with Homoqenous : Placement vs. Lateral Placement of Kirk Homogeneous Placement (prior art) 1600 420cc Lateral Placement (Invention) 17~0 290cc volume Increase I
*700 watt microwave oven, cooking lime minutes, charge 3.5 oz.
at OF.
; Refer now to Figures 3 through 9 which Illustrate anon then form of the invention. As shown best In Figures 3 and 4, a package 40 Is provided comprising a bay formed From flexible sheet materials such as paper preferably with a greaseproof paper : 15 finer of suitable known construction and Including first and se a-on parallel collateral tubes 42 and 44 both of which extend ion-gltudlnally and communicate with one another along midline at 46.
:. The bag Is sealed by means of a bottom seal 48 and prior to fill-In Is open at the top I such that a charge of popcorn and fat I can be Introduced as shown In Flyer 5. After the charge has been Introduced, the top I Is sealed as shown at aye In Figure 6. It can be seen In Figures 3 and 4 that the collateral tubes 42 and 44 are separated by Indentations I and 56 and although . not essential to the Invention, the Indentations are conveniently formed by constructing the bag with longitudinally extending eon-tally projecting gussets at 54 and 56. The bag after being con-strutted will usually be flattened to the condition shown In Fig-: use 4 with the Innermost aspect of the gussets 54 and 56 compels-In folds Indicated by dotted fine aye and aye. Accordingly the bag Is provided with two lonyltudlnally extending face panels;
3 panel 58 and panel 60 which Is smaller In width and area than face panel I While size Is not critical It Is preferred that the panel 60 be about 18% to 50% smaller In area than the panel 58. Consequently tube 44 Is smaller In cross sections than tube 42. The term "cross section" heroin has reference to the tubes ,,~
I
' X ' .
I
when fur Ivy expanded to circular conFI0uratlon as shown In Figure 3. The bag Illustrated Is a tune type bag, that Is, a jag ore trot a continuous tube ox paper manufactured on a so called bag tuber and cut transversely at uniform In~ervais to define the top and bottom ends 50 and 48. The bag can however, be ox the pasted bottom type Wylie folding pane 15 at the top and bottom of the bag which are pasted shut aster the bag Is filled. It should be noted that the charge 52 Is placed approximately Intermediate to the ends of Tao bug as Stalin on Flyer S and 6. Al ton f I I I In and sealing the top 50 at soar the bag Is folder transversely at 62 and 64 to divide the bag roughly Into three equal sections For convenient shipment with the charge 52 In approximately the eon-ton 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 propped, the package I Is post-toned horizontally and placed In a microwave oven I with the panel 60 lacing downward. The charge 52 Is thus located adjacent the floor 69 of the cooking chamber 72 within oven 68. The microwave oven I which Is Itself entirely conventional, 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 F l guru 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, more and more of the charge 52 will pop and the package will become filled with popped kernels 74. The Invention results In a substantial Increase In volumetric yields as shown In Table 2 and Flogger 17.
A reduction of the bottom panel Jo to Z9.25 square Inches pro-dupes a 6X Increase In popped volume, a reduction to 24.75 square inches produces a 10% Increase and a reduction to 20.75 square Inches produces a 16% Increase in the popped volume of the corn.
This Is Illustrated graphically In Figure 7.
Popped Volume of Corn vs. Area of Bottom Face of Container Percent Reduction Percent awry of Faces Popped Volume of Bottom Face Increase In (sun. In.) of corn go Panel Area popped vol.
Top Bottom 35.75 35.75 1805 250 (None, both Panels equal) 35.7~ 2g.25 1920 220 I 6%
35.75 24.75 1990 190 31% 10%
35.7~ 20.75 2100 200 43% 16%
35.75 24.00 1980 210 33% 9%
Refer now to Figure 10 wherein the save numerals refer to correspondln~ parts Illustrated In Figures 3 through 9. As can be seen, the bags 60 have been foxed transversely along fine 62 and are located In an upright position during flown they are transferred laterally from left to fight In the figure using any of several well known filling machines that are commercially available. Thus the package 40 Is carried from left to rl~ht by means of a conveyor that is part of transfer and filling machine (not shown). In this form of the Invention the upper end of tube 44 Is shorter than tube 42. This Is accomplished by gutting off the top portion of tube 44 beginning at the marginal edges aye and aye ox the gussets 54 and 56. The upper edge of tube 42 slides within a downwardly opening U-shaped gulderall 76. This allows the tube 44 to be opened at the proper lime by means of a suction cup 78 which engages panels 60 and draws the panel away from panel I A flying spout 8 Is placed In proximity with each successl~e bag such that Its bottom end Is aligned with the upper open end of the small tube 44. As the bag passes beneath Lo f I I I In spout 80, a charge of popcorn and fat 52 Is Inserted and as can be seen, falls entirely within tube 44 so that the larger collateral tube 42 Is maintained substantially free of the charge of fat and popcorn. Tile transverse fold 62 maintains the charge 52 In approximately the center of the bag, that Is to say, Inter-mediate the ends 48 and I This function can be accomplished In other ways, e.g. with a clamp, placed on the bag. After filling, the top 50 the bag Is sealed In any conventional well known man-nor as by means of adhesive or heat sealing Refer now to F l gurus 1 1 and 12 which the same numbers refer to corresponding parts In the previous views. The package 40 Is the same as previously described expect that Instead of the entire upper end of tube 44 being sorter than tube 42, a cutout section 84 Is provided entirely within the panel 60. The cutout 84 may extend downwardly toward the bottom of the bag about 1/2 to 1 Inch to accommodate a filling spout 86 having tabs or lateral extensions 88 and 89 which engage the-uppermost edges of the gust sets 56 and 54 respectively as best seen In Figure 11 . The spout end Its extensions 88 and 89 hold the gussets on top of the bag against the upper edge of the larger tube 44 which Is In turn ` pressed against a ver$1cal plate or other surface which for sum-pllclty has not been shown In the figures. After the spout 86 nod the extensions engage the gussets, 54 and 56, the panel 60 Is pulled outwardly e.g. by a suction cup (not shown) to open tube 44. Once tube 44 Is opened, the charge of corn and fat Is dropped In the spout 86, and Is allowed to fall Into tube 44 thereby locating It In the desired position entirely within tube 44. The tube 42 which Is maintained In a flattened condition at this point will be substantially free of the food product.
Figure 13 Illustrates a similar flown method where the same numerals refer to corresponding parts. In this case a filling spout 90 Is used. Spout 90 Is not provided with tabs and I Is somewhat longer from top to bottom than spout 86. In this filling method, the lower open end 92 of the spout 90 Is Inserted ;
_ 10 --' Into tube 44 which us then drawn upwardly over the spout. As can be seen, this will open the tube I allowing the charge of corn and fat to be Introduced while the collateral tube 42 remains flattened and tree from any substantial quantity of the food product. It Is to be understood that In all of the embodiments of the Invention, Incldenta~ quantities of the food product may spill over Into the unfilled tube and that such Spy I lover which sometimes happens In high speed commercial production fines wow not depart from the spirit or scope ox the present Invention.
In Figures 14 and 15 a similar filling method Is shown except that no spout Is employed. In this case a pelf of penal-lot downwardly depending fixed retaining arms 94 and 96 supported from a stationary framework 98 hold the side edges of the flat-toned tube 42. A suction cup 100 enrages panel 60 and draws It away from panel 58 thereby expending the smaller collateral tube 44. The charge Is then dropped Into tube 44.
Flyer I shows a somewhat similar arrangement except that In this case panel I Is engaged by a stationary suction cupJ02 and a pelf of pincher arms 104 and 106 which enrage the 5 Ire edges of panel 60 are brought centrally towards one another In the direction shown by the arrows thereby.plnchlng the tube 44 to expand It for flailing. Once tube 44 has been expanded a shown In the Figure, the charge Is Introduced.
The charge 52 can be Introduced In many forms. For example the corn and fat can be Introduced separately or together and the fat may be either solid or heated till fluid. However, If solid, less transfer to the other tube will take place. One preferred form of the charge Is shown I n Figure 10. The charge Is composed of fat and corn generally In the shape of a doughnut lye. annular. It was found that the heat transfers to the food faster when It Is In this shape.
I
Bags may be manufactured by any known method but are preferably formed on a bag tuber. The folding shoes of the tuber should be arranged for all embodiments other than Figures 1 and 2 such that the gusset folds are formed In the prover location to make one face of the bag smaller than the other. The tube form-lung apparatus Is otherwise standard. A ~yplcal bag when folded flit no shown In Figures 1 through 9 may have Hewlett of 1Z~ and a width of l/2 n, Where panel 60 Is reduced In width It may be from about 4 to 4 1/2" wide. It was found that for each I
decrease In the area of one face the popped volume will Increase by about 3% (See Figure 17).
The charge 52 of popcorn and fat can have any known commercially acceptable formula preferably about 10 parts corn for each 4 parts of fat. One satisfactory formula used with the present Invention Is 68.5% corn, 27.6% Nat and 2.8% salt by weight. The fat comprises hydrogenated coconut oil having a molting point between about 80F to 130F. Packages are skipped f Rosen and maintained under reFrlDerated conditions prior to use.
Accorldngly It can be seen that the fat Is normally In solid form when below about 80F. The charge placed In the bag will there-fore remain In the position where It Is placed at the lime of filling.
While the reason for the success of the Invention In Improving volumetric yields Is not known with certainty, It Is believed that the lateral placement ox the charge described and the location of It adjacent to the bottom of the wall of the oven permits the bag to expand more easily as soon as gas and vapor Is ; 30 generated responsive to healing and even before the fat Is all melted. It Is also believed that the Invention as described In Figures other than 1 and 2 performs better than the prior art because the reduced panel size concentrates the charge and causes more of the corn to remain Immersed In the hot fat during the I cooking operation thereby promoting better heat transfer to the unpopped kernels. The narrower the smaller face panel Is made .
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the greater will be the volume ox popped corn. Of course, the face dimensions cannot be reduced to such an extent that the package Is not capable of holding the volume of corn to be con-tanned In the package. Therefore reduction on the smaller panel area of less than 50% of the area of the large Panel Is not US-Al Ivy practical.
Many variations of the Invention within the scope of the appended claims will be apparent to those skilled In the art.
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Claims (14)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of filling and sealing a popcorn bag comprising, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a rela-tively large face panel on one side, a narrower face panel on the other side and sections of interconnecting folded gusset material projecting centrally between the side edges of the first and second panels with the centrally protecting gussets approaching each other loosely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section, and the other relatively small in cross-sec-tion, placing a charge of fat and corn substantially entirely within the tube of smaller cross-section, and maintaining the other tube substantially free of fat and corn and sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller cross-section and centrally thereof, said tubes being in communica-tion with each other between the gussets whereby when the bag containing the popcorn is heated within a microwave oven by the application of microwave energy, the popcorn will pass from the smaller tube to the larger tube during popping within the bag as the bag expands to achieve a popped volume increase on the order of 10% to 15% or more compared to an equivalent package with tubes of equal cross-section.
2. The method of claim 1 wherein prior to filling one of said tubes is maintained in a collapsed condition while the other said tube is expanded to an open condition and the charge is thereafter introduced into the open tube.
3. A method of filling and sealing a popcorn bag comprising, providing a bag for storing and shipping popcorn, the bag being formed form flexible sheet material transparent to microwave energy and having a top and bottom and a rela-tively large face panel on one side, a narrower face panel on the other side and sections of interconnecting folded gusset material protecting centrally between the side edges of the first and second panels with the centrally protecting gussets approaching each other loosely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section and the other relatively small in cross-section, holding the bag in an upright position, opening the smaller tube at least at the top, inserting a charge of corn and fat into the smaller tube while in an open condition and maintain-ing the other tube substantially free of fat and corn and sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller cross-section and centrally thereof, said tubes being in communication with each other between the gussets whereby when the bag containing the popcorn is heated within a microwave oven by the application of microwave energy, the popcorn will pass from the smaller tube to the larger tube during popping within the bag as the bag expands to achieve a popped volume increase on the order of 10% to 15% or more com-pared to an equivalent package with tubes of equal cross-sec-tion.
4. The method of claim 3 wherein the smaller tube is cut shorter at one end than the larger tube, the bags are advanced continuously in an upright position and a means is provided to retain the large tube in a collapsed condition, the smaller tube is held open at its upper end and the food product is introduced into the open end of the small tube.
5. A method of filling and sealing a popcorn bag comprising, providing a bag for storing and shipping popcorn, the bag being formed from flexible sheet material transparent to microwave energy and having a top and bottom and a first relatively large face panel on one side, a second narrower face panel on the other side and sections of interconnecting folded gusset material protecting centrally between the side edges of the first and second panels with the centrally pro-tecting gussets approaching each other closely enough to divide the bag into a pair of collateral tubes, one of which is relatively large in cross-section and the other relatively small in cross-section, during the filling operation maintain-ing the tube of relatively large cross-section in a collapsed condition and the other tube in an expanded condition, holding the smaller tube in a collapsed condition transversely at a point below the center of the bag but spaced upwardly from the bottom thereof, holding the bag in an upright position and inserting a charge of corn and fat into the smaller tube while the small tube is in an open condition with a portion thereof collapsed to thereby temporarily maintain the charge at the center of the bag during the filling operation and in only one tube, sealing the top and bottom of the bag to seal the tubes and maintaining the charge of popcorn and fat in the tube of smaller cross-section and centrally thereof, the charge of popcorn and fat is thereby confined substantially entirely in the tube of smaller cross-section, said tubes being in commu-nication with each other between the gussets whereby when the bag containing the popcorn is heated within a microwave oven by the application of microwave energy, the popcorn will pass from the smaller tube to the larger tube during popping within the bag as the bag expands to achieve a popped volume increase on the order of 10% to 15% or more compared to an equivalent package with tubes of equal cross-section.
6. A method of filling and sealing a popcorn bag comprising: providing a bag for storing and shipping popcorn, said bag being formed from flexible sheet material transparent to microwave energy and having first and second rectangular face panels each having parallel transversely extending top and bottom edges and parallel vertically extending side edges, sections of interconnecting folded gusset material projecting centrally between the side edges of the face panels with the centrally projecting gussets approaching each other closely enough to divide the bag into first and second collateral tubes, holding the bag in an upright position with the top edges of the panels uppermost, expanding the first tube to open said tube by drawing the first face panel away from the second collateral tube, maintaining the second collateral tube in a collapsed condition by keeping said second panel in con-tact with adjacent sections of gusset material, inserting a charge of popcorn and fat into the expanded tube by allowing the charge to fall into the tube from its open end by gravity, the close proximity of the second panel of the bag and the gussets preventing transfer of the corn and fat during the filling operation into the collapsed tube, sealing the bag and maintaining the bag in a collapsed condition during shipment and storage to prevent expansion and outward folding of the gussets to thereby hold the charge of fat and corn substan-tially entirely within said first tube until the corn is popped, the tubes being in communication with each other between the gussets whereby the bag containing the popcorn is heated within a microwave oven by the application of microwave energy the popcorn will transfer from the first tube to the second tube during popping within the bag as the bag expands and the gussets move apart.
7. The method of claim 6 wherein the charge placed in said package comprises about 10 parts of corn for each 4 parts of fat and the package is sealed after the charge is inserted into the bag.
8. The method of claim 6, wherein the charge is dropped into the open tube and means is provided for prevent-in the charge from falling past a point located approximately intermediate top and bottom ends of the package.
9. The method of claim 6 wherein a filling spout which inserts said charge is provided and the filling spout is slid longitudinally of the bag into the open end of said first tube.
10. The method of claim 6 where a suction cup is secured to said first tube and is moved in the direction pro-ceeding away from the other tube to thereby open said first tube prior to filling.
11. The method of claim 6 wherein a bottom portion of said first tube is maintained in the collapsed position to thereby temporarily maintain the charge at the center of the bag during the filling operation and in only the first tube, the charge of fat and corn thereby falling through the open end of the first tube by gravity until striking the collapsed portion of the first tube whereby the charge is maintained intermediate the ends of the bag.
12. The method of claim 6 wherein a holding means is placed against said second tube, a suction cup means is engaged with the first panel and said suction cup is then moved away from the second tube to expand the first tube while the second tube is kept in a collapsed condition by the hold-ing means.
13. The method of claim 6 wherein a filling spout which inserts said charge is placed in proximity to the bag with its bottom end aligned with the upper free open end of said first tube.
14. The method of claim 13 wherein tabs are provided on the filling spout and the tabs are engaged against the top edge of the gussets to hold them against the upper edge of said second tube.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/581,028 US4548826A (en) | 1980-07-07 | 1984-02-17 | Method for increasing the volumetric yield of microwave cooked popcorn |
| US581,028 | 1984-02-17 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1239129A true CA1239129A (en) | 1988-07-12 |
Family
ID=24323610
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000465535A Expired CA1239129A (en) | 1984-02-17 | 1984-10-16 | Method for increasing the volumetric yield of microwave cooked popcorn |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JPS60172681A (en) |
| CA (1) | CA1239129A (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6282974U (en) * | 1985-11-14 | 1987-05-27 | ||
| JP4525904B2 (en) | 2004-06-08 | 2010-08-18 | 日立工機株式会社 | Impact tool |
Family Cites Families (2)
| 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 |
-
1984
- 1984-10-16 CA CA000465535A patent/CA1239129A/en not_active Expired
- 1984-12-14 JP JP59263139A patent/JPS60172681A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS60172681A (en) | 1985-09-06 |
| JPH0536291B2 (en) | 1993-05-28 |
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| MKEX | Expiry |