US3052554A - Popcorn package - Google Patents

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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
  • B65D81/3407—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 over a heat source, e.g. a hob, campfire
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23L—FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES, NOT OTHERWISE PROVIDED FOR; PREPARATION OR TREATMENT THEREOF
  • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
  • A23L7/10—Cereal-derived products
  • A23L7/161—Puffed cereals, e.g. popcorn or puffed rice
  • A23L7/174—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough
  • A23L7/183—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough by heating without using a pressure release device
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
  • A47J36/00—Parts, details or accessories of cooking-vessels
  • A47J36/02—Selection of specific materials, e.g. heavy bottoms with copper inlay or with insulating inlay
  • A47J36/022—Cooking- or baking-vessels or supports thereof for using only once
• • 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

Definitions

• This invention relates to popcorn packages and more particularly to a popcorn package which is made in a flat inflatable, expandable pouch of metal foil containing popcorn grains with or without a frying fat. The popcorn grains are popped directly in the flat pouch.
• the invention involves a flat, inflatable, expandable pouch made of one or two sheets of light gauge metal foil, such as aluminum foil.
• the sheet can be folded to provide one folded side edge of the pouch, the two layers, formed by folding, overlying each other in substantially face to face relationship and secured together substantially along their edges by adhesive or mechanical means.
• a first sheet of metal foil, cut in rectilinear or circular shape is charged on its surface with popcorn grains and, if desired, with a frying fat, preferably in plastic rather than liquid form.
• An adhesive stripe is imprinted upon the metal foil sheet adjacent its edges.
• the second or covering metal foil sheet in the same form and size, is laid upon the first sheet, closely overlying the corn and fat.
• the second sheet is also provided with an adhesive stripe along its edges so that the two adhesive stripes will come into register with each other.
• An adhesive which has been used and appears adequate for securing the edges of the foil sheet or sheets together is a neoprene reacted-phenolic adhesive. Such an adhesive is acceptable under the Federal Food and Drug Act, as presently in force.
• the amount of popcorn grains charged into the pouch is determined by the volumetric capacity of the pouch when inflated. Popcorn expands about 30 times its original size. A pouch approximately nine or ten inches square, when flat, and charged with a quarter pound (4 ounces) of unpopped corn and about two ounces of plastic frying fat or shortening, inflates to a volumetric capacity large enough to accept and retain all of the popcorn. The popcorn grains are in an amount less than will fully cover the entire surface of one side of one layer of metal foil. As the metal foil pouch expands, upon the application of heat, it assumes a rotund or pillow shape having somewhat semi-elliptical upper and lower sections.
• the popcorn grains tend to move toward and to concentrate upon the bottom of the rotund pouch Where the pouch is in contact with a heating surface and the greatest amount of heat is present, and are there exploded, flying into and filling the enlarged chamber of the pouch.
• the metal foil pouch package is heated in a household utensil or vessel, such as a frying pan, or in another usual cooking utensil of that type, having a bottom heating surface coming into contact directly or indirectly with a source and supply of heat.
• the pouch package is placed directly upon the bottom heating surface of the utensil and there receives the heat from the utensil which will explode and pop the corn within the pouch.
• the top layer of foil is ripped open and the popcorn is ready for consumption. Salt, butter, syrup, or other seasonings may be added to the popcorn while it is in the opened pouch, or the popcorn can be discharged into a bowl or other vessel and there seasoned to suit the taste.
• the adhesive securing the edges of the metal foil sheet or sheets together tends to soften slightly under the continued application of heat to the metal foil pouch.
• the outer adhesive secured edges begin to wrinkle in some short sections.
• the combination of the mechanical wrinkling and the softening of the adhesive appears to bring about a vent opening in an edge so that the internal gases escape with relative ease.
• the vent opening does not enlarge beyond that required to release the gases generated within the pouch, and only infrequently does any of the contained popcorn escape through this edge vent.
• Still another object is the provision of a flat metal foil pouch which is heatable in a vessel, adapted in its initial state and form to readily conform to the contours of the vessel, and to receive heat from the vessel, whereby the popcorn grains contained in the pouch can be exploded and expanded into popcorn for consumption within the pouch.
• a flat, inflatable, expandable metal foil pouch formed of a single or two layers of very light gauge metal foil, lacking self-supporting characteristics, and containing popcorn grains and a frying fat has not heretofore been known not considered as a means by which corn may be popped therein.
• the unobvious results achieved by a fiat metal foil pouch formed to two such layers include the discovery that a flat metal foil pouch is expandable into a rotund chamber of substantial volumetric capacity upon heating and expanding the gases of a frying fat, and exploding popcorn therein.
• a flat metal foil pouch formed of a single or two very light gauge metal foil sheets is much less expensive than preformed heavy gauge metal foil pans press formed from metal about seven (7) to ten (10) times thicker than one of the foil sheets.
• the simplicity of securement together of the edges of the single or two metal foil sheets by an adhesive, which can be imprinted by a roller or silk-screened onto the foil sheets further simplifies the processing of the popcorn package of this invention by comparison to those heretofore known and made, and permits a marked reduction in costs and the market selling price.
• Add to this the simplicity of boxing fiat pouches, a reduction in market shelf space requirements, transportation savings occasioned by more compact packages, and the desirable and unobvious advantages of the instant invention become instantly apparent.
• a frying pan or other base utensil for heating the inventive popcorn package heredisclosed provides a heat distributing device under the package which substantially eliminates burning of the corn if the package is properly handled by shaking.
• the to-and-fro sliding of the fry pan over the heating unit causes the corn in the package to move relative to the foil layer resting on the bottom of the fry pan.
• the bottom foil layer portion of the pouch assumes, and is caused to assume a concave, dished, bowl-shaped form.
• the popcorn grains within the pouch tend to concentrate at the bottom of the bowl-shaped portion which is in direct contact with the bottom of the fry pan.
• the heat directed to the fry pan is broadly distributed and is not concentrated upon the small pouch bottom portion in contact therewith. Thus, heat is not concentrated across the entire pouch bottom layer in such amounts as to readily burn the popcorn.
• FIG. 1 is a perspective view of one embodiment of the flat metal foil popcorn package of this invention.
• FIG. 2 is a vertical sectional view taken substantially on the line 22 of FIG. 1.
• FIG. 3 is a perspective view of the flat metal foil popcorn package of FIG. 1 disposed in a heating vessel.
• FIG. 4 is an enlarged vertical sectional view of the metal foil pouch in its inflated state after heating in the vessel shown in FIG. 3.
• FIG. 5 is a view similar to FIG. 2, in which the fiat metal foil pouch contains popcorn and a frying fat.
• FIGS. 6 and 7 are fragmentary perspective views of slight modifications of the flat metal foil pouch.
• FIG. 8 is a perspective view of another form of the fiat metal foil pouch, with a portion broken away.
• FIG. 9 is a perspective view of a single sheet metal foil pouch, formed by folding the sheet into two overlying layers.
• FIG. 10 is a vertical sectional view of the pouch package of FIG. 9 expanded in a fry pan after popping the corn.
• FIG. 11 is a perspective view :of another single sheet metal foil pouch, formed by folding the sheet into two upper layer portions secured together at their edges and overlying the lower layer, the ends of the upper layer and lower layer portions being secured together.
• FIG. 12 is a vertical sectional view taken substantially on the line 12-12 of FIG. 11.
• the flat metal foil popcorn package 10 comprises a pouch formed of a top layer of metal foil 12, a bottom layer of metal foil 14, and popcorn grains 16.
• the package 10 can optionally also contain an amount of frying fat 18.
• the two layers of metal foil 12 and 14 are secured together adjacent their outer edges by a suitable adhesive 22 disposed therebetween.
• the popcorn grains 16 being of relatively small volume in the unpopped state, lie upon the bottom foil layer 14, the top covering foil layer 12 directly overlying the corn and the bottom layer 14 in face to face relationship.
• the layer of corn and fat may be slightly thicker due to the layer of fat, but it is still quite flat.
• An adhesive 22 which has been used and found satisfactory is a neoprene reacted-phenolic adhesive.
• the adhesive is applied as a stripe of relatively narrow width along or adjacent the edges of the foil layers 12 and 14, on one side of each of the layers.
• the adhesive stripes are placed in register with each other by bringing the two foil layers into edge contact with each other over the popcorn grains and fat.
• the adhesive is then activated by heat and a slight amount of pressure to provide an edge secured pouch.
• the top foil layer 12 is made of aluminum foil .0005 thick
• the bottom foil layer 14 is .0007 thick
• about 4 ounces of popping corn is charged into the pouch.
• the fat 13 is added in amounts of from 1 to 4 ounces, depending upon the desires of the person making the popcorn for a fatty or oily coating on the popped corn.
• the pouch is formed to a square of about 9 to 10* inches per side.
• Slight modifications of the package 10 include closing the edges by overfolding on each side into the folded edges 24 (FIG. 6), or by mechanically crimping the edges together between dies in a pressing or rolling operation into the crimped edges 26 (FIG. 7), or by die cutting the pouch foil into circular shape and sealing the edges 28 with adhesive 22 (FIG. 8).
• the frying fat 18 can be any suitable type of cooking shortening, preferably in a plastic state; or a cooking oil may be used, in which latter case the metal foil pouch should be checked for leaks, pinholes in the foil, and edge sealing.
• the bottom metal foil layer 14 preferably ranges from .0005 to .001 in thickness and still permits the package 10 to expand. Of course, the lighter the metal foil gauge the more readily the pouch will expand.
• the top metal foil layer 12 is preferably made of .0005" thick foil, although metal foil from .0003 to .001 in thickness can be used. The internal pressure of the gases generated by the frying fat and by the exploded popcorn is considerable and the pouch inflates in a very positive manner to form a rotund chamber large enough to receive the popped corn.
• the top foil layer 12 is free of vent holes; however, a top vent hole (not shown) may be pierced in the foil layer 12 before popping the corn, if desired.
• the pouch 40 made of a single sheet of metal foil, illustrated in FIGS. 9 and 10, is provided with a folded edge 42, a top layer 44, a bottom layer 46, and overlying side edges 48 secured together with adhesive 22. Popcorn grains 16, and optionally, frying fat 18 are contained within the pouch 40.
• FIGS. 11 and 12 Another form of a single sheet metal foil pouch is the pouch 50 illustrated in FIGS. 11 and 12.
• the pouch 50' is formed with two folded edges 52, 54 providing two top layer portions 56, 58 having their edges 60, 62, respectively, meeting intermediate the side edges.
• the edges 60, 62 are secured together with adhesive 22 so that the top layer portions 56, 58 form a single top layer over the bottom layer 64.
• the end edges 66, of the top layer portion 56, and 68, of the top layer portion 58, are secured to the end edges 70 of the bottom layer 64 by adhesive 22, providing a closed fiat metal foil pouch.
• Popcorn grains 16, and, optionally, frying fat 18 are contained within the pouch 50.
• Pouch packages 40 and 50 preferably made of .0007 inch thick foil, are used and operated in the same manner as pouch package 10.
• the pouch package 10, 40 or 50 is laid in a vessel such as the frying pan 30 (FIGS. 3 and 4), or upon a griddle plate or other cooking utensil suitable for accepting and transmitting heat to the package.
• the pouch package is deformed to accommodate the contour of the heating surface of the device 30, and to place a layer of the pouch as a fiat side thereof directly upon the heating surface of the device.
• heat is applied to the bottom of the vessel, heat is transferred to the foil pouch resting thereon, the pouch is caused to inflate and to expand into a rotund chamber, and the corn is popped.
• the pouch package 10, 40 or 50 containing popcorn '16 and fat 18 both the heated fat and the exploding popcorn emit gases that fill and expand the pouch to its enlarged capacity.
• the pouch package without fat the pouch package without fat.
• the top and bottom foil layers 12 and 14 move apart at their centers forming the rotund chamber 32 shown in FIG. 4 or the rotund chamber shown in FIG. 10.
• the popping of the corn 16 is preferably accompanied by shaking the pan 30 so that the pouch is caused to move, and to eliminate or reduce burning and sticking of the popcorn grains to the lower foil layer of the pouch.
• the corn in the package 10, 40 or 50 can be popped without shaking by placing the pack- :age in a controlled-heat electric fry pan.
• the heat control should be set for a temperature of from 500 -700 F. Temperatures below 500 heat the corn too slowly and popping of the corn is somewhat less effective and the quality of the popped corn less desirable.
• the temperature of the pan has reached the temperature setting, the popcorn package is placed on the bottom of the electric fry pan. Within minutes the pouch package has inflated and the corn has popped. No shaking is required, (and the corn does not burn.
• top foil layer 12 When a pouch package made with mechanically overfolded edges 24 or crirnped edges 26 has inflated substantially, it may be desirable to pierce .the top foil layer 12 with an instrument to provide a limited vent opening 34 for the gases generated within the pouch, to reduce the internal pressure acting on the edges or seams of the package, as well as to prevent an enlarged disassociation of such mechanically secured edges.
• the neoprene reacted-phenolic adhesive 22 appears to provide an advantage over mechanically closed or locked edges.
• the inflation of the pouch under heat and the mechanical wrinkling occasioned by such inflation and the heating of the metal foil so that a-certain amount of adhesive softening occurs results in a vent opening in an adhesive-secured edge so that the internal gases escape with relative ease.
• the vent opening does not enlarge beyond that required to release the gases generated Within the pouch, and only infrequently does any of the popped corn escape through this edge vent.
• the top foil layer is torn open and the popcorn is available for consumption. Salt and butter, or other seasoning may be added, if desired.
• the popcorn can be emptied from the pouch into the bowl, or served in the pouch, the latter providing a heat-containing vessel to keep the popcorn Warm.
• the metal foil pouch package comprises two flat layers of metal foil which are extremely thin in thickness, each layer being less than .002 inch.
• the thickness of the pouch in its initial compressed state except for the popcorn grains is less than A inch.
• the metal foil on both sides of the pouch is substantially of the same thickness, so that either side can be placed on the heating surface of a device being heated.
• the metal foil pouch package comprises two thin flat layers of metal foil, with popcorn grains therebetween in a thin layer, in face to face relationship. The metal foil is so thin that the pouch package is not self-supporting when it is grasped at one side edge, but drops down where grasped.
• both layers of the metal foil are so thin, they are easily subject to fracture or tearing by undue mishandling, although this same characteristic permits the pouch package to be readily deformed to accommodate the contour of a heating surface, and, when heated, to readily deform from its flat state into an inflated, expanded rotund chamber to contain the popped corn. Further, the very thin metal foil bottom layer in contact with the heating surface curves into a bowl shape during heating of the pouch so that the popcorn grains tend to concentrate at the bottom of the curved foil layer, where the heat into the package pouch 6 is the greatest.
• the metal foil pouch package is deformable to fit a heating pan without impairing the utility of the package.
• the popcorn pouch package of this invention can also be produced by forming a metal foil pouch such as that represented by 10, 40 or provided with an opening or entry port for popcorn grains 16 which are packaged separately. A quantity of popcorn grains could be inserted through the pouch port and the pouch sealed about the popcorn grains to form a popcorn package embodying the invention.
• the use of two very thin layers of metal foil provides an inexpensive popcorn package, providing the same amount of popcorn as in other popcorn packages but at a great reduction in cost.
• the package of this invention will therefore sell at a much lower price than currently marketed popcorn packages.
• the package cost is less than V2 the cost of these other packages, and permits substantially the same profit margins.
• a closed flat, inflatable, expandable, pouch formed of metal foil, popcorn grains contained within said pouch, said pouch essentially consisting of a first flat substantially uniplanar layer of metal foil, a layer of popcorn grains and a second flat substantially uniplanar layer of metal foil overlying said popcorn grains, said pouch having one of said layers of metal foil as a flat side thereof adapted to rest upon and to receive heat from a heated surface, whereby when sufiicient heat is received by said pouch flat side said pouch is caused to inflate and expand and substantially distort both said layers upon the heating of gases therewithin and upon the explosion of said popcorn grains, forming an enlarged chamber to contain said popcorn in its exploded expanded state.
• a closed flat, inflatable, expandable pouch of metal foil, popcorn grains contained within said pouch said pouch except for its contents comprising .a plurality of flat layers of metal foil in face to face relationship, said pouch having one of said layers of metal foil as a flat side thereof adapted to rest upon and to receive heat from a heated surface, whereby when suflicient heat is received by said pouch flat side said pouch is caused to inflate and expand and substantially distort said layers upon the heating of gases therewith and upon the explosion of said popcorn grains, forming an enlarged chamber to contain said popcorn in its exploded expanded state.
• a closed fiat, inflatable, expandable pouch of metal foil, popcorn grains contained within said pouch said pouch except for its contents comprising two flat layers of metal foil, said two flat layers of metal foil being of such thickness that either layer of metal foil can be placed upon and receix e heat from a heated surface, whereby when sufficient heat is received by said layer of metal foil said pouch is caused to inflate and expand and substantially distort both of said layers upon the heating of gases therewithin and upon the explosion of said popcorn grains, forming an enlarged chamber to contain said popcorn in its exploded expanded state.
• a closed flat, inflatable, expandable pouch of metal foil, popcorn grains contained within said pouch said pouch except for its contents essentially consisting of two flat layers of metal foil, said pouch having one of said layers of metal foil as a flat side thereof adapted to rest upon and to receive heat from a heated surface, the thickness of said flat side layer of metal foil aosasea resting upon said heated surface being such that during heating said flat side will readily deform into a bowl shape and tend to concentrate said popcorn grains at the bottom of said bowl shape where said pouch is in contact with said heating surface and the heating of said pouch is greatest, whereby when sufficient heat is received by said pouch flat side said pouch is caused to inflate and expand and to substantially distort both of said layers upon the heating of gases therewithin and upon the explosion of said popcorn grains, forming an enlarged chamher to contain said popcorn in its exploded expanded state.
• a closed flat, inflatable, expandable pouch of metal foil popcorn grains contained within said pouch, said pouch except for its contents comprising two flat layers of metal foil in face to face relationship, said pouch being formed of a single sheet of metal foil, said sheet being folded upon itself to provide an upper layer and a lower layer, said two layers being secured together to form said pouch, said pouch having one of said layers of metal foil as a flat side thereof adapted to rest upon and to receive heat from the heating surface of a device being heated, whereby when suflicient heat is received by said pouch flat side said pouch is caused to inflate and expand upon the heating of gases therewithin and upon the explosion of said popcorn grains, forming an enlarged chamber to contain said popcorn in its exploded expanded state.
• a closed flat, inflatable, expandable pouch of metal foil, popcorn grains contained within said pouch said pouch except for its contents comprising two flat layers of metal foil in face to face relationship, said pouch being formed of a single sheet of metal foil, said sheet being folded upon itself to provide two upper layer portions aligned in substantially the same plane and a lower layer and having two folded side edges, said two upper layer portions being secured together intermediate said folded side edges, the ends of said lower layer and said two upper layer portions being secured together to provide said closed pouch, said pouch having said lower layer of metal foil as a flat side thereof adapted to rest upon and to receive heat from the heating surface of a device being heated, whereby when sufiicient heat is received by said pouch flat side said pouch is caused to inflate and expand upon the heating of gases therewithin and upon the explosion of said popcorn grains, forming an enlarged chamber to contain said popcorn in its exploded expanded state.
• a closed flat, inflatable, expandable pouch formed of metal foil, popcorn grains contained within said pouch, said pouch essentially consisting of a first flat substantially unipl'anar layer of metal foil, a layer of popcorn grains and a second flat substantially uniplanar layer of metal foil overlying said popcorn grains and in face to face relationship with said first layer of metal foil, the thickness of said pouch in its compressed fiat state except for its contents being less than onesixteenth inch, said two flat layers of metal foil being of substantially the same thickness, the amount of popcorn grains in said pouch being limited to an amount less than enough to cover the entire surface of one side of one layer of said metal foil, each said layer of metal foil being less than .002 inch in thickness, said pouch package containing said popcorn grains being without sufficient rigidity to support itself when grasped at one side edge of said pouch package, said two layers of metal foil being secured together along their edges by an adhesive and forming said pouch, said pouch having one of said layers of metal foil as a flat side thereof adapted to

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• Engineering & Computer Science (AREA)
• Food Science & Technology (AREA)
• Life Sciences & Earth Sciences (AREA)
• Health & Medical Sciences (AREA)
• Nutrition Science (AREA)
• Chemical & Material Sciences (AREA)
• Polymers & Plastics (AREA)
• Mechanical Engineering (AREA)
• Package Specialized In Special Use (AREA)
• Grain Derivatives (AREA)

Description

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Applications Claiming Priority (1)

Publications (1)

Family

ID=22090709

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Cited By (57)

Citations (5)

• 1960
  • 1960-11-16 US US69707A patent/US3052554A/en not_active Expired - Lifetime

Patent Citations (5)

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