Package for microwaveable popcorn, method for production of the package, and apparatus for sealing the package

Claim 2

A package of corn kernels suitable for popping with microwaves comprising: an elongate bag with a pair of ends between which a front panel, a back panel, and inwardly-folded, gussetted side panels connecting the front panel and the back panel extend, wherein the front panel, the back panel, and the side panels are arranged so that when said bag is flattened with the gussetted side panels folded fully inwardly toward each other, the front panel and the back panel contact each other along a center strip located between the inwardly-folded, gussetted side panels; a plurality of corn kernels and oil or shortening within said bag; and a seal across at least one end of said bag formed by applying heat and pressure to said bag which causes the front panel and the back panel to bond each other at the center strip and to each of the inwardly-folded, gussetted side panels, wherein said seal has at least one weakened portion where the front and back panels are bonded to at least one of said inwardly-folded, gussetted side panels, whereby only at least one of weakened portions will open after a predetermined pressure within said bag is reached during the popping of corn kernels.

Claim 3

A package according to claim 1, wherein said bag comprises a laminate having an outer layer of paper, an inner layer of greaseproof paper, and a layer of metallized polymeric film between the inner and outer layers.

Claim 4

A package according to claim 2, wherein said layer of metallized polymeric film is located only on the front panel.

Claim 5

A package according to claim 2 or 3, wherein the metallized polymeric film is polyethylene terephthalate metallized with aluminum.

Claim 6

A package according to claim 1, wherein said bag is a lay-down bag.

Claim 7

A package according to claim 1, wherein said bag is a stand-up bag having a flat bottom panel at one end.

Claim 8

A package according to any preceding claim, wherein the inwardly-­folded portions of each of the gussetted side panels are substantially equal, whereby the inwardly-folded portion of each of the gussetted side panels adjacent the front panel define a longitudinal-extending tube equal to that defined by the back panel and the adjacent inwardly-folded portion of each of the gussetted side panels.

Claim 9

A package according to any preceding claim, wherein said plurality of corn kernels and said oil or shortening substantially fill said bag cross-sectionally.

Claim 10

A package according to any preceding claim, wherein said oil or shortening is solidified.

Claim 11

10 A package according to any preceding claim, wherein said corn kernels are selected so that 60 to 75 kernels will have a total mass of 10 grams.

Claim 12

A package according to any preceding claim, further comprising salt in admixture with said corn kernels and said oil or shortening.

Claim 13

a package according to claim 11, further comprising a flavoring material and optionally a coloring additive, wherein the flavoring material is selected from the group consisting of butter flavoring, brown sugar flavoring, caramel flavoring, maple flavoring, cheese flavoring, cheese flavoring with jalapeno, nacho, or pizza spices, barbeque flavoring, meat flavoring, and mixtures thereof in admixture with said corn kernels, said oil or shortening, and said salt.

Claim 14

A package according to any preceding claim, wherein said corn kernels and said oil or shortening is substantially equidistant from the ends of said bag.

Claim 15

A package according to any preceding claim, wherein said seal is formed from a material within said bag which adheres to itself upon application of heat and pressure.

Claim 16

A package according to any preceding claim, wherein said seal is formed as a plurality of impressed lines extending across at least a portion of said bag.

Claim 17

A package according to claim 15, wherein only a few of said impressed lines extend entirely across said bag and the remaining impressed lines are interrupted across the at least one weakened portion.

Claim 18

A package or corn kernels suitable for popping with microwaves comprising: an elongate bag with a pair of ends between which a front panel, a back panel, and inwardly-folded, gussetted side panels connecting the front panel and the back panel extend, wherein the front panel, the back panel, and the side panels are arranged so that when said bag is flattened with the gussetted side panels fully loaded inwardly toward each other, the front panel and the back panel contact each other along a center strip located between each of the inwardly-folded, gussetted side panels, wherein said bag is a laminate having an outer layer of paper, an inner layer of greaseproof paper, and a layer of polyethylene terephthalate film metallized with aluminum between the inner and outer layers only on said front panel, and wherein the inwardly-folded portion of each of the gussetted side panels adjacent the front panel define a longitudinally-extending tube equal to that defined by the back panel and the adjacent inwardly-folded portion of each of the gussetted side panels; a plurality of corn kernels, solidified oil or shortening, a coloring additive, salt, and a flavoring material substantially filling said bag cross-sectionally and located substantially equidistant from the ends of said bag; and a seal across at least one end of said bag formed by a material within said bag which adheres to itself upon application of heat and pressure which causes the front and back panels to bond to each other at the center strip and to each of the inwardly-folded, gussetted side panels with a plurality of impressed lines extending across at least a portion of said bag, and wherein said seal creates weakened portions where the front and back panels are bonded to said inwardly-folded, gussetted side panels through which only a few of the impressed lines extend due to interruption of the remaining impressed lines at the weakened portions, whereby only at least one of the weakened portions will open after a predetermined pressure within said bag is reached during popping of the corn kernels.

Claim 19

A package or corn kernels suitable for popping with microwaves comprising: an elongate bag with a pair of ends between which a front panel, a back panel, and inwardly-folded, gussetted side panels connecting the front panel and the back panel extend, wherein the front panel, the back panel, and the side panels are arranged so that when said bag is flattened with the gussetted side panels fully loaded inwardly toward each other, the front panel and the back panel contact each other along a center strip located between each of the inwardly-folded, gussetted side panels, wherein said bag is a laminate having an outer layer of paper, an inner layer of greaseproof paper, and a layer of polyethylene terephthalate film metallized with aluminum between the inner and outer layers only on said front panel, and wherein the inwardly-folded portion of each of the gussetted side panels adjacent the front panel define a longitudinally-extending tube equal to that defined by the back panel and the adjacent inwardly-folded portion of each of the gussetted side panels; a plurality of corn kernels, solidified oil or shortening, a coloring additive, salt, and a flavoring material substantially filling said bag cross-sectionally and located substantially equidistant from the ends of said bag; and a seal across at least one end of said bag formed by a material within said bag which adheres to itself upon application of heat and pressure which causes the front and back panels to bond to each other at the center strip and to each of the inwardly-folded, gussetted side panels with a plurality of impressed lines extending across at least a portion of said bag, and wherein said seal creates weakened portions where the front and back panels are bonded to said inwardly-folded, gussetted side panels through which only a few of the impressed lines extend due to interruption of the remaining impressed lines at the weakened portions, whereby only at least one of the weakened portions will open after a predetermined pressure within said bag is reached during popping of the corn kernels.

Claim 22

A method according to claim 18 further comprising: sealing the second end of said bag by folding the second end across said bag against the front or the back panel and applying an adhesive where the second end contacts said bag prior to said providing a plurality of corn kernels and oil or shortening.

Claim 23

A method according to claim 18 further comprising: sealing the second end of said bag and folding the sealed second end across said bag and against the front or back panel prior to said providing a plurality of corn kernels and oil or shortening.

Claim 24

A method according to claim 18, 19 or 20, wherein said providing a plurality of corn kernels and oil or shortening comprises: injecting the plurality of corn kernels into said bag through the first end, while the second end is sealed and folded across said bag and injecting the oil or shortening in liquified from into said bag containing the plurality of corn kernels through the first end.

Claim 25

A method according to claim 21 further comprising: permitting the oil or shortening within said bag to cool and solidify.

Claim 26

A method according to claim 22 further comprising: folding the sealed first end across said bag to form a compact package for shipment and storage.

Claim 29

A method according to claim 25, wherein only a few of said impressed lines extends entirely across said bag and the remaining impressed lines are interrupted across said at least one weakened portion.

Claim 30

A method according to claim 26, wherein said sealing across the first end is achieved by compressing the front and back panels between first and second aligned jaws at least one of which is heated to seal the first end so that the seal will withstand a uniform maximum pressure significantly higher than the predetermined pressure except at the weakened portion.

Claim 31

A method according to claim 27, wherein the first jaw is a metal block with a metal sealing surface, while the second jaw is a metal block fitted with a rubber sealing surface positioned in alignment with the metal sealing surface.

Claim 32

A method according to claim 28, wherein the metal sealing surface has a plurality of longitudinally-extending serrations, wherein all serrations except a few are interrupted by a depression in the metal sealing surface defined by a cut out extending across the serrations from a first edge of the metal sealing surface toward a second edge of the metal sealing surface to a location defined by a cut out wall.

Claim 33

A method according to claim 27, wherein the first jaw and the second jaw are metal blocks with a plurality of longitudinally-­extending serrations, and wherein the serrations of first jaw mesh with those of the second jaw.

Claim 34

A method according to claim 30, wherein all except a few of the serrations of the first jaw are interrupted by a depression in the metal sealing surface of the first jaw defined by a cut out extending across the serrations from a first edge of the metal sealing surface toward a second edge of the metal sealing surface to a location defined by a cut out wall.

Claim 35

A method according to claim 29 or 31, wherein the strength of the at least one weakened portion can be increased by decreasing the cut out size in a direction parallel to the serrations or by increasing the distance from the second edge to the cut out wall.

Claim 36

A method according to claim 29 or 31, wherein the strength of the at least one weakened portion can be decreased by increasing the cut out size in a direction parallel to the serrations or by decreasing the distance from the second edge to the cut out wall.

Claim 37

A method according to claim 31, wherein the sealing surface of the first jaw has a centrally-located raised portion with the serrations extending through it and, wherein the raised portion is positioned above the remainder of the first jaw sealing surface.

Claim 39

A bag sealing apparatus comprising: a first jaw having a longitudinal-extending sealing surface; heating means to heat at least said first jaw and its longitudinally-extending sealing surface; a second jaw having a longitudinally-extending sealing surface, wherein said first and second jaws are positioned so that their sealing surfaces face and are aligned with each other; and a cutout in the sealing surface of said first jaw which produces a weakened portion in a package sealed between said first and second jaws in alignment with where said cutout contacts the package.

Claim 40

A bag sealing apparatus comprising: a first jaw having a longitudinal-extending sealing surface; heating means to heat at least said first jaw and its longitudinally-extending sealing surface; a second jaw having a longitudinally-extending sealing surface, wherein said first and second jaws are positioned so that their sealing surfaces face and are aligned with each other; and a cutout in the sealing surface of said first jaw which produces a weakened portion in a package sealed between said first and second jaws in alignment with where said cutout contacts the package.