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Patent 2129110 Summary

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(12) Patent: (11) CA 2129110
(54) English Title: SINGLE LAYER, GREASEPROOF, FLEXIBLE PAPER POPCORN PACKAGE
(54) French Title: PAPIER A EPAISSEUR UNIQUE, INGRAISSABLE ET SOUPLE POUR L'EMBALLAGE DE MAIS ECLATE
Status: Deemed expired
Bibliographic Data
(51) International Patent Classification (IPC):
  • B65D 81/34 (2006.01)
(72) Inventors :
  • MCDONALD, DUANE L. (United States of America)
(73) Owners :
  • GENERAL MILLS, INC. (United States of America)
(71) Applicants :
  • GENERAL MILLS, INC. (United States of America)
(74) Agent: FETHERSTONHAUGH & CO.
(74) Associate agent:
(45) Issued: 2005-01-25
(86) PCT Filing Date: 1993-01-29
(87) Open to Public Inspection: 1993-08-19
Examination requested: 1999-10-27
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US1993/000849
(87) International Publication Number: WO1993/015976
(85) National Entry: 1994-07-28

(30) Application Priority Data:
Application No. Country/Territory Date
07/834,185 United States of America 1992-02-06

Abstracts

English Abstract




A package for use im microwave
ovens is disclosed in its preferred
form of a flexible, tubular
bag (18) including expandable side
walls (26) interconnected between
bottom and top walls (20, 22), an
openable end (28); and a permanent
end wall (24). The side walls (26)
include pleats (26a, 26b; 26c, 26d)
which are folded in a collapsed
condition of the bag (18) and expand
due to internal expansion forces
generated by the popping of kernels
and the creation of water vapor. In
a preferred form, the bag, (18) is
formed from a single layer of flexible,
greaseproof paper of highly refined
raw fibers of 100% chemical
softwood pulp and having a basis
weight in the order of 35 lb/ream.
The single layer of paper forming the bag (18) provides greaseproof properties
in storage, transportation, and cooking throughout
the thickness of the paper to prevent wicking and leaking of grease or oil
through the single layer. The bag (18) in a preferred
form includes grease protectors (42a; 42b, 42c, 42d) located inside of the bag
(18) for sealing the bottom and top walls (20, 22) to
the pleats (26a, 26b; 26c, 26d) adjacent to their respective connecting edges
and in a most preferred form further includes grease
protectors (44a, 44b) outside of the bag (18) for sealing the first and second
pleats (26a, 26b) together and the third and fourth
pleats (26c, 26d) together adjacent to their respective connecting edges. The
grease protectors (42a, 42b, 42c, 42d, 44a, 44b) seal
the surfaces of the bag (18) just above aid adjacent the connecting edges to
block the flow of grease to prevent grease wicking or
leaking from the bag (18).


Claims

Note: Claims are shown in the official language in which they were submitted.




-15-


CLAIMS:

1. Expandable, paper, popcorn package for holding
popcorn kernels and grease or oil for popping in a microwave
oven comprising, in combination: a bag having an interior
volume and a closed end openable by the consumer after
microwave cooking; and susceptor means for converting
microwave energy into heat extending over a portion of the
bag, with the popcorn kernels and the grease or oil
generally overlying the susceptor means during microwave
cooking; characterized in that the bag is formed of a single
layer of greaseproof paper having a thickness allowing the
single layer to be flexed by the popping of the popcorn
kernels and also preventing the wicking and leaking of the
grease or oil through the single layer.

2. The popcorn package of claim 1, wherein the
greaseproof paper is formed of raw fibers which are highly
refined.

3. The popcorn package of claim 2, wherein the raw
fibers are selected from the group of 100% chemical softwood
pulps.

4. The popcorn package of any one of claims 1 to 3,
wherein the single layer has a basis weight in the order of
16 kg/ream.

5. Package for holding a food product including
grease or oil and for heating in a microwave oven
comprising, in combination: a flexible bag including a
bottom wall, a top wall, and at least a first side wall
extending between the top and bottom walls, with the top,
bottom and side walls including first and second ends, with
the first side wall including first and second pleats with
the pleats being connected together at first edges and with


-16-


the first pleat having a second, opposite edge connected to
the bottom wall and the second pleat having a third,
opposite edge connected to the top wall, with the bag
further including an end wall at the first ends of the top,
bottom and side walls; susceptor means for converting
microwave energy into heat extending over a portion of the
bottom wall spaced from the first and second ends of the
bottom wall; and means for closing the second ends of the
top, bottom, and side walls and for allowing the consumer to
open the package after microwave cooking; characterized in
means inside of the bag for sealing the first pleat to the
bottom wall adjacent to the second edge; means inside of the
bag for sealing the second pleat to the top wall adjacent to
the third edge, with the sealing means preventing the grease
or oil from leaking or wicking from inside the bag through
the edges, and further characterized in that the bottom,
top, and side walls are formed of a single layer of
greaseproof paper which prevents wicking and leaking of the
grease or oil through the single layer.

6. The package of claim 5, wherein the sealing means
are peelable during microwave cooking.

7. The package of claim 5 or claim 6, wherein the
sealing means comprise adhesive or cohesive applied adjacent
to the edges.

8. The package of any one of claims 5 to 7, wherein
the bottom, top, and side walls are of paper having a
thickness allowing the paper to be flexed by the microwave
cooking of the food product.

9. The package of any one of claims 5 to 8, wherein
the greaseproof paper is formed of raw fibers selected from
the group of 100% chemical softwood pulp and which are


-17-


highly refined, and having a basis weight in a range of
about 11.5 kg/ream to 20.5 kg/ream.

10. The package of any one of claims 5 to 9, wherein
the bag includes a second side wall extending between the
top and bottom walls opposite to the first side wall, with
the second side wall including at least third and fourth
pleats, with the third and fourth pleats being connected
together at fourth edges and with the third pleat having a
fifth, opposite edge connected to the bottom wall and the
fourth pleat having a sixth, opposite edge connected to the
top wall; means inside of the bag for sealing the third
pleat to the bottom wall adjacent to the fifth edge; means
inside of the bag for sealing the fourth pleat to the top
wall adjacent to the sixth edge; and means outside of the
bag for sealing the third pleat to the fourth pleat adjacent
to the fourth edges.

11. The package of any one of claims 5 to 10 further
comprising, in combination: means outside of the bag for
sealing the first pleat to the second pleat adjacent to the
first edges.

12. Package for holding a food product including
grease or oil comprising, in combination: an expandable bag
having an interior volume for holding the food product and
the grease or oil, with the interior volume being defined by
at least first and second walls connected together at first
edges, with each of the first and second walls having first
and second surfaces, with the bag having a collapsed
condition and an expanded condition, with the interior
volume of the bag increasing as the bag expands from the
collapsed condition to the expanded condition, with the
first and second walls being folded about the first edges
with the first surfaces overlying each other in the


-18-


collapsed condition, with the first and second walls
extending from the first edges with the first surfaces being
spaced from each other in the expanded condition,
characterized in means for sealing the first surfaces
together adjacent to the first edges to prevent the grease
or oil from leaking or wicking from the interior volume of
the bag, and further characterized in that the first and
second walls are formed of a single layer of greaseproof
paper which prevents wicking and leaking of the grease or
oil through the single layer.

13. The package of claim 12, wherein the sealing means
is peelable as the bag expands from the collapsed condition
to the expanded condition.

14. The package of claim 12 or claim 13, wherein the
sealing means comprise adhesive or cohesive applied to one
or both of the first surfaces of the first and second walls
adjacent to the first edges.

15. The package of any one of claims 12 to 14, wherein
the first surfaces are inside of the bag.

16. The package of any one of claims 12 to 14, wherein
the first surfaces are outside of the bag.

17. The package of claim 14, wherein the bag is
sealed, wherein the bag expands from the collapsed condition
to the expanded condition during cooking of the food product
including the grease or oil.

18. The package of any one of claims 12 to 17, wherein
the first and second walls have a flexibility allowing
flexing of the first and second walls by the microwave
cooking of the food product.



-19-


19. The package of any one of claims 12 to 18, wherein
the greaseproof paper is formed of raw fibers selected from
the group of 100% chemical softwood pulp and which are
highly refined, and having a basis weight in a range of
about 11.5 kg/ream to 20.5 kg/ream.

Description

Note: Descriptions are shown in the official language in which they were submitted.





WO 93/15976 ~ I 2 9 I 10 PCT/US93/00849
-1-
SINGLE LAYER, GREASEPROOF, FLEXIBLE PAPER POPCORN PACKAGE
BACKGROUND
The present invention relates generally to packages
for use in microwave ovens, and pertains more
particularly to an expandable bag having protection from
grease leaking and/or wicking from its expansion creases
or folds and/or to a flexible popcorn package made from a
single layer of greaseproof paper.
When microwave popcorn packages were first introduced
utilizing a microwave susceptor, the packages typically
were formed by expandable paperboard containers and often
the load of the microwave popcorn popping package was
located in a plastic bag positioned inside of the




WO 93/15976 PCT/US93/00849
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-2-
paperboard container including the microwave susceptor.
The paperboard container in most instances was unfolded
into an expanded size by the consumer prior to popping of
the popcorn kernels in the microwave oven but in some
instances was unfolded by the popping of the popcorn
kernels, with the popped popcorn being served in the
expanded paperboard containers. Early packages suffered
from several disadvantages including the bulk of
expandable paperboard containers which increased the
amount of material required to make the container and
thus its cost, increased the size of the packaging and
storage requirements, as well as increased the amount of
material which had to be disposed of after the
consumption of the popcorn raising environmental
concerns. Further, the dynamics of expanding the
paperboard container and/or plastic bag by the forces
generated while popping the kernels were typically
insufficient to maximize the volume of the package which
in turn prevented the popcorn from popping with greater
volume. Also, plastic bags are susceptible to melting
and often are difficult to handle with a hot food product
at least due to the poor insulating qualities of plastic.
To avoid these and other problems and with the development
of microwave susceptors applied in the form of a thin
coating such as disclosed in U.S. Patent No. 4,267,420
issued to William A. Brastad, the microwave popcorn
industry has turned to popcorn packages formed from
flexible paper bags.
However, paper microwave popcorn popping bags
including microwave susceptors encountered different
types of problems. For example, the load of a microwave
popcorn popping package includes unpopped popcorn
kernels, a cooking oil or grease, salt, and other .
ingredients such as colorings, flavorings, or the like.
It can be appreciated that during storage or
transportation of the filled microwave popcorn package by


212J1~0 -
-3-
1 the processor, the marketing agencies, and the consumer,
the oil and/or grease have a tendency to leak from
flexible paper packages, especially at high temperatures,
causing aesthetically unpleasant appearances. Further,
during microwave popping, the.oil and/or grease have a
tendency to wick from flexible paper packages. Current
flexible paper popcorn bags such as disclosed in United
States Patent No. 5,044,777 typically use a tri-laminate
of a greaseproof paper adhered to an outer fluorocarbon
treated, grease resistant paper with a microwave
susceptor sandwiched between. For example, the inner
layer could be formed of bleached greaseproof Kraft paper
of 11.5 kg. (25 lb.)/ream basis weight and the outer layer
could be formed of plain bleached Kraft paper of 13.5 kg.
(30 lb.)/ream basis weight. The two paper layers and the
adhesive therebetween together provide the needed grease
barrier in both storage and/or transportation at high
temperatures as well as during microwave cooking.
However, laminated paper popcorn bags suffer from several
disadvantages. First, the paper bag has a great deal of
stiffness resulting from the multiple layers themselves
but also their adhesive interconnection. Stiffness
detracts from the ability of the bag to inflate or expand
during microwave popping of the popcorn which may in turn
detrimentally affect the volume of the popped kernels.
Also, the lamination of the materials requires extra
assembly costs and the amount of materials used for each
bag adds to the economic and environmental costs.
Thus, there is a need to reduce the amount of
material and/or layers utilized in the formation of
flexible paper popcorn packages including a microwave
susceptor. Current efforts in single ply paper bags
which have been unsuccessful prior to the present
invention involve common greaseproof paper in combination
with surface coatings of fluorocarbons, such as FC-807
made by 3M, Inc., St. Paul, Minnesota, or equivalent.
However, such efforts have not resulted in commercially
p,MENDED SHEET




WO 93/15976 PCT/US93/00849
~~12~~i~~ _
-4-
successful packages as they do not provide adequate
greaseproof properties in storage, transportation, or
cooking throughout the paper. Further, when this paper
is creased such as at the corners in the pleats and
between the pleats and the top and bottom walls, fibers
in the paper and the coatings applied thereto fracture
and separate and reveal uncoated fiber ends which absorb
grease. Moreover, breaks or fractures might occur and
the oil and/or grease can leak out of the package.
Consequently, there is a continuing need for a
flexible paper popcorn package with reduced layers and
particularly formed of a single layer of flexible paper.
Further, as set forth above, the problem of grease
wicking and actual leaking is especially present at folds
and creases where the fibers of the paper and coatings
applied thereto for the greaseproofing characteristics
are fractured and/or separated. This problem has been
one of the major factors in limiting the amount that the
material and/or number of layers can be reduced in
flexible paper popcorn bags, as the mass and number of
layers of material are relied upon to provide the needed
grease barrier. Thus, a need exists for optionally
providing an added grease barrier at only those locations
especially at folds and creases where grease wicking and
leaking are a problem, with the added grease barrier
allowing minimization of the material and/or number of
layers at the remaining locations where grease wicking
and leaking are not such a problem.
Surprisingly, the above needs and other objectives
can be satisfied by providing a package in the form of a
bag including grease protectors for sealing the surfaces .
of the walls of the bag adjacent to their connecting,
folding edges to prevent the grease or oil from leaking .
or wicking from the interior volume of the bag.
In a preferred aspect, the package includes pleated,
expandable side walls, with the grease protectors located
_______. ____ ":..~_


CA 02129110 2003-10-09
22694-1540
-5-
inside of the bag where the inside surfaces of the pleats
overlie other inside surfaces of the bag and also located
outside of the bag where the outside surfaces of the pleats
overlie other outside surfaces of the bag.
In yet another preferred aspect of the present
invention, the bag holds popcorn kernels and grease or oil
for popping in a microwave oven, with the bag formed of a
single layer of greaseproof paper having a thickness
allowing the single layer to be flexed by the popping of the
popcorn kernels and also preventing the wicking and leaking
of the grease or oil through the single layer.
In yet another preferred aspect of the invention,
there is provided an expandable, paper, popcorn package for
holding popcorn kernels and grease or oil for popping in a
microwave oven comprising, in combination: a bag having an
interior volume and a closed end openable by the consumer
after microwave cooking; and susceptor means for converting
microwave energy into heat extending over a portion of the
bag, with the popcorn kernels and the grease or oil
generally overlying the susceptor means during microwave
cooking; characterized in that the bag is formed of a single
layer of greaseproof paper having a thickness allowing the
single layer to be flexed by the popping of the popcorn
kernels and also preventing the wicking and leaking of the
grease or oil through the single layer.
In yet another preferred aspect of the invention,
there is provided a package for holding a food product
including grease or oil and for heating in a microwave oven
comprising, in combination: a flexible bag including a
bottom wall, a top wall, and at least a first side wall
extending between the top and bottom walls, with the top,
bottom and side walls including first and second ends, with


CA 02129110 2003-10-09
22694-1540
-5a-
the first side wall including first and second pleats with
the pleats being connected together at first edges and with
the first pleat having a second, opposite edge connected to
the bottom wall and the second pleat having a third,
opposite edge connected to the top wall, with the bag
further including an end wall at the first ends of the top,
bottom and side walls; susceptor means for converting
microwave energy into heat extending over a portion of the
bottom wall spaced from the first and second ends of the
bottom wall; and means for closing the second ends of the
top, bottom, and side walls and for allowing the consumer to
open the package after microwave cooking; characterized in
means inside of the bag for sealing the first pleat to the
bottom wall adjacent to the second edge; means inside of the
bag for sealing the second pleat to the top wall adjacent to
the third edge, with the sealing means preventing the grease
or oil from leaking or wicking from inside the bag through
the edges, and further characterized in that the bottom,
top, and side walls are formed of a single layer of
greaseproof paper which prevents wicking and leaking of the
grease or oil through the single layer.
In yet another preferred aspect of the invention,
there is provided a package for holding a food product
including grease or oil comprising, in combination: an
expandable bag having an interior volume for holding the
food product and the grease or oil, with the interior volume
being defined by at least first and second walls connected
together at first edges, with each of the first and second
walls having first and second surfaces, with the bag having
a collapsed condition and an expanded condition, with the
interior volume of the bag increasing as the bag expands
from the collapsed condition to the expanded condition, with
the first and second walls being folded about the first


CA 02129110 2003-10-09
22694-1540
-5b-
edges with the first surfaces overlying each other in the
collapsed condition, with the first and second walls
extending from the first edges with the first surfaces being
spaced from each other in the expanded condition,
characterized in means for sealing the first surfaces
together adjacent to the first edges to prevent the grease
or oil from leaking or wicking from the interior volume of
the bag, and further characterized in that the first and
second walls are formed of a single layer of greaseproof
paper which prevents wicking and leaking of the grease or
oil through the single layer.
The present invention will become clearer in light
of the following detailed description of an illustrative
embodiment of this invention described in connection with
the drawings.
Brief Description of the Drawings
The illustrative embodiment may best be described
by reference to the accompanying drawings where:
Figure 1 shows a perspective view of a package
fabricated in accordance with the preferred teachings of the
present invention in generally its collapsed, storage
condition, but illustrated slightly expanded to show
constructional details.
Figure 2 shows a top plan view of the package of
Figure 1, with portions broken away to show constructional
details.
Figure 3 shows a perspective view of the package
of Figure 1 in its expanded condition.


CA 02129110 2003-10-06
22694-1540
-5c-
Figure 4 shows a cross-sectional view of the
package of Figure 1 in a condition slightly prior to its
expanded condition of Figure 3.
All figures are drawn for ease of explanation of
the basic teachings of the present invention only; the
extensions of the Figures with respect to number, position,
relationship, and dimensions of the parts to form the
preferred embodiment will be explained or will be within




WO 93/15976 PCT/US93/00849
X129110 _6_
1 the skill of the art after the following teachings of the
present invention have been read and understood. Further,
the exact dimensions and dimensional proportions to
conform to specific force, weight, strength, and similar
requirements will likewise be within the skill of the art
after the following teachings of the present invention
have been read and understood.
Where used in the various figures of the drawings,
the same numerals designate the same or similar parts.
Furthermore, when the terms "top", "bottom", "first",
"second", "side", "end", and similar terms are used
herein, it should be understood that these terms have
reference only to the structure shown in the drawings as
it would appear to a person viewing the drawings and are
utilized only to facilitate describing the invention.
Description of the Preferred Embodiment
A package for use in microwave ovens according to the
preferred teachings of the present invention is shown as
an expandable, flexible bag in the drawings and generally
designated 18. It will facilitate the ensuing
description to consider bag 18 in the horizontal position
when placed in the microwave oven as opposed to a
vertical or upright position when the contents of bag 18
are being consumed by the consumer. Therefore, bag 18
includes a bottom wall 20, a top wall 22; an end wall 24,
side walls 26 and a closed end 28. In the preferred
form, the width of bottom wall 20 is less than the width
of top wall 22, although the widths of walls 20 and 22
could be equal.
End wall 24 provides a non-opening permanent seal to
the first end of bag 18. Particularly, the cross sectional
makeup of end wall 24 includes a number of folds that are
not important to an understanding of the present invention
so will not be specifically described, although end wall
24 should be constructed so as to seal adequately the
vapor created within bag 18 during the heating thereof in
the microwave oven. In the preferred form of the present




WO 93/15976 PCT/US93/00849
-7-
1 invention, end wall 24 is shown as being of the type
shown in U.S. Patent No. 4,973,810 and is formed by
folding the first ends of bottom, top, and side walls 20,
22, and 26 over top wall 22. Alternatively, end wall 24
can have a flat rectangular or square configuration, with
such bags being commonly referred to as square bottom
bags in the trade. Further, bag 18 can optionally
include the non-heated flap of the type shown and
described in U.S. Patent No. 4,864,090. However, it
should be appreciated that end wall 24 can be a variety
of types and configurations such as but not limited to
the types shown in U.S. Patent Nos. 3,973,045; 4,450,180;
4,691,374; and 5,044,777.
In the most preferred form, side walls 26 include
gussets or pleats 26a, 26b, 26c and 26d that enable side
walls 26 to expand during a heating cycle. Particularly,
in the preferred form, pleats 26a and 26b are connected
together at first edges and have second and third,
opposite edges connected to bottom wall 20 and top wall
22, respectively. Likewise, pleats 26c and 26d are
connected together at fourth edges and have fifth and
sixth, opposite edges connected to bottom wall 20 and top
wall 22, respectively. In the preferred form, in its
collapsed condition, pleats 26a and 26c have the same
width and overlie bottom wall 20, and pleats 26b and 26d
have the same width which is greater than the width of
pleats 26a and 26c and overlie pleats 26a and 26c, ~.~ith
top wall 22 overlying pleats 26b and 26d. In the
preferred form, bottom and top walls 20 and 22 have a
width extending beyond the interconnections of pleats 26a
and 26b and of pleats 26c and 26d when bag 18 is in its
collapsed condition. The second, free ends of pleats
26a, 26b, 26c and 26d forming side walls 26, of bottom
wall 20, and of top wall 22 are co-planar, and have the
same extent or length from end wall 24.


CA 02129110 2003-10-06
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-8-
1 End 28 provides a peelable closure seal which fails
during microwave cooking adjacent the second, free ends
of bottom,~top and side walls 20, 22, and 26 or~in other
words, adjacent~the second end of bag 18. This peelable
seal failure allows trapped steam to vent from the
package, as well as allowing the consumer to open bag 18
after microwave cooking and prior to eating. In the most
preferred form, end 28 is formed in a manner as shown and
described in U.S. Patent No. 5,189,272, and includes first
and second V-shaped adhesive strips 34 and 36. Strip 34 is
located on bottom wall 20 having first and second,
straight legs 34a and 34b interconnected by their first
ends at an angle in the order of 140° and having their
second ends extending to. the interconnection of pleats
26a and 26c to~bottom wall 20~, respectively. Strip 36
overlies strip 34 and is located on top wa11.22 having
first and second, straight legs 36a and 36b
interconnected by their first ends at an angle in the
order of 140° and having their second ends extending to
the interconnection of pleats 26b and 26d to top wall 22,
respectively. The distance or spacing of the second ends
of legs 34a, 34b, 36a, and 36b from the second, free ends
of walls 20, 22, and 26. is greater than the distance or
spacing of the first ends and intersections of legs 34a,
34b, 36a, and 36b from the second, free ends of walls 20,
22, and 26. It can then be appreciated that leg 34a
adheres and seals pleat 26a to bottom wall 20, leg 34b
adheres and seals pleat 26c to bottom wall 20, leg 36a
adheres and seals pleat 26b to top wall 22, and leg 36b
adheres and seals pleat 26d to top wall 22. Further,
strips 34 and 36 adhere and seal bottom wall 20 to top
wall 22 at their central portions 37 intermediate the
interconnections of pleats 26a and 26b and of pleats 26c
and 26d.
Areas 38a, 38b, 38c and 38d are formed and defined by
the material between the free ends of walls 20, 22, and 26




WO 93/15976 ~ ~ ~ ~ ~ ~ ~ PCT/US93/00849
_g_
1 and strips 34 and 36 and located on the opposite side of
strips 34 and 36 forming the peelable seal than end 24,
with areas 38a, 38b, 38c, and 38d being free of adhesive
and unsealed in the preferred form. Due to the angular
orientation of legs 34a, 34b, 36a, and 36b, areas 38a,
38b, 38c, and 38d are of a triangular configuration.
Further, since the first ends of legs 34a, 34b, 36a, and
36b are located in the central portions 37 of bottom and
top walls 20 and 22 having widths extending beyond pleats
26a, 26b, 26c, and 26d and since legs 34a, 34b, 36a and
36b extend therefrom in a linear manner at an obtuse
angle to the opposite edges of pleats 26a, 26b, 26c, and
26d, areas 38a, 38b, 38c, and 38d are of a large size for
grasping by the consumer and specifically are considerably
larger than flaps formed by adhesive extending at small
angles relative to each other and only through the pleats
such as when a box-like shape is desired as disclosed in
U.S. Patent 5,044,777.
However, it should be appreciated that end 28 can be
a variety of types and configurations according to
preferred aspects of the present invention such as but
not limited to the types shown in U.S. Patent Nos.
3,973,045; 4,450,180; 4,691,374; 4,864,090; 4,973,810;
and 5,044,777.
Attention is now directed to a susceptor pad 30 that
extends over a portion of bottom wall 20 spaced from end
wall 24 and end 28. Susceptor pad 30 can be formed in
any suitable manner known in the art such as a metalized
plastic film adhered to bottom wall 20, as a paper backed
susceptor, or as a coating applied or printed to bottom
wall 20. Further, although susceptor pad 30 is shown as
overlying bottom wall 20 and thus located inside of bag
18, susceptor pad 30 can be located outside of bag 18
with bottom wall 20 overlying susceptor pad 30. Further,
placement of susceptor pad 30 can occur at the material
convertor or on the manufacturing lines.
It can then be appreciated that bag 18 can be
manufactured as current bags are manufactured for example




WO 93/15976 PCT/US93/00849
219110
-10-
1 of the type shown and described in U.S. Patent Nos.
4,450,180; 4,735,513; 4,878,765; 4,691,374; or 5,044,777.
In this regard, bag 18 can be formed by cutting a web of
material to length, folding that length of material to
form the tubular bag stock including bottom, top, and
side walls 20, 22, and 26, and then forming end wall 24
by folding and adhering bottom, top and side walls 20, 22,
and 26. It should be noted that the overlapping edges of
the web of material forming the tubular bag stock has
been omitted in Figures 1-3 for ease of illustration.
It should also be noted that the free, second ends of
bottom, top, and side walls 20, 22, and 26 are all of the
same length and specifically do not require any special
cuts and/or do not require extra components to form tabs
or flaps.
It can further be appreciated that bag 18 can be
filled with the desired food product as current bags are
filled for example of the type shown and described in
U.S. Patent 4,450,180. After filling, strips 34 and 36
can be adhered to walls 20, 22, and 26 utilizing standard
equipment presently utilized to form the peelable seal of
current bags. It of course should be appreciated that
the particular manner of manufacture and filling of bag
18 can be done in a variety of ways and manners such as
but not limited to the example set forth above.
For the sake of completeness, it will be assumed
that the contents of bag 18 are popcorn kernels and the
popped kernels have been generally indicated by the
reference numeral 40, having been popped when in the
microwave oven. Particularly, as with current bags, bag
18 in a collapsed condition is placed in a microwave oven
with bottom wall 20 resting upon the bottom surface of
the oven cavity. When subjected to microwave energy,
susceptor pad 30 converts microwave energy into heat,
with the heat and remaining microwave energy causing the
popping of the kernels and the creation of water vapor.
The water vapor and heated air cause side walls 26 to

r.. ~ 2129I1~ ! f~
-11-
1 expand to extend from their connecting edges at an
angular relation to each other and the inside surfaces of
pleats 26a, 26b; 26c, and 26d being spaced from the inside
surfaces of bottom and top walls 20 and 22, expanding bag
18 and increasing the interior volume inside of bag 18
for popped kernels 40. It can then be appreciated that
due to its flexible nature, bag 18 will expand to a
football like shape, including separating pleats 26a and
26b and pleats 26c and 26d adjacent to the second ends of
bottom, top and side walls 20, 22, and 26.
According to the most preferred teachings of the
present invention, bag 18 is formed of a single layer of
greaseproof paper having a thickness allowing the single
layer to be flexed by the popping of the popcorn kernels
and also providing adequate greaseproof properties in
storage, transportation,, or cooking throughout the thick-
ness of the paper to prevent wicking and leaking of grease
or oil through the single layer. It has been discovered
that by the selection of raw fibers as well as highly
refining the raw fibers in the process of making the
paper, the fibers themselves in the paper are resistant
to.grease staining and gives the paper greaseproof
properties even when folded or creased. Particularly,
the highly refined fibers have less tendency to fracture
revealing uncoated fiber ends which absorb grease, but
rather the bonds between the fibers tend to stretch, bend,
or fracture and thus not revealing fractured fiber ends.
Specifically raw fibers selected from the group of 100
chemical softwood pulp such as 100 bleached Kraft
softwoods and which are highly refined to a freeness
level in the order of 150 to 250 cubic centimeters have
been found to provide adequate greaseproof properties
when formed into paper having a basis weight of 11.5 kg.
(25 lb.)/ream to 20.5 kg. (45 lb.)/ream and in the most
preferred form in the order of 16 kg. (35 lb.)/ream.
In the most preferred form, bag 18 is formed of a single
layer of paper, Code No. 220-3510 produced by Rhinelander
Paper Company, 515 w. Davenport Street, Rhinelander,
wisconsin 54501.
n~NDE~ SNEEZ




WO 93/15976 : ~..~ '~ 9 ~~~~ A PCT/US93/00849
-12-
1 Consequently, with the foregoing description in mind,
it should now be apparent that bag 18 according to the
teachings of the present invention is much more flexible
than current conventional popcorn bags because of its
single layer and elimination of the laminating adhesive.
Further, benefits of the single layer of paper softening
during microwave cooking due to heat and steam give bag
18 more flexibility and less stiffness. Due to this
increased flexibility, bag 18 according to the preferred
teachings of the present invention inflates or expands
from its collapsed, storage condition to an inflated or
expanded condition having a larger interior volume than
the same size current conventional popcorn bags, with bag
18 of the present invention allowing the popped kernels
to pop with greater volume.
It can further be appreciated that the single
layer forming bag 18 according to the teachings of the
present invention provides economic advantages over
current multilaminate popcorn bags by reducing the amount
of paper material used for each bag 18 and also by
eliminating the adhesive and the laminating steps
required in multilaminate popcorn bags. Additionally,
with the reduction in the amount of paper material used
for each bag 18 and the elimination of the laminating
adhesive, less package material in the form of garbage
after the consumption of the popcorn is required to be
disposed of resulting in environmental advantages over
multilaminate popcorn bags.
When the amount of paper material utilized in the
formation of bags 18 is minimized, whether of a
multilaminate and especially of a single-ply construction,
the consistent prevention of grease wicking and actual
leaking in the fold or creased areas is a problem. Bag
18 according to the most preferred teachings of the
present invention provides an added option of provisions
for built-in grease leak protection at the creases.
Particularly, in the most preferred form, grease
protector .42a " 42b, 42c, and 42d are provided located




WO 93/15976 PCT/US93/00849
2129110
-13-
1 inside of bag 18 for sealing bottom wall 20 to pleat 26a,
top wall 22 to pleat 26b, bottom wall 20 to pleat 26c,
and top wall 22 to pleat 26d, respectively, adjacent to
their respective connecting edges, with grease protectors
42a, 42b, 42c, and 42d sticking or joining the inside
surfaces of bottom wall 20 to pleat 26a, top wall 22 to
pleat 26b, bottom wall 20 to pleat 26c, and top wall 22
to pleat 26d, respectively, together adjacent to their
respective connecting edges. Further, in the most
preferred form, grease protectors 44a and 44b are
provided located outside of bag 18 for sealing pleat 26a
to pleat 26b and pleat 26c to pleat 26d, respectively,
adjacent to their respective connecting edges, with
grease protectors 44a and 44b sticking or joining the
outside surfaces of pleat 26a to pleat 26b and pleat 26c
to pleat 26d, respectively, together adjacent to their
respective connecting edges. In the most preferred form,
grease protectors 42a, 42b, 42c, 42d, 44a and 44b are
applied during the printing process in the form of strips
of preapplied heat seal adhesive on one or both sides of
the connecting edges or of strips of preapplied cohesive
on both sides of the connecting edges, such as Duraset 12,
or equivalent.
Grease protectors 42a, 42b, 42c, 42d, 44a and 44b
are selected to actually seal the paper forming bag 18
together just above and adjacent the connecting edges.
Grease protectors 42a, 42b, 42c, and 42d actually block
the flow of grease to the folded or creased areas of the
connecting edges, and grease protectors 44a and 44b block
the flow of grease away from the folded or creased areas
of the connecting edges, thus preventing grease wicking
or leaking. Further, in the preferred form, the adhesive
. or cohesive forming grease protectors 42a, 42b, 42c, 42d,
44a and 44b is selected to release or peel during
expansion or inflation of bag 18 during microwave cooking
such that the expanded or inflated volume of bag 18 will




WO 93/15976 PCT/US93/00849
0
-14-
1 not be reduced utilizing grease protectors 42a, 42b, 42c,
42d, 44a and 44b from the expanded or inflated volume of
bag 18 not utilizing grease protectors 42a, 42b, 42c,
42d, 44a and 44b.
It can then be appreciated that grease protectors
42a, 42b, 42c, 42d, 44a and 44b according to the
teachings of the present invention provide an added
grease barrier at the folded and creased areas where
grease wicking and leaking are especially a problem,
with grease protectors 42a, 42b, 42c, 42d, 44a, and 44b
allowing minimization of the material and/or number of
layers forming bag 18 where grease wicking and leaking
are not such a problem.
Thus since the invention disclosed herein may be
embodied in other specific forms without departing from
the spirit or general characteristics thereof, some of
which forms have been indicated, the embodiments
described herein are to be considered in all respects
illustrative and not restrictive. The scope of the
invention is to be indicated by the appended claims,
rather than by the foregoing description, and all changes
which come within the meaning and range of equivalency of
the claims are intended to be embraced therein.
What is claimed is:

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2005-01-25
(86) PCT Filing Date 1993-01-29
(87) PCT Publication Date 1993-08-19
(85) National Entry 1994-07-28
Examination Requested 1999-10-27
(45) Issued 2005-01-25
Deemed Expired 2008-01-29

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $0.00 1994-07-28
Maintenance Fee - Application - New Act 2 1995-01-30 $100.00 1994-12-12
Registration of a document - section 124 $0.00 1995-10-05
Maintenance Fee - Application - New Act 3 1996-01-29 $100.00 1995-12-18
Maintenance Fee - Application - New Act 4 1997-01-29 $100.00 1997-01-17
Maintenance Fee - Application - New Act 5 1998-01-29 $150.00 1998-01-13
Maintenance Fee - Application - New Act 6 1999-01-29 $150.00 1999-01-14
Request for Examination $400.00 1999-10-27
Maintenance Fee - Application - New Act 7 2000-01-31 $150.00 2000-01-04
Maintenance Fee - Application - New Act 8 2001-01-29 $150.00 2001-01-04
Maintenance Fee - Application - New Act 9 2002-01-29 $150.00 2002-01-03
Maintenance Fee - Application - New Act 10 2003-01-29 $200.00 2003-01-03
Maintenance Fee - Application - New Act 11 2004-01-29 $200.00 2003-12-15
Final Fee $300.00 2004-11-16
Maintenance Fee - Application - New Act 12 2005-01-31 $250.00 2004-12-13
Maintenance Fee - Patent - New Act 13 2006-01-30 $250.00 2005-12-14
Registration of a document - section 124 $100.00 2010-07-13
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
GENERAL MILLS, INC.
Past Owners on Record
MCDONALD, DUANE L.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Claims 1995-08-19 4 278
Representative Drawing 1998-07-28 1 21
Description 2003-09-26 14 700
Claims 2003-09-26 4 245
Description 2003-10-06 17 788
Claims 2003-10-06 5 178
Description 2003-10-09 17 798
Description 1995-08-19 14 1,029
Cover Page 1995-08-19 1 43
Abstract 1995-08-19 1 98
Drawings 1995-08-19 4 300
Description 1999-12-15 14 694
Claims 1999-12-15 4 187
Representative Drawing 2004-05-07 1 31
Cover Page 2004-12-21 1 73
Prosecution-Amendment 1999-11-12 1 30
Assignment 1994-07-28 9 392
PCT 1994-07-28 19 786
Prosecution-Amendment 1999-10-27 1 45
Prosecution-Amendment 2003-03-26 2 66
Prosecution-Amendment 2003-09-26 9 482
Prosecution-Amendment 2003-10-06 11 404
Prosecution-Amendment 2003-10-09 5 185
Correspondence 2004-11-16 1 30
Assignment 2010-07-13 6 149
Fees 1997-01-17 1 49
Fees 1995-12-18 1 52
Fees 1994-12-12 1 44