Container for microwave popcorn and method and apparatus for making the same

Abstract

A container for use in making popcorn in a microwave oven has an outer enclosure enclosing an outer cavity. The outer enclosure is preferably made from a rigid or semi-rigid microwave transparent material. An inner enclosure is enclosed within the outer cavity. A susceptor is provided for absorbing microwave radiation to heat popcorn kernels. The inner enclosure will release a plurality of un-popped popcorn kernels and a charge enclosed in the inner enclosure when the container is subjected to a heat source such as microwave radiation. The outer enclosure is movable, by application of external forces to the outer enclosure, from a first configuration to a second erected configuration and the outer cavity has increased in size so as to accommodate popped kernels released from the inner enclosure.

1 . A container for use in making popcorn in a microwave oven, said container comprising: 
 a) an outer enclosure comprising a plurality of panels enclosing an outer cavity, said outer enclosure made from a rigid or semi-rigid microwave transparent material;    b) an inner enclosure enclosed within said outer cavity and enclosing an inner cavity, said inner enclosure including a base portion with a susceptor for absorbing microwave radiation to heat popcorn kernels located in the vicinity of said susceptor, said inner enclosure having an opening sealed by a seal;    c) a plurality of un-popped popcorn kernels and a charge enclosed in said inner cavity, wherein at least some of said plurality of kernels will pop and expand when said container is subjected to microwave radiation, and wherein the pressure in said inner cavity will increase and said seal will be released to release said popped kernels from said inner enclosure within said outer cavity;    said outer enclosure wherein said panels are in generally flattened rectangular configuration with four side edges, and wherein said panels are formed as opposed generally symmetrical wedge shapes at each of the four side edges of said rectangle, and wherein said outer enclosure and said inner enclosure are adapted such that said outer enclosure is movable, by application of external forces to said outer enclosure, from a first configuration wherein said outer enclosure and said inner enclosure are in said generally flattened configuration to a second configuration wherein said outer enclosure is in a self-supporting, erected generally rectangular parallelepiped configuration and said outer cavity has increased in size so as to accommodate said popped kernels released from said inner cavity.    
   
   
       2 . A container for use in making popcorn in a microwave oven, said container comprising: 
 a) a self erecting panel container made from a rigid or semi-rigid microwave transparent material and having an expandable internal enclosed cavity, said container being movable from a first generally flat configuration to a second self-supporting, erected configuration, whereby the size of said cavity is increased;    b) an inner pouch containing a plurality of popcorn kernels and an associated charge, said pouch having a susceptor for absorbing microwave radiation to heat said kernels, and said pouch being located within said expandable cavity, wherein at least some of said plurality of kernels will pop and be released by said pouch within said cavity and accommodated within said enclosed cavity, when said container is subjected to microwave radiation.    
   
   
       3 . A container as claimed in  claim 1  wherein said microwave transmissible material is a cardboard and said cardboard is coated on at least one side with a grease resistant coating.  
   
   
       4 . A container as claimed in  claim 1  wherein said seal at said opening is formed with a heat activated adhesive, such that when said container is subjected to microwave radiation, said adhesive will soften to release said seal.  
   
   
       5 . A container as claimed in  claim 1  wherein said inner enclosure is formed with a generally rectangular or square configuration and is sealed on three sides thereof.  
   
   
       6 . A container as claimed in  claim 1  wherein said outer enclosure has a base and said inner enclosure is affixed to said base.  
   
   
       7 . A container as claimed in  claim 5  wherein said outer enclosure has a square or rectangular base and a side wall surrounding and extending up from said base, and wherein said inner enclosure is affixed to said base at a bottom panel, and said bottom panel extends beyond said base of said outer enclosure to provide a trough above said base.  
   
   
       8 . A container for use in making popcorn in a microwave oven, said container comprising: 
 a) a rigid or semi-rigid, outer housing made from a microwave transmissible material, said housing defining and enclosing an internal cavity; said housing having at least one side wall panel and an outwardly extending tab portion protruding outwardly in relation to said side wall panel and being configured and oriented to be suitable for holding said container when said internal cavity is closed;    b) a plurality of popcorn kernels and an associated charge in said cavity,    c) a susceptor for absorbing microwave radiation to heat said kernels, wherein at least some of said plurality of kernels will pop within said cavity, when said container is subjected to microwave radiation.    
   
   
       9 . A container as claimed in  claim 8  wherein said housing is constructed with at least two housing portions joined together with at least one overlapping housing section positioned proximate said tab portion, and wherein said tab portion is attached to a removable lid portion, said tab portion permitting said lid portion to be readily opened.  
   
   
       10 . A container for making popcorn in a microwave oven, comprising: 
 a) an outer enclosure made from a rigid or semi-rigid material having and being movable between a first, low volume configuration wherein said outer enclosure is in a generally flat configuration, and a second high volume, self-supporting configuration;    b) a pouch within said outer enclosure, said pouch containing popcorn kernels;    said outer enclosure comprising a plurality of hinged, at least partially overlapping panels having at least portions which slide across each other while said outer enclosure moves from said first configuration to and substantially reaches said second configuration.    
   
   
       11 . The container of  claim 10  further comprising a latch for latching said outer enclosure in said high volume configuration, wherein said latch comprises co-operating positions of at least two of said overlapping panels.  
   
   
       12 . The container of  claim 10  wherein said outer enclosure has a pair of side walls which, in said high volume configuration are upstanding, said pair of side walls having co-operating features which latch together in said high volume configuration in order to maintain said outer enclosure in said high volume configuration.  
   
   
       13 . The container of  claim 10  wherein said container further comprises a susceptor.  
   
   
       14 . The container of  claim 13  wherein said pouch also contains a charge to facilitate popping of said kernels.  
   
   
       15 . The container of  claim 10  wherein said pouch has a closed opening which opens when said kernels are popping under the influence of a source of microwave heating.  
   
   
       16 . A container for use in making popcorn in a microwave oven, said container comprising: 
 a) an outer enclosure comprising a plurality of panels defining an outer cavity, said outer enclosure made from a rigid or semi-rigid microwave transparent material;    b) an inner enclosure enclosed within said outer cavity and defining an inner cavity, said inner enclosure having a sealed opening;    c) a susceptor for absorbing microwave radiation to heat popcorn kernels located in the inner enclosure;    d) a plurality of un-popped popcorn kernels and a charge enclosed in said inner cavity, wherein at least some of said plurality of kernels will pop and expand when said container is subjected to microwave radiation, and wherein the pressure in said inner cavity will increase a seal at said sealed opening will be released to release said popped kernels from said inner enclosure to said outer cavity;    said outer enclosure and said inner enclosure being adapted such that said outer enclosure is movable, by application of external forces to said outer enclosure, from a first configuration wherein said outer enclosure and said inner enclosure are in a generally flat configuration to a second configuration wherein said outer enclosure is in an erected, self-supporting configuration and said outer cavity has increased in size so as to accommodate within said enclosed inner cavity, all of said popped kernels released from said inner cavity.    
   
   
       17 . A container for use in making popcorn in a microwave oven, said container comprising: 
 a) a self erecting outer enclosure having an internal cavity, said outer enclosure being movable from a first generally flattened configuration to a second erected self-supporting configuration, whereby the volume of said internal cavity is increased in said second erected configuration, said outer enclosure comprising a plurality of hinged, at least partially overlapping panels which have at least portions that slide across each other while said outer enclosure moves from said first configuration to said second configuration;    b) an inner enclosure containing a plurality of un-popped popcorn kernels and said inner enclosure being located within said expandable internal cavity, said pouch inner enclosure being arranged for releasing popping kernels into said internal cavity, when said container is in said second configuration and is subjected to a source of heat, and said inner cavity encloses and accommodates all of the popped kernels therein.    
   
   
       18 . A container as claimed in  claim 17  further comprising a susceptor adapted to absorb heat energy from said heat source to heat said kernels, wherein said source of heat is microwave radiation and said outer enclosure is made from a microwave transparent material.  
   
   
       19 . A container as claimed in  claim 18  wherein said susceptor is positioned in said internal cavity of said outer enclosure.  
   
   
       20 . A container as claimed in  claim 17  wherein said inner enclosure is made with an opening formed between two parts of said inner enclosure, said opening being sealed with a heat activated adhesive before said inner enclosure is subjected to heating by microwave radiation, such that when said container is subjected to microwave radiation, said heat activated adhesive will soften to release said seal and allow said opening to open.  
   
   
       21 . A container as claimed in  claim 17  wherein said outer enclosure is adapted so that said container is self-supporting when said outer enclosure is in said erected configuration.  
   
   
       22 . A container as claimed in  claim 17  where said outer enclosure comprises: 
 a) a top panel, a rear wall panel, a base panel and a front wall panel, each of said top, rear, base and front panels, being interconnected at transverse fold lines, in series, along at least one transverse edge and each of said top, rear, base and front panels having a first side edge and a second opposite side edge, each of said first side edges of said top, rear base and front panel being in general longitudinal alignment with each other, and each of said second side edges of said top, rear base and front panel being in general longitudinal alignment with each other;    b) a plurality of side wall panels, each of said top, rear, base and front panels having a side wall panel interconnected at longitudinal fold lines along each of said first and second side edges;    said side panels of said top, rear, base and front panels, co-operating to provide an outer enclosure adapted for movement between said first and second configurations.    
   
   
       23 . A container as claimed in  claim 22  wherein side panels interconnected along said first side edge have features which interlock when said container is moved to said second configuration relationship for assisting in maintaining said outer enclosure in said second configuration.  
   
   
       24 . A container as claimed in  claim 22  wherein said top panel has one or more score lines defining the outline of an at least partially removable lid portion of said container.  
   
   
       25 . A container as claimed in  claim 22  wherein said top panel has a tab extension for holding said container.  
   
   
       26 . A container as claimed in  claim 25  wherein said front panel has a slot for receiving said tab extension to thereby temporary close said lid portion.  
   
   
       27 . A container as claimed in claim in  claim 10  wherein said microwave transparent material is cardboard.  
   
   
       28 . A container as claimed in  claim 1  wherein said outer enclosure comprises at least two panels, said panels adapted for movement in sliding relation relative to each other when said outer enclosure moves from said first configuration to said second configuration.  
   
   
       29 . A container as claimed in  claim 2  wherein said outer enclosure comprises at least two panels, said panels adapted for movement in sliding relation relative to each other when said outer enclosure moves from said first configuration to said second configuration.  
   
   
       30 . A container as claimed in  claim 2  wherein said microwave transmissible material is a cardboard.