Pod-based grain popping apparatus and methods of popping grains

Abstract

A grain-popping machine and associated pod-based popping method is disclosed. The grain-popping is configured to receive a pod. Each pod includes a plurality of cells, with each cell preferably containing a single grain kernel or seed, flavoring, and a cooking medium such as oil or shortening. In a preferred embodiment, the pod is loaded into the grain-popping machine through a slot so that it is held in position below a heating element. The heating element is activated to begin a popping sequence. When each grain kernel or seed in the pod reaches popping temperature, it absorbs the flavoring in its cell and ejects through the bottom of the pod, which is weakened to ease ejection, into a bowl positioned in a receiving area of the grain-popping machine. The pod is then removed and disposed of.

1 . A grain popping system comprising:
 a housing defining a chamber, wherein the chamber is at least partially enclosed to define an interior space, and wherein the chamber comprises a top and a bottom;   a heating element positioned in the interior space of the chamber;   a grain pod comprising at least one cell, wherein the cell is defined by cell walls having a top edge and a bottom edge, the cell having a first width between the top edge of the cell walls and a second width between the bottom edge of the cell walls, each cell containing flavoring, a cooking medium, and one or more grains, wherein the grain pod comprises a top cover and a bottom cover, wherein the cell walls extend between the top cover of the grain pod and the bottom cover of the grain pod, and wherein the top cover of the grain pod is attached to the top edge of the cell walls;   a pod dock configured to receive the grain pod, wherein the pod dock is positioned inside the interior space of the chamber adjacent to the heating element, and wherein the pod dock is positioned closer to the bottom of the upper chamber than the heating element;   wherein the bottom cover of the grain pod faces the bottom of the chamber when the grain pod is positioned in the pod dock;   wherein heating the grain pod heats the cooking medium and the one or more grains in the cell, thereby causing the one or more grains to exit the grain pod by piercing the bottom cover of the grain pod.   
     
     
         2 . The grain popping system of  claim 1 , wherein the chamber includes a mechanical weakener that weakens the bottom cover of the grain pod along a portion of the bottom edge of the cell walls to facilitate exit of the one or more grains from the cell. 
     
     
         3 . The grain popping system of  claim 2 , wherein the mechanical weakener is a perforating device. 
     
     
         4 . The grain popping system of  claim 2 , wherein the mechanical weakener is configured to weaken the bottom cover along seventy five percent or less of the bottom edge of the cell wall. 
     
     
         5 . The grain popping system of  claim 4 , wherein the mechanical weakener is configured to weaken the bottom cover along fifty percent or less of the bottom edge of the cell wall. 
     
     
         6 . The grain popping system of  claim 1 , wherein each cell contains a single grain. 
     
     
         7 . The grain popping system of  claim 1 , wherein the bottom cover of the grain pod is attached to the bottom edge of the cell walls at least in part by a temperature sensitive adhesive that weakens at elevated temperatures. 
     
     
         8 . The grain popping system of  claim 1 , wherein the grain pod is formed from a piece of a polymer material. 
     
     
         9 . The grain popping system of  claim 8 , wherein the cells of the grain pod are formed by mechanically deforming the heated polymer to form the at least one cell. 
     
     
         10 . The grain popping system of  claim 9 , wherein the bottom cover of the grain pod comprises the deformed polymer material. 
     
     
         11 . The grain popping system of  claim 1 , wherein at least one protrusion extends from a bottom surface of the heating element, and wherein the at least one protrusion is positioned such that when the grain pod is positioned in the pod dock, the at least one protrusion is centered over the at least one cell. 
     
     
         12 . The grain popping system of  claim 1 , wherein the first width is less than and the second width. 
     
     
         13 . A method of popping grains, the method comprising:
 providing a grain pod, the grain pod comprising at least one cell defined by cell walls having a top edge and a bottom edge, the cell having a first width between the top edge of the cell walls and a second width between the bottom edge of the cell walls, each cell containing flavoring, a cooking medium, and one or more grains, wherein the grain pod comprises a top cover and a bottom cover, wherein the cell walls extend between the top cover and the bottom cover, and wherein the top cover of the grain pod is attached to the top edge of the cell walls and the bottom cover of the grain pod is attached to the bottom edge of the cell wall;   providing a grain popping machine, said grain popping machine comprising:
 a housing defining a chamber, wherein the chamber is at least partially enclosed to define an interior space, and wherein the chamber comprises a top and a bottom; 
 a heating element positioned in the interior space of the chamber; 
 a pod dock configured to receive the grain pod, wherein the pod dock is positioned inside the interior space of the chamber adjacent to the heating element, and wherein the pod dock is positioned closer to the bottom of the upper chamber than the heating element; 
   inserting the grain pod into the pod dock such that the bottom cover of the grain pod faces the bottom of the chamber when the grain pod is positioned in the pod dock;   activating the heating element to heat to the cooking medium and grains in the cell, thereby causing the grains to exit the grain pod by piercing the bottom cover of the grain pod.   
     
     
         14 . The method of popping grains according to  claim 11 , further including mechanically weakening the bottom cover of the grain pod along a portion of the bottom edge of the cell walls to facilitate exit of a grain from the cell. 
     
     
         15 . The method of popping grains according to  claim 12 , wherein mechanically weakening the bottom cover of the grain pod comprises perforating the bottom cover of the grain pod. 
     
     
         16 . The method of popping grains according to  claim 11 , wherein the bottom cover is mechanically weakened along seventy five percent or less of the bottom edge of the cell wall. 
     
     
         17 . The method of popping grains according to  claim 14 , wherein the bottom cover is mechanically weakened along fifty percent or less of the bottom edge of the cell wall. 
     
     
         18 . The method of popping grains according to  claim 11 , wherein each cell of the grain pod contains a single grain. 
     
     
         19 . The grain popping system of  claim 11 , wherein the grain pod is formed from a piece of a polymer material. 
     
     
         20 . The grain popping system of  claim 16 , wherein the cells of the grain pod are formed by mechanically deforming the heated polymer to form the at least one cell. 
     
     
         21 . The grain popping system of  claim 17 , wherein the bottom cover of the grain pod comprises the deformed polymer material 
     
     
         22 . The method of popping grains according to  claim 11 , wherein at least one protrusion extends from a bottom surface of the heating element, and wherein the at least one protrusion is positioned such that when the grain pod is positioned in the pod dock, the at least one protrusion is centered over the at least one cell. 
     
     
         23 . The method of popping grains according to  claim 11 , wherein the first width is less than and the second width.