WO1992022475A1

WO1992022475A1 - Microwave popcorn product

Info

Publication number: WO1992022475A1
Application number: PCT/US1992/004955
Authority: WO
Inventors: William E. Archibald
Original assignee: Hunt-Wesson, Inc.
Priority date: 1991-06-14
Filing date: 1992-06-11
Publication date: 1992-12-23
Also published as: CA2111328A1; MX9202863A; CA2111328C

Abstract

A food product comprising an edible charge of popping corn (10) and a bag (12) containing that charge and suitable for use in a microwave open. The bag is preferably of a tube type, and includes generally flat front (14) and back (16) panels and two inwardly folded side panels (20 and 22). The folds of the side panels preferably form two or more gussets (20a, 20b, 22a, 22b). The bag may be made of single ply paper sufficiently stiff to support the bag in an expanded position and maintain its approximate expanded shape achieved during cooling but flexible enough to be readily expanded. The gussets in the side panels are formed to open readily, and have independently movable ends (23), thereby enabling the bag to inflate more completely and become more rounded.

Description

MICROWAVE POPCORN PRODUCT

FIELD OF THE INVENTION

The present invention relates to microwave food products, and more particularly to bags containing popping corn.

BACKGROUND OF THE INVENTION

Currently available popcorn intended for cooking in a microwave oven is usually packaged in a two-ply paper bag, which may have a flat bottom or a wedge-shaped bottom. The bag contains a charge of edible ingredients, usually including corn kernels, shortening and sometimes seasoning or flavoring.

The bags are first formed in a bag-making plant and are later filled as part of a separate operation, usually at a different location. The bags should there- fore be readily stackable, shipable and be handleable in a mechanized manner.

Since the volume of popped corn is vastly greater than that of the unpopped kernels, the container must have the ability to expand during cooking. For this reason, the bag is capable of unfolding under the internal pressure of the steam released by the exploding kernels and the pressure of the expanding kernels themselves. Bags of this type are described in U.S. Patents Nos. 4,571,337 (Cage et al.) and 3,851,574 (Katz et al.). Although these patents show bags with flat bottoms, bags with wedge-shaped bottoms are presently more common.

The configuration and construction of the bag should help to maximize the "pop volume"; of the corn. Not only does increased pop volume result in a larger volume of edible product (both real and perceived) , but it has been found that increased pop volume results in a lighter, fluffier popcorn product with improved textural qualities. In general, bags with wedge-shaped bottoms containing ready-to-pop corn are of either pinched bottom or tube construction. These two types of bags are similar in most respects, the bottom being formed by bonding together the front and back panels of the bag at their bottom edges. There is thus no separate bottom panel. A typical bag may include a seamless and generally flat front panel, a generally flat back panel with an over¬ lapping seam running its full length at or near its center, and two side panels that connect the front and back panels. The side panels are each folded inwardly to form a gusset that permits the bag to expand. In a pinched bottom bag the sealed bottom edge is folded over itself, whereas in a tube bag there is no such fold at the bottom.

In a typical ready-to-pop bag the edible charge is placed inside the bag, resting on a susceptor that is contiguous with a center section of the front panel. The bag is sealed at the top after filling by bonding together the top edges of the front and back panels. The gussets of the folded bag intrude well into the bag interior, extending between at least some portion of the charge and the back panel. Since the upper and lower sections of the bag remain essentially empty, they are easily flattened and folded over the more bulky center section.

When the still folded bag is to be used, it is placed inside the oven with the center section of the front panel resting on the oven floor, so that the charge rests on the susceptor and the gussets of the side panels overlay a portion of the charge. During cooking, the internal pressure of the steam released by the kernels and the pressure of the popped kernels themselves cause the two end sections of the bag to unfold gradually.

A typical popcorn bag may, however, yield less than the maximum possible pop volume. This common deficiency in bag performance can be attributable, at least in part, to the configuration of the bag and to such factors as the size and stiffness of the gussets.

The gussets intrude into the bag to the greatest extent when the bag is folded flat and the gussets are closed. As the cooking commences, the gussets define a relatively narrow channel between them, which widens as the cooking progresses and the bag expands. The popped kernels must pass through this channel to move vertically into the upper section of the bag. Consequently some of the kernels that are among the first to pop are forced to move laterally a considerable distance toward the center of the bag before they can move upwardly away from the susceptor.

In addition, some kernels break loose from the charge prior to or during cooking and lodge themselves in the folds between the panels and the gussets. In many instances the gussets do not open sufficiently or early enough to release these kernels and allow them to pop properly.

The opening of the gussets as the bag expands is essential to freeing the trapped kernels, but does not, in itself, assure that these kernels return to the susceptor and the center of the bag. The loose kernels are, how¬ ever, prompted to so move by any rounding of the front panel (on which the bag rests during cooking) that takes place and by the shaking movement of the bag caused by the exploding kernels. The more pronounced the curvature of the front panel, the more tendency the kernels will have to move toward the susceptor. SUMMARY OF THE INVENTION

The present invention provides a microwave food product comprising an edible charge of popping corn and an expandable bag containing that charge. The improved design of the bag decreases the number of unpopped kernels and increases the pop volume, thus improving the textural qualities of the corn.

The bag is preferably made of paper. It may have an inner layer of non-wicking greaseproof paper and an outer layer of kraft paper, or it may be of single ply construction. The paper used should have dimensional stability and should be flexible, yet sufficiently stiff to maintain an expanded shape and keep the bag from sagging or drooping after the corn has popped.

The bag can have generally flat front and back panels, and two side panels folded inwardly to form gussets. Advantageously, each side panel forms two or more gussets. This multiple gusset construction, with each gusset being smaller, results in a larger channel at the center of the bag between the gussets that permits relatively free upward movement of the corn as the bag expands. In addition, the multiple gusset construction allows the bag to expand more fully and with less resis¬ tance. These features of the bag promote increased pop volume.

According to another aspect of the invention, the bag can be formed in such a manner that the gusset ends, i.e., the corners at the ends of the gussets, are each independently movable. The resulting bag is thus more easily expanded during cooking and takes on a more rounded shape. Its rounded bottom surface promotes desirable rocking movement during cooking. The features of multiple gussets and independently movable gusset ends can be advantageously combined in a single bag to promote the highest pop volume and best textural qualities of the corn.

An alternative bag construction has a pinched bottom configuration. The gusset ends at the bottom of this bag are not independently movable, but the bag retains many other advantages of multiple gusset construction. Still another multiple gusset bag has a flat bottom, the side panels being scored to define triangular and trapezoidal areas near the bottom end.

In one form of the invention the back panel of the bag, in the collapsed configuration, is folded so as to expose a portion of each side panel that forms at least one gusset. The back panel is thus folded along score lines, thereby defining strips extending along each side edge of the bag in which the bag has a thickness of four layers. A center section of the bag between the strips has a lesser thickness.

Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an unexpanded bag of ready-to-pop popcorn when first placed in a micro¬ wave oven;

FIG. 2 is a cross-sectional view of the bag of FIG. 1 and contents taken along a line 2-2;

FIG. 3 is a perspective view of the bag of FIG. 1 in the early stages of cooking and in a partially expanded condition;

FIG. 4 is a cross-sectional view of the bag of Fig. 1 and its contents taken along a line 4-4 of FIG. 3;

FIG. 5 is a perspective view of the bag of FIG.

1 after full expansion;

FIG. 6 is a cross sectional view of the expanded bag and contents taken along line 6-6 of FIG. 5.;

FIG. 7 is a perspective of an alternative bag construction, having reverse folded gussets, shown in an unexpanded condition;

FIG. 8 is an end view of the unexpanded bag of FIG. 7;

FIG. 9 is a perspective view of an alternative pinched bottom bag construction, shown in an expanded condition;

FIG. 10 is a perspective view of another alter¬ native bag, of flat bottom construction, shown in a partially expanded condition; and

FIG. 11 is a perspective view of the bag of FIG.

10, shown in a fully expanded condition.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

An exemplary microwave food product made in accordance with the present invention (shown in FIGS. 1 through 6) consists of an edible charge of popcorn and shortening 10, packed in a bag 12. The bag 12 serves as a cooking container and can function as a convenient serving vessel as well.

The bag 12 is formed from a sheet of single-ply, machine-finished kraft paper treated with a commercially available fluorocarbon stain inhibitor. Machine glazed papers are also suitable, but more rigid. More compressed papers such as grease proof and glassine are not as desirable. The desired paper weight is 35-60 lbs., preferably about 40 lbs. This preferred weight is less than the total weight of the two plies of bags that are in common use. Lighter paper is conducive to freer bag expansion and improved pop volume, but the paper must be heavy enough to avoid tearing during the bag making and filling processes, and sufficiently stiff to maintain the desired expanded shape.

It is also possible to use a bag 12 of two ply construction, as is common today. Preferably the inner layer is then of 20-25 lb. greaseproof paper and the outer layer is of 20-30 lb. machine finished paper.

The bag 12 has a generally flat seamless front panel 14, a generally flat back panel 16 of the same size with an overlapping seam 18 running the length of that panel (usually at or near its center) . Two side panels 20 and 22, each having two inwardly folding gussets, 20a and

20b, or 22a and 22b, respectively. Each gusset is defined by score lines that define generally elongated rectangular upper and lower sections. The multiple gussets thus have a pleated or accordion-like configuration with a natural resilience or spring-like quality, causing the bag 12 to expand readily and with reduced resistance. This resiliency of the bag 12 is one of the features that can contribute to improved pop volume.

The general configuration of the bag 12 is that of a tube closed at either end by seams formed by bonding together the inner surfaces at the edges of the front and back panels 14 and 16, and by bonding together the inner surfaces at the edges of the folds in the side panels 20 and 22. Accordingly, the bag 12 can be said to have a wedge-shaped bottom. The two gussets (20a and 20b, or 22a and 22b) on each side are of equal size. The gussets of each side panel 20 and 22 are separable along their full length, and the gusset ends or corners 23 at both ends of the bag 12 are thus free to move independently and to separate from each other when the bag is expanded, as shown in FIG. 5. Preferably the seam 18 is not located in the gussets where it could regidify the bag 12 and inhibit free unfolding movement.

A susceptor 28 is coextensive with the inside of a center section 30 of the bag 12 and is bonded to the exposed inner surface of the bag by a suitable adhesive such as Duraset 12 or Airflex 421 (Air Prodducts & Chemicals, Inc.). In the case of a two ply bag, the susceptor 28 may instead be positioned between the plies of the front panel 14.

When the bag 12 is filled, the edible charge 10 is deposited on the susceptor 28. The side panels 20 are then folded inwardly along score lines 29 on the side panels 20 and 22, thereby closing the gussets and flattening the bag 12. The top end 30 of the bag 12 is sealed by applying sufficient heat and pressure across the front panel 14 and the back panel 16 to activate a strip of heat seal coating (not shown) applied to the inner circumference of the bag, bonding together the top edges of the front panel 14 and the rear panel 16. An empty top section 32 and a bottom section 34, adjacent a middle section 35, are then folded transversely to the longi¬ tudinal axis of the bag 12, on top of the back panel 16 of the middle section 35. It is preferable that the bag 12 be folded symmetrically so that the top and bottom sections 32 and 34 are of the same size.

Any corn that becomes trapped on top of the gussets (20a and b and 22a and b) most likely will not pop as well, or possibly not at all, resulting in reduced pop volume and inferior textural qualities. It should be noted however, that, in comparison to a conventional single gusset bag, it is relatively easy to prevent the charge 10 from being deposited on top of the gussets (20a and b and 22a and b) when filling the bag 12. These gussets intrude into the bag 12 only about half as far as would a single gusset (See FIG. 4) .

It is also important during cooking that the use of multiple gussets leaves a relatively wide channel in the middle of the bag 12 between the opposing gussets (20a, 20b, 22a and 22b) , again because the gussets do not intrude as far into the bag as in a single gusset bag (See FIG. 4) . This wide channel helps to improve the pop volume because most of the kernels, as they pop, can move straight up, without moving laterally to avoid the gussets (20a and b and 22a and b) . Moreover, if a kernel should be trapped within a relatively shallow gusset, less lateral movement is needed before it can return to the susceptor 28.

If a kernel should be carried upwardly away from the susceptor 28 before it is popped, it is desirable that the kernel move downwardly again, onto the susceptor 28, as soon as possible. The wider channel between the gussets (20a and b and 22a and b) further facilitates this downward movement and tends to reduce the time that the kernel is away from the susceptor 28.

In the exemplary bag 12 there are two gussets on each side. However, other multiple gusset constructions, such as three gussets on each side, are also advantageous. It should be noted that a bag with multiple gussets on each side will always include at least one outwardly pointed fold in each side panel 20 and 22. In contrast, a single gusset bag has only inwardly pointed folds. Out- wardly pointed folds not only cause the bag 12 to expand more readily and with less resistance, but allow the side panels 20 and 22 to bulge outwardly to a greater extent. This configuration gives the bag 12 a more pillow-like shape, shown in FIG. 5, the bag being widest at its vertical and longitudinal center point between the front and back panels 14 and 16 (See Fig. 6) . As compared to a single gusset bag, the multiple gusset bag 12 becomes more rounded with a more convex bottom formed by the front panel 14. Not only does a bag that expands in this manner have a greater volume, but it is susceptible to more rocking movement during cooking. This rocking movement tends to return unpopped kernels to the susceptor 28, for still more volume and fewer unpopped kernels.

The seams that close the top 30 and bottom 38 of the bag 12 are formed when pressure is applied to heat seal strips. Sometimes heat is also applied. Though these two seams are similar, the seam at the bottom end 38 is able to withstand higher internal pressures and temperatures than the seam at the top end 30. This causes the top seam to open and vent steam before any other seam

(including the overlapping seam 18 running the length of the back panel 16) as the pressure and temperature inside the bag 12 increases. The preferred manner in which steam is vented is described in more detail in U.S. Patent No. 4,571,337.

Preferably, the kernels of the charge 10 are all of approximately equal size so that substantially all kernels will pop uniformly and within a limited time, the popping time in a microwave oven being partially dependent on kernel size. Since popping is attributable to the moisture content of the kernels, it is also important that there be sufficient moisture. The moisture content of the kernels should be between 13 to 14 percent by weight (13.5 percent being optimal) and no less than 11.5 percent. Too little moisture results in small popped kernels the density of which is too high for the fluffy texture desired.

The shortening in the charge 10 is a solid at room temperature. Since no refrigeration is required for any of the ingredients, the product can be described as shelf-stable.

When the folded bag 12 is ready for use, it is placed in a microwave oven 40 with its front panel 14 resting on the oven floor 42 (as shown in FIG. 1) so that the susceptor 28 is positioned underneath the charge 10. Microwave energy is absorbed by the corn kernels of the charge 10. The moisture content of the kernels turns to steam, which causes the kernels to explode or "pop", releasing the steam inside the bag 12. As the number of popped kernels increases during cooking, the pressure of the steam released by the popped kernels and that of the popped kernels 44 themselves increases. This pressure causes the empty end sections 32 and 34 on either side of the charge 10 to unfold, thereby straightening the bag 12 and extending it horizontally, and causing the gussets (20a and b and 22a and b) to open gradually, as shown in FIGS. 3 and 5. To permit free and unrestricted popping action, thus minimizing the number of unpopped kernels, the internal steam pressure must create sufficient vertical space 46 above the charge 10 to allow the kernels to move off the susceptor 28 as they pop.

The popping action has the beneficial effect of shaking the bag 12 as the exploding kernels impact the walls of the bag. As the expanding bag 12 assumes an increasingly spherical shape, the exterior surface of the front panel 14 (on which the bag rests) becomes pro¬ gressively more rounded, as shown in FIG. 6, thus facili¬ tating the rocking motion of the bag caused by the impact 5 of exploding kernels. The shaking of the bag 12 encou¬ rages any remaining unpopped kernels that have moved off the susceptor 28 to roll back onto the susceptor, located at what becomes the low point at the bottom of the bag.

An alternative bag 50 shown in FIGS 7 and 8, is 0 general similar to the bag 12 of FIGS. 1-6, being a tube- style bag with a wedge-shaped bottom. The sole difference relates to the manner in which the two bags 12 and 50 are folded prior to expansion.

The bag 50 is characterized by a reverse folded gusset on each side. The back panel 51, which faces upwardly when the bag 50 is placed in an oven in the position shown in FIG. 7, is folded along score lines 52 and 54 that are parallel to the longitudinal edges 56 and 58 of the bag and spaced inwardly from the edges by the width of a gusset. Thus the upper and lower sections 60 and 62 of the uppermost gusset on each side are exposed when the bag 50 has not yet expanded. Only a relatively narrow center area 64 of the back panel 51 is exposed between the upper gusset sections 60.

It should be noted that a strip 66,68 the width of two gussets extending along each edge 56,58 of the bag 50 (on either side of the exposed center area 64 of the back panel 51) has a thickness of four layers of the paper of which the bag is made. Two score lines 70 and 72 - extend along the centers of these strips 66 and 68, over¬ lying the score lines 52 and 54 of the back panel 51. The remaining portion of the bag, having a thickness of only two layers, is relatively narrow. (As best shown in FIG. 8.) No portion of the bag 50 has a thickness of more than four layers.

Two exposed score lines 70 and 72 extend along the centers of the strips 66 and 68, overlying the score lines 52 and 54 of the back panel 16, which likewise extend along the centers of the strips. The exposed score lines 70 and 72 are two of the score lines 24 mentioned above that outline the sections of the gussets 20a and b and 22a and b. When the bag 12 assumes its expanded configuration (FIG. 6) , these score lines 70 and 72 become oblique creases where the side panels 20 and 22 meet the back panel 16.

If the reverse folded bag 50 is compared with the multiple gussetted bag 12 that is not reverse folded, it can be seen that the non-reverse folded bag has a maximum thickness of six layers (along the edges) and a much larger area in which there are only two layers (see FIG. 4) . Because of this difference, a stack of the non- reverse folded bags 12 will be 50 per cent higher than a stack of the same number of reverse folded bags 50. Accordingly, the reverse folded bags 50 are advantageous from a handling, shipping and storage viewpoint.

Moreover, a stack of reverse folded bags 50, having a wider area of maximum thickness along the edges and a narrower "void" area of minimum thickness at the center, is relatively stable as compared to a stack of multiple gusset bags 12 that are not reverse folded and have a larger "void." The reverse folded bags 50 are therefore more easily handled, as in a filling process.

When expanded, the reverse folded bag 50 takes on the same shape and appearance as the non-reverse folded multiple gusset bag 12, as shown in FIG. 5.

An alternative bag construction 150, shown in FIG. 9, is similar to the bag 12 of FIGS. 1 through 6 , except that at the bottom end 152 the front and back panels are folded to form a strip 158 of increased thickness that extends across the bag transversely. Thus, the bag 150 is of pinched bottom construction and is not a tube-style bag, although it can be described as having a wedge-shaped bottom. The gusset ends 160 at the top of the bag 150 are free to move independently, but at the bottom 152 of the bag the gusset ends 162 are prevented from moving independently by the folded strip 58. For this reason, the expansion of the bag 150 is more restricted near the bottom end 152 and the bag will take on a slightly more rounded shape near the top end 164 as cooking proceeds. However, the bag 150 does have multiple gussets formed by its side panels 166 and therefore has many of the advantages of the bag 12 of Figs. 1 through 6. It will expand more readily and with less resistance and as compared to conventional single gusset bags, and it will take on a more rounded shape, extending outwardly at the sides beyond the periphery of the front and back panels. Moreover, the back panel (not shown) on which the bag 150 rests during cooking will take on a convex outer shape to facilitate rocking movement during popping, but not to the same extent as the bag 12 which has independently movable gussets 23 at both end. The back panel on which the bag 150 rests during cooking will tend to have a flatter shape in the vicinity of the strip 158.

An advantage of the bag 150 is that it can be made on equipment designed for pinched bottom bags and still retain many of the advantages that arise from the use of multiple gussets. It should also be noted that a tube style bag without independently movable gusset ends can be made without folding over the bottom end of the bag to form the strip 158. Instead, the gusset ends 162 can simply be bonded together by an adhesive, applied to their opposing exterior surfaces near the bottom, providing a bag having characteristics very similar to those of the pinched bottom bag 150.

Still another embodiment of the invention is a flat bottom or stand-up bag 170, shown in FIGS. 10 and 11. This bag 170 has the advantage that it is more conven¬ iently used as a serving container as it can stand on its flat bottom panel 172 once the corn it contains has been fully popped. It should be noted that because of the manner in which a flat bottom bag is conventionally folded, the bottom panel 172 is formed of multiple layers and is relatively rigid.

The flat bottom bag 170 has a large volume in relation to its length, making it more suitable for use in smaller microwave ovens, particularly those of the carousel type. The bag 170 includes multiple gussets 174 and 176, two on each side, as in the case of the bags discussed above. This construction requires folding of the bag 170 along score lines, as best shown in FIG. 9. The score lines of each side panel define a triangular section 178 near the bottom panel 172, bordered by a lower section 80 of the top gusset and an upper section 182 of the bottom gusset. The score lines also define a trapezoidal section 184 bounded by an upper section 186 of the top gusset, a lower section 188 of the bottom gusset 176, the triangular section 178 and the bottom panel 172.

It should be noted that the use of flat bottom construction precludes the formation of independently movable gusset ends at the bottom of the bag 170. More- over, the front panel on which the bag 170 rests during cooking (as shown in FIGS. 8 and 9) is precluded from becoming as rounded as desired, particularly in the area where it is adjacent to the more rigid bottom panel 172, thus inhibiting rocking movement. However, the bag 170 of FIGS. 8 and 9 does have the advantage of being more readily expandable to promote increased popping and pro¬ vides a wider interior channel in which the corn kernels can expand and move upwardly between the gussets. The bag 170 may also take on a slightly more billowy shape when fully expanded, as compared to a single gusset flat bottom bag. It will thus tend to have slightly increased interior volume.

While particular forms of the invention have been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.

Claims

I claim:

1. A food product comprising: an edible charge of popping corn; and a bag containing said charge, suitable for use in cooking said charge in a microwave oven, said bag having a front panel, a back panel, and two side panels each connecting said front panel to said back panel, each of said side panels being inwardly folded to form at least two gussets, whereby said bag can be flattened with said gussets closed.

2. A product as defined in claim 1 wherein said front and back panels are joined at their bottom ends, said bag thus having a wedge-shaped bottom.

3. A food product as defined in claim 1, wherein said bag is formed of paper.

4. A food product as defined in claim 1 wherein said bag is formed of a single ply of machine finished paper.

5. A food product as defined in claim 1, wherein: said paper is sufficiently flexible to permit full expansion and rounding of said front panel to permit rocking; and said paper is sufficiently stiff to retain its approximate expanded shape.

SUBSTITUTE SHEET

6. A food product as defined in claim 5, wherein said paper is a machine-finished paper of 50 lb. weight or less.

7. A food product as defined in claim 5, wherein said bag is of single ply construction.

8. A microwave food product as defined in claim 1, further comprising a susceptor mounted at the approximate center of said front panel.

9. A food product as defined in claim 1, wherein said two gussets are of approximately equal depth.

10. A food product comprising: an edible charge of popping corn; and a bag containing said charge and suitable for use in a microwave oven, said bag having a front panel and a back panel connected at their respective ends and two side panels each connecting said front panel to said back panel, each of said side panels being inwardly folded to form one or more gussets, said gussets having gusset ends that are independently movable at each end of said bag.

11. A food product as defined in claim 10, wherein said bag is made of paper that is sufficiently stiff to support said bag in an expanded position and maintain its approximate expanded shape.

12. A food product as defined in claim 10, further comprising a susceptor mounted at the center of said front panel.

13. A food product as defined in claim 10, wherein said bag is formed of a single ply of machine- finished paper of 50 lb. weight or less.

SUBSTITUTESHEET

14. A food product comprising: an edible charge of popping corn; and a bag containing said charge and suitable for use in cooking said charge in a microwave oven, said bag having a front panel, a back panel connected to said front panel to form a wedge-shaped bottom, and two side panels each connecting said front panel to said back panel, each of said side panels being inwardly folded to form two or more gussets, said gussets each having gusset ends that are independently movable at each end of said bag.

15. A food product as defined in claim 14, wherein said bag is formed of paper that is sufficiently stiff to support said bag in an expanded position and maintain its approximate expanded shape.

16. A food product as defined in claim 14, further comprising a susceptor mounted at the center of said front panel.

17. A food product comprising: an edible charge of popping corn; and a bag suitable for cooking said charge in a microwave oven, said bag being constructed of a single ply of machine-finished paper of about 40 lb. weight, said bag having a generally flat front panel, a generally flat back panel, and two side panels each connecting said front panel to said back panel, each of said side panels being inwardly folded to form two or more gussets, the exterior surfaces of said gussets being separated along their entire lengths so that said gussets have independently movable gusset ends at both ends of said bag, whereby said bag can be flattened with said gussets closed and folded transversely to its longitudinal axis, thus forming a center section on which a susceptor is mounted on an interior surface.

SUBSTITUTE SHEET 18. A food product comprising: an edible charge of pop corn; and a bag containing said charge, said bag having a front panel, a back panel, two side panels each connecting said front panel to said back panel, each side panel being folded inwardly to form at least two gussets, and a bottom panel adjoining said front, back and side panels.

19. The microwave food product of claim 18 wherein: said side panels are divided by score lines said score lines defining a top gusset with upper and lower sections and a bottom gusset with upper and lower sections; and said score lines further defining a triangular section bounded by said lower section of said top gusset and said upper section of said bottom gusset.

20. The microwave food product of claim 19 wherein said score lines further define a trapezoidal section bounded by said upper section of said top gusset, said lower section of said bottom gusset, said triangular section and said bottom panel.

21. A food product comprising: an edible charge of popping corn; a bag capable of assuming collapsed and expanded configurations in which said charge is enclosed and in which said charge can be cooked in a microwave oven, said bag comprising a front panel, a back panel, and two side panels connecting said front and back panels, each of said side panels forming at least two gussets defined by score lines, said back panel being folded when said bag is in said collapsed configuration to expose a portion of each side panel that forms at least one gusset.

22. The food package of claim 21, further

SUBSTITUTESHEET comprising a susceptor mounted on an interior surface of said front panel.

23. The food package of claim 21, wherein said bag has a wedge-shaped bottom formed by joining said front and back panels.

24. The food package of claim 21, wherein each of said side panels forms only two gussets.

25. The food package of claim 21, wherein said bag, when in said collapsed configuration, has a maximum thickness of four layers.

26. The food package of claim 21, whereby said bag is of single ply construction.

27. The food package of claim 21, wherein said bag is formed of a single ply of machine finished paper.

28. A food product comprising: an edible charge of popping corn, and a bag capable of assuming collapsed and expanded configurations in which said charge is enclosed and in which said charge can be cooked in a microwave oven, said bag comprising a front panel with parallel side edges, a back panel, two side panels each connecting said front panel to said back panel and each forming two gussets defined by score lines, said back panel being folded along two additional score lines when said bag is in said collapsed configuration so as to expose a portion of each side panel that forms one gusset, wherein said bag

^■ when in said collapsed configuration forms a strip extending along each of said side edges in which it has a thickness of four layers.

29. The food product of claim 28, wherein said

SUBSTITUTE SHEET additional score lines each extend along the center of one of said strips.

30. The food product of claim 28 wherein said strips each have the width of an unfolded gusset.

31. The food product of claim 28, wherein said bag when in said folded configuration, has a center portion between said strips that is of a lesser thickness than said strips.

32. The food product of claim 28, wherein said bag, when in said folded configurations, has a center portion between said strips, formed by parts of said front and back panels, that has a thickness of two layers.

33. The food package of claim 28, further comprising a susceptor mounted on an interior surface of said front panel.

34. The food package of claim 28, wherein said bag has a wedge-shaped bottom formed by joining said front and back panels.

35. A food product comprising: a top edge and a bottom edge; an edible charge of popping corn, and a bag capable of assuming collapsed and expanded configurations and formed of a single ply of machine finished paper, said bag enclosing said charge, said bag comprising a front panel with two side edges, a back panel of the same size as said front panel and joined

• to said front panel along said bottom edge to form a wedge-shaped bottom, two side panels each connecting the side edges of said front panel to said back panel, each side panel forming gussets of equal size defined by score lines, said back panel being folded along two additional

SUBSTITUTESHEET score lines parallel to said side edges when said bag is in said collapsed configuration so as to expose a portion of each side panel that forms one gusset, whereby said bag when in said collapsed configuration forms a strip extending along each of said side edges in which it has a thickness of four layers, each of said strips having the width of a single gusset, said strips defining therebetween a center portion of said bag having a thickness less than that of said strips.

SUBSTITUTE SHEET [received by the International Bureau on 19 October 1992 19.10.92 original claims 19,20 and 21-35 replaced by amended claims 19,20 and 21-30

(3 pages)]

18. A food product comprising: an edible charge of pop corn; and a bag containing said charge, said bag having a front panel, a back panel, two side panels each connecting said front panel to said back panel, each side panel being folded inwardly to form at least two gussets, and a bottom panel adjoining said front, back and side panels.

19. The microwave food product of claim 18 wherein: said side panels are divided by fold lines said fold lines defining a top gusset with upper and lower 5 sections and a bottom gusset with upper and lower sections; and said fold lines further defining a triangular section bounded by said lower section of said top gusset and said upper section of said bottom gusset.

20. The microwave food product of claim 19 wherein said fold lines further define a trapezoidal section bounded by said upper section of said top gusset, said lower section of said bottom gusset, said triangular section and said bottom panel.

21. A food package comprising: a bag capable of assuming collapsed and expanded configurations, said bag including a first panel with a top, a bottom and two 5 sides; a second panel opposing said first panel, said second panel including a top, a bottom and two sides, said sides of said panels substantially identical in length; two pleated side panels connecting said first

10 and second panels, along their sides, each of said side panels forming first and second gussets along said sides of said first and second panels, when said bag is in said collapsed configuration, said first and second gussets being non-overlapping and oriented in opposite directions.

22. The food package of claim 21 wherein the first and second panels are rectangular.

23. The food product of claim 22, wherein said package has a wedge-shape formed by joining said bottoms of said first and second panels.

24. The food package of claim 23, wherein said package is formed of a single ply of machine finished paper.

25. A food package comprising: a bag capable of assuming collapsed and expanded configurations, said bag having a first panel; a second panel opposing said first panel; said first panel wider than said second panel and said first and second panels substantially identical in length; two pleated side panels connecting said first and second panels, along their lengths, each of said side panels forming first and second gussets having opposite orientations, along said lengths, when said bag is in said collapsed configuration; said first gusset overlapping only said first panel and said second gusset overlapping said second panel.

26. The food package of claim 25 wherein the first and second panels are rectangular.

27. The food product of claim 26, wherein said package has a wedge-shape formed by joining said bottoms of said first and second panels.

28. A food product comprising: an edible charge of popping corn; a bag capable of assuming collapsed and expanded configurations in which said charge is enclosed and in which said charge can be cooked in a microwave oven, said bag having a first panel; a second panel opposing said first panel; said first panel wider than said second panel and said first and second panels substantially identical in length; two pleated side panels connecting said first and second panels, along their lengths, each of said side panels forming first and second gussets having opposite orientations, along said.lengths, when said bag is in said collapsed configuration; said first gusset overlapping only said first panel and said second gusset overlapping said second panel.

29. The food package of claim 25 wherein the first and second panels are rectangular.

30. The food product of claim 26, wherein said package has a wedge-shape formed by joining said bottoms of said first and second panels.