A flexible paper popcorn package in the form of an easily expandable, nontrapping bag (18) is disclosed including a bottom wall (20) and a top wall (22) interconnected together adjacent their circular outer peripheries (20a, 22a) by first and second interconnection portions (26a, 26b). In one preferred form, the top wall (22) is formed by first and second wall portions (22b, 22c) interconnected together by a peelable closure seal (28). In another preferred form, the top wall (22) is formed from a first portion (22d) having an access opening closed by a closure portion (22e) interconnected by a seal (40) including the peelable closure seal portion (40a) to the first portion (22d). In still another preferred form, the bottom and top walls (20, 22) are interconnected together by their interconnection to gussetted side panels (50, 52), with the peelable closure seal being formed in the interconnection between the bottom and top walls (20, 22). The bottom and top walls (20, 22) expand into an opposing double domed shape as the popcorn kernels are being popped in the microwave oven. This domed shape of the bottom wall (22) keeps the unpopped popcorn huddled closer together and enhances the bag (18) to rock to maximize gravimetric separation. The bag (18) provides a serving bowl function when the peelable closure seal has been opened providing access to the interior of the bag.

BACKGROUND 
The present invention relates generally to packages for use in microwave 
ovens, pertains particularly to an easily expandable, nontrapping, 
flexible, microwave package formed of non-extendable material for the 
popping or puffing of grains and especially popcorn kernels, and pertains 
more particularly to a microwave package providing serving bowl and/or 
easy open features. 
To conserve space during shipping and storage, microwave popcorn packages 
are often folded flat. During popping by use of microwave energy, the 
popcorn package expands, with the expansion due to the internal pressure 
of the steam produced by the popping of the popcorn kernels, the pressure 
of the popped kernels themselves, as well as other factors. An important 
feature for maximizing the volume of the popped kernels is the ability of 
the microwave popcorn package to easily expand. Another important factor 
for maximizing the volume of the popped kernels is that the number of 
kernels which are actually popped be maximized by insuring that the 
unpopped kernels are located together on the susceptor with sufficient 
dwell time to receive sufficient heat energy to result in popping. The 
shape of the bag plays an important role in the ability of the bag to 
expand as well as the ability of unpopped kernels to come in contact with 
each other and the susceptor before and during popping. 
One form of conventional popcorn packages is a bag having a rectangular 
top, a rectangular bottom and pleated sides and with at least one end 
being sealed together by attaching the top and bottom together such as but 
not limited to by folding the end of the bag over onto itself. It is a 
common problem for unpopped kernels to be propelled in the popping process 
into folds and crevices in the bag and especially those created by the 
pleats in the sides adjacent to the end(s) of the bag. Such kernels may 
tend to be captured in such folds and crevices so that they are unable to 
travel towards the susceptor and are less likely to be popped during 
microwave cooking. 
Further, conventional rectangular popcorn bags tend to get hung up in the 
corners of the microwave ovens. This is undesirable for microwave ovens 
including turntables as the bag will no longer rotate inside of the 
microwave cavity but is locked in position by the corner. However, even 
for microwave ovens which are not equipped with turntables, the expansion 
of the bag and/or the vibration of the bag caused by the popping of the 
popcorn does not result in moving the bag to the center of the microwave 
cavity when the bag gets hung up in a corner of the microwave cavity. This 
is undesirable as cooler spots typically exist in the corners of the 
microwave cavity and as lack of movement of the bag subjects certain 
points in the bag to see specific hot spots or electronic nulls. 
Thus, a need continues to exist for an improved flexible paper popcorn 
package which is easily expandable by the dynamics involved in popping the 
kernels, which is less likely to capture unpopped kernels during the 
expansion of the package while subjected to microwave energy, and which 
provides the most consistent and uniform distribution of microwave energy 
in maximizing the number and volume of popped popcorn. In further aspects 
of the present invention, the popcorn package which is utilized to pop the 
popcorn kernels has the ability to be utilized as the serving bowl during 
consumption of the popped kernels. In still other aspects of the present 
invention, the expanded popcorn package can be easily opened by the 
consumer with minimal instructions. 
Surprisingly, the above need and other objectives can be satisfied by 
providing, in the preferred form, an expandable microwave package in the 
form of a bag formed by top and bottom walls of flexible, non-extendable 
material interconnected together adjacent to their round-like shaped outer 
peripheries so that the top and bottom walls expand into an opposing 
double domed shape when the popcorn kernels are popped in the microwave 
oven. 
In a most preferred form, the top wall includes a peelable closure seal 
which vents during microwave cooking and which can be physically separated 
after microwave cooking for ease of access to the popped popcorn and so 
that the bag clearly functions as a serving bowl. In most preferred 
aspects, the peelable closure seal is formed in the interconnection 
between first and second wall portions, and in a preferred form the bag 
further includes first and second extensions extending outwardly from the 
first and second wall portions for grasping to separate the first and 
second wall portions. 
In another most preferred form, the top wall is fabricated from multiple 
layers and includes a first annular portion having an access opening and a 
closure portion of a size greater than the access opening and 
interconnected to the first portion by a seal. In most preferred aspects, 
the seal includes a peelable closure portion which fails during microwave 
cooking, and an extension is formed on the outer periphery of the closure 
portion for grasping when removing the closure portion. 
In still another preferred form, the peelable closure seal is formed in the 
interconnection between the bottom and top walls. In most preferred 
aspects, extensions are formed on the outer peripheries of the top and 
bottom walls adjacent the peelable closure seal and outward of the 
interconnection, with the consumer grasping and pulling the extensions to 
open the bag for removing the popped popcorn from the interior of the bag. 
In other preferred aspects of the present invention, the bottom and top 
walls are interconnected together by their interconnection to first and 
second gussetted side panels, with the outer periphery of the bottom wall 
being interconnected to the outer peripheries of the first panel portions 
of the first and second gussetted side panels and the outer periphery of 
the top wall being interconnected to the outer peripheries of the second 
panel portions of the first and second gussetted side panels, with the 
outer peripheries of the panel portions corresponding to the outer 
peripheries of the bottom and top walls. 
In still other preferred aspects of the present invention, the bag formed 
by the interconnection of top and bottom walls having round-like shaped 
outer peripheries is folded about first and second, parallel, fold lines 
located on opposite sides of a periphery interconnection portion, then 
folded about a third fold line extending perpendicularly between the first 
and second fold lines at which time the popcorn kernels are introduced 
through the periphery interconnection portion which is then sealed, and 
then folded about a fourth fold line extending parallel to the third fold 
line, with the folded bag having a conventional, rectangular shape for 
secondary packaging. 
The present invention will become clearer in light of the following 
detailed description of illustrative embodiments of this invention 
described in connection with the drawings.

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 embodiments will be explained or will be within 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", "inner", "outer", "inside", 
"outside", 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 preferred embodiments. 
DESCRIPTION OF THE PREFERRED EMBODIMENTS 
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. Therefore, bag 18 includes a bottom wall 20 and a top 
wall 22 of a shape and size generally corresponding to bottom wall 20. 
Each wall 20 and 22 is formed by a sheet of flexible but non-extendable 
material such as papers including but not limited to base coated paper or 
similar cellose structures, polymers including but not limited to 
polyethylene terephthalate, polyester and nylon, or other like 
microwaveable materials. The material forming walls 20 and 22 can be 
opaque, translucent, clear, or combinations thereof. Each wall 20 and 22 
includes an outer periphery 20a and 22a, respectively, which is generally 
equidistant from the center 24 of the shape of walls 20 and 22 and in the 
most preferred form is generally circular in shape. However, peripheries 
20a and 22a could be in other substantially round or round-like shapes 
which are arcuate and/or include peripheral edge interconnections which do 
not have a tendency of getting hung up in the corners of the microwave 
oven such as symmetrical shapes including ovals, pentagons, hexagons, 
heptagons, octagons, etc. and such as non-symmetrical shapes such as a 
generally egg shape. 
To define a hollow interior, walls 20 and 22 are interconnected together 
adjacent to peripheries 20a and 22a by a seal which maintains the 
integrity of bag 18 during manufacture, handling, transportation and 
retailing of bag 18 and its contents and until microwave cooking. In the 
most preferred form, the interconnection between walls 20 and 22 is 
sufficient so as to seal adequately the vapor created within the bag 18 
during the heating thereof in the microwave oven as well as to prevent 
undesired opening during the consumption of the popped kernels. In the 
most preferred form, a suitable annular adhesive strip 26 is added to the 
inside surface of one or both of walls 20 and 22 to secure walls 20 and 22 
together adjacent peripheries 20a and 22a after the application of heat 
and/or pressure. Additionally, when interconnected by adhesive strip 26, 
walls 20 and 22 can be positioned so that they are generally planar and 
continuously abut without bulges or folds in the most preferred form. 
In the most preferred form, bag 18 includes a susceptor patch 30 that 
extends over a portion of bottom wall 20 spaced from periphery 20a and in 
the most preferred form generally centered about center 24. Susceptor 
patch 30 can be formed in any suitable manner known in the art such as a 
metalized plastic film adhered to bottom wall 20 as diagrammatically shown 
in FIG. 8 (with the thickness of susceptor patch 30 being exaggerated for 
ease of illustration) or adhered between separate layers forming bottom 
wall 20, as a paper backed susceptor, or as a coating applied or printed 
to bottom wall 20. Further, although susceptor patch 30 is shown as 
overlying bottom wall 20 and thus located inside of bag 18, susceptor 
patch 30 can be located outside of bag 18 with bottom wall 20 overlying 
susceptor patch 30. Further, placement of susceptor patch 30 can occur at 
the material converter or on the manufacturing lines. 
In the preferred form shown in FIGS. 1, 2, 8 and 9, top wall 22 is formed 
from first and second wall portions 22b and 22c which are interconnected 
together by a fin seal 28. In the preferred form, portions 22b and 22c are 
generally semicircular in shape and fin seal 28 extends between opposite 
points on periphery 22a and specifically along a diameter of the circular 
shape of periphery 22a. Fin seal 28 provides a peelable closure which 
partially fails during microwave cooking. Specifically, this partial 
failure of fin seal 28 allows trapped steam to vent from bag 18 as well as 
allows the consumer to continue to peel seal 28 to open bag 18 after 
microwave cooking to provide access to the popped popcorn kernels in the 
hollow interior of bag 18 for consumption. 
Bag 18 can be manufactured according to the preferred teachings of the 
present invention in the following manner. Specifically, walls 20 and 22 
are positioned with their inside surfaces abutting together and with 
peripheries 20a and 22a aligned. A first, interconnection portion 26a of 
strip 26 is suitably activated to interconnect walls 20 and 22 together 
aside from a second, interconnection portion 26b. While first, 
interconnection portion 26a extends a substantial portion of peripheries 
20a and 22a, second, interconnection portion 26b in the preferred form has 
a radial extent generally equal to one half of the diameter of the shape 
of peripheries 20a and 22a. 
At that time, the partially formed bag 18 can be folded along parallel fold 
lines 32a and 32b which are radially spaced generally equal to one half of 
the diameter of the shape of peripheries 20a and 22a and extending from 
first and second points on opposite sides of and generally coextensive 
with the ends of portion 26b. In the preferred form, fold lines 32a and 
32b are located on opposite sides of the diameter of the shape of 
peripheries 20a and 22a and equidistant therefrom. Thus, bag 18 is divided 
into a central portion 34a and first and second wings 34b and 34c which 
are folded to overlay central portion 34a. Wings 34b and 34c have a radial 
width generally equal to one fourth of the diameter of the shape of 
peripheries 20a and 22a and generally equal to one half of the radial 
width of central portion 34a. Thus, wings 34b and 34c do not overlay each 
other when folded to overlay central portion 34a. Bag 18 as folded at this 
point includes first and second, parallel, straight side edges defined by 
fold lines 32a and 32b and upper and lower edges which are generally 
convex defined by peripheries 20a and 22a intermediate fold lines 32a and 
32b. 
The partially formed bag 18 can then be folded about a third fold line 36 
extending generally perpendicularly between the first and second straight 
side edges defined by fold lines 32a and 32b and located about one third 
of the diameter of the shape of peripheries 20a and 22a from the lower 
edge. Thus, bag 18 includes a wing 36a which includes the lower parts of 
portion 34a and wings 34b and 34c and which is folded to overlay wings 34b 
and 34c, with portion 26b being opposite to wing 36a. Bag 18 as folded at 
this point includes first and second, parallel, straight side edges 
defined by fold lines 32a and 32b, a straight lower edge defined by fold 
line 36 extending generally perpendicular to the side edges, and an upper 
edge which is generally convex defined by peripheries 20a and 22a 
intermediate fold lines 32a and 32b and including portion 26b. 
While in a folded condition and held with walls 20 and 22 being vertical 
with the upper edge located vertically above the lower edge, peripheries 
20a and 22a in the upper edge are separated and a charge of popcorn 
kernels, fat or oil, salt, flavorings, or the like are introduced into the 
interior of bag 18. It should be appreciated that due to the folded 
condition of bag 18, the charge is generally prevented from passing beyond 
fold lines 32a, 32b and 36 and into wings 34b, 34c, and 36a but is 
retained adjacent center 24 of bag 18. 
After the charge has been introduced, portion 26b can be suitably activated 
to interconnect walls 20 and 22 together. Thus, walls 20 and 22 are 
interconnected together around the entire length of peripheries 20a and 
22a. Additionally, strip 26 and seal 28 close bag 18 so that the charge in 
the hollow interior of bag 18 is completely sealed from the environment. 
After portion 26b is sealed, bag 18 can again be folded about a fourth fold 
line 38 extending generally perpendicularly between the first and second 
straight side edges defined by fold lines 32a and 32b and parallel to fold 
line 36 and located about one third of the diameter of the shape of 
peripheries 20a and 22a from the upper edge. Fold line 38 is located 
adjacent to peripheries 20a and 22a of wing 36a and is located above the 
charge in the hollow interior of bag 18. Thus, bag 18 includes a wing 38a 
which includes the upper parts of portion 34a and wings 34b and 34c and 
which is folded to overlay wing 36a. It should be appreciated that due to 
the folded condition of bag 18, the charge is also generally prevented 
from passing beyond fold line 38 and into wing 38a but is retained 
adjacent center 24 of bag 18. Bag 18 as folded at this point is generally 
rectangular shaped of a size and shape of conventional folded, paper 
popcorn bags and includes first and second parallel side edges defined by 
fold lines 32a and 32b, and parallel lower and upper edges defined by fold 
lines 36 and 38, respectively. In the most preferred form, the folded, 
charged bag 18 is sealed into a flexible overwrap for packaging and 
storage. Conventionally, such overwrap is formed by clear or opaque 
translucent plastic but could be formed by metalized film, sputtered 
glass/ceramic or other barrier constructions. It of course should be 
appreciated that typically such overwrap is removed by the consumer just 
prior to microwave cooking. 
For the sake of completeness, it will be assumed that the contents or 
charge of bag 18 are popcorn kernels or any suitable grain such as rice, 
maze, barley, sorghum, or the like for being popped or puffed when in the 
microwave oven. Particularly, as with current bags, bag 18 is placed in a 
microwave oven with bottom wall 20 resting upon the bottom surface of the 
oven cavity and preferably with bag 18 being partially or completely 
unfolded by the consumer. When subjected to microwave energy, susceptor 
patch 30 converts microwave energy into heat, with the heat and remaining 
microwave energy causing the popping of the kernels and the generation of 
water vapor/steam. The water vapor and heated vapor pressure air cause 
wings 38a, 36a, 34b and 34c to unfold or to continue to unfold about fold 
lines 38, 36, 32a and 32b, respectively, so that walls 20 and 22 have a 
continuous shape. Each wall 20 and 22 expand into a bowl, hemispheric or 
parabolic curve shape from their peripheries 20a and 22a with the inside 
surfaces of bottom and top walls 20 and 22 being spaced, expanding bag 18 
and increasing the interior volume inside of bag 18 for the popped 
kernels. It can then be appreciated that due to its flexible nature, bag 
18 will expand to an opposing, double dome shape. However, due to the 
non-extendable nature of the material forming walls 20 and 22, the 
interconnection between walls 20 and 22 adjacent to peripheries 20a and 
22a will tend to gather and pucker as best seen in FIGS. 1, 8, and 9 as 
walls 20 and 22 change their shape from being generally planar to being 
dome shaped. When bag 18 is formed of paper conventionally utilized for 
popcorn packages without further processing, the size, shape and direction 
of such puckers will generally not be uniform around peripheries 20a and 
22a and will tend to vary between different bags 18. 
Bag 18 according to the preferred teachings of the present invention is 
advantageous over prior microwave popcorn bags. Particularly, when first 
placed in the microwave oven, the pleats of the sides of conventional 
popcorn packages extend at least partially over the charge of popcorn 
kernels to be popped. Thus, the initial microwave energy has to penetrate 
several layers of material which forms the bag. As the material is not 
completely transparent to microwave energy, part of the microwave energy 
is absorbed by the material which then is generally not available to the 
charge of popcorn kernels. However, only a single layer of material 
forming walls 20 and 22 of bag 18 extends over the charge of popcorn 
kernels generally from the start of microwave cooking. Thus, it is not 
necessary for the initial microwave energy to penetrate several layers of 
material before reaching the charge and therefore the microwave energy is 
generally available quicker and in greater amounts to the charge. 
Further, the bowl or parabolic curve shape of the inflated bag 18 keeps the 
unpopped kernels huddled closer together even in more than a single layer 
at the bottom of the shaped wall 20 and in closer contact with susceptor 
patch 30 in the preferred form. This close nesting or clustering of the 
unpopped kernels is a very efficient and attractive load for incoming 
microwaves. Specifically, the cluster load radiates less heat, and 
temperature increases at a quicker rate. The cluster load has a higher 
loss tangent (more lossy) than a dispersed load. 
Further, as the bowl or parabolic curve shape has a relatively low surface 
area to volume relationship similar to that of a sphere, walls 20 and 22 
include less material which competes for microwave energy with the 
kernels. 
Additionally, when the kernels pop, the popping kernels may spray unpopped 
kernels from the nesting. However, bag 18 according to the teachings of 
the present invention allows the unpopped kernels to settle to the bottom 
of the shaped wall 20 much like a covered Japanese Wok pan does. Further, 
the expansion of bag 18 according to the teachings of the present 
invention generally does not create folds or crevices which capture 
unpopped kernels and prevent their movement towards the cluster of any 
other unpopped kernels and/or susceptor patch 30. 
Furthermore, the force of the popping kernels hitting against walls 20 and 
22 jostles or vibrates bag 18 which enables the unpopped kernels to fall 
through the popped kernels and reengage wall 20 and to slide on wall 20 to 
the bottom thereof. Specifically, the vibration of bag 18 creates 
agitation of the popped and unpopped kernels in bag 18 resulting in 
gravimetric separation of the unpopped kernels to the bottom of the popped 
kernels due to their greater density. In this regard, the bowl or 
parabolic curve shape of bottom wall 20 enhances the ability of bag 18 to 
rock in any direction from the force of the popping kernels hitting 
against walls 20 and 22 to maximize the gravimetric separation of the 
unpopped kernels to the bottom of the popped kernels. 
Still further, the bowl or parabolic curve shape of inflated bag 18 greatly 
improves popping performance in the diverse microwave ovens available to 
consumers. As much as a 40% improvement in popping performance was 
experienced with bag 18 according to the preferred teachings of the 
present invention compared to paper popcorn bags of conventional shapes 
under variations experienced in normal use. These variations include but 
are not limited to microwave ovens of differing wattage, volume, and/or 
efficiency, fluctuations in electric current, different magnetrons of the 
same or different manufacture, different wave guides, and the like. 
If susceptor patch 30 is provided as in the preferred form, there is no 
need to include susceptor patch 30 at locations where unpopped kernels are 
not. Thus, susceptor patch 30 is located only at the bottom of the shaped 
wall 20 and can be of a minimized size due to the bowl or parabolic curve 
shape of wall 20. In this regard, and especially due to the bowl or 
parabolic curve shape of wall 20, susceptor patch 30 may be shaped to 
minimize material utilized such as being circular in shape or being in 
non-continuous areas. In the most preferred form, patch 30 is located 
within fold lines 32a, 32b, 36, and 38. 
Also, the round-like shapes of peripheries 20a and 22a of walls 20 and 22 
and thus of bag 18 distribute the popped kernels into a wider distribution 
field. Being spread in the microwave oven cavity, the popped kernels 
become less attractive and are fairly transparent to the microwave energy. 
In addition to the less dense load configuration, the popped kernels are 
able to dissipate the heat better and therefore not allowing the popped 
kernels to continue to overcook, carmelize, burn, char, or dry out any 
further. This results in bag 18 that is less prone to scorching the popped 
product. 
Further, the round-like shapes of peripheries 20a and 22a of walls 20 and 
22 and thus of bag 18 work very well in all microwave ovens equipped with 
or without turntables. No matter where the consumer places bag 18 in the 
microwave oven, bag 18 will always inflate and position itself near the 
center of the microwave oven. The round-like profile does not allow bag 18 
to get hung up in the corners of the microwave ovens where typically 
cooler spots exist. The round-like shape always continues to rotate on the 
turntable ovens. This centered and/or rotating positioning of bag 18 
allows bag 18 to move so that it is less likely for any particular point 
in bag 18 to see specific hot spots or electronic nulls and allows the 
opportunity for the most consistent and uniform distribution of microwave 
cooking. 
It should be noted that fin seal 28 of the most preferred form partially 
releases to vent steam from bag 18 during microwave cooking. Additionally, 
after removal from the microwave oven, the consumer can grasp portions 22b 
and 22c on opposite sides of seal 28 and pull them apart to further 
release fin seal 28 and if desired the interconnection between peripheries 
20a and 22a adjacent to fin seal 28 in a manner as shown in FIG. 9 to 
allow access to the hollow interior of bag 18 and specifically to the 
popped popcorn located therein. It can then be appreciated that bag 18 
having top wall 22 including the peelable closure clearly functions as a 
serving bowl. 
In alternate forms of bag 18, the serving bowl function can be accomplished 
by fabricating top wall 22 from multiple layers of material. In a 
preferred form as shown in FIGS. 10 and 11, top wall 22 is formed from 
first and second wall portions 22d and 22e which are interconnected by a 
seal 40. In the preferred form shown, portion 22d is generally annular in 
shape including outer periphery 22a and an inner periphery 22f defining an 
access opening which is circular in the most preferred form. The size of 
the access opening should be sufficient to extend a hand into the interior 
of bag and grasp popped popcorn therefrom. Portion 22e is generally 
circular in shape and includes an outer periphery 22g which is of a shape 
generally corresponding to periphery 22f but of a size slightly greater 
than periphery 22f. In the most preferred form, outer periphery 22g 
includes an extension 42 beyond the otherwise circular shape, with 
extension 42 being of a size located within outer periphery 22a of top 
wall 22 in the preferred form shown. Seal 40 is annular in shape having an 
inner diameter corresponding to inner periphery 22f of portion 22d and an 
outer diameter corresponding to outer periphery 22g of portion 22e. 
Extension 42 in the most preferred form is not adhered and specifically in 
the form shown is not adhered to portion 22d or any other portions of top 
wall 22 or bag 18. Additionally, in the most preferred form, seal 40 
includes a first, peelable closure portion 40a which has an arcuate extent 
generally equal to the circumferential extent of extension 42 and a 
second, interconnection portion 40b extending the remaining 
circumferential extent of seal 40. In particular, portion 40a fails during 
microwave cooking to provide venting and to allow ease of separation when 
desired to open bag 18 whereas portion 40b as well as adhesive strip 26 
remain secured during microwave cooking. 
Bag 18 of FIGS. 10 and 11 can be manufactured according to the preferred 
teachings of the present invention in the following manner. Specifically, 
portion 22e is positioned to overlie portion 22d, and portions 22d and 22e 
are positioned to overlie wall 20. Interconnection portion 26a of strip 26 
and seal 40 are suitably activated to interconnect portions 22d and 22e to 
form wall 22 and to interconnect walls 20 and 22. After activation of 
first, interconnection portion 26a and seal 40, bag 18 according to the 
teachings of the present invention can be folded, filled, sealed, folded, 
and overwrapped in generally the manner as set forth in FIGS. 3-7. 
Bag 18 of FIGS. 10 and 11 will expand to an opposing, double dome shape in 
a similar manner as bag 18 of FIGS. 1, 8, and 9. Thus, the advantages of 
the bowl, hemisphere, or parabolic curve shape are also obtained by 
inflated bag 18 of FIGS. 10 and 11 according to the preferred teachings of 
the present invention. 
It should be noted that portion 40a of seal 40 partially releases during 
microwave cooking to vent steam from bag 18 during microwave cooking 
whereas adhesive strip 26 and portion 40b remain secured. After removal 
from the microwave oven, the consumer can grasp extension 42 between the 
consumer's thumb and one or more fingers of one hand and pull upwardly and 
diametrically, with extension 42 being free of adhesive securement 
resulting in advantages in its ability to be grasped. If necessary, bag 18 
can be held by the consumer's other hand such as by grasping the rim 
defined by adhesive strip 26 between walls 20 and 22 at the 
circumferential position corresponding to extension 42. Due to the 
peelable nature of portion 40a, initial movement of extension 42 will 
release any remaining securement of portion 40a so that the part of 
portion 22e overlying portion 22d and portion 40a will separate from 
portion 22d without tearing. However, with continued movement of extension 
42 and due to the greater securement of portion 40b in the most preferred 
form, portion 22d will tend to tear following the outer periphery of seal 
40 in a manner as best seen in FIG. 11 rather than having portion 22e 
separate from portion 22d. In the most preferred form, portion 22e (and 
any parts of portion 22d corresponding to seal 40 and which are torn off) 
is completely removed from the remaining portions of bag 18. After removal 
of portion 22e, portion 22d acts like an annular rim in holding the 
remaining portions of bag 18 in a serving bowl function. 
It should be appreciated that although the serving bowl function is 
accomplished by the peelable closure formed by fin seal 28 and by the 
multipaper fabrication provided by portions 22d and 22e in most preferred 
forms, the serving bowl function can be formed by other manners including 
by using perforations, tear strips, cut scoring, thinning sealant, and 
controlled delamination according to the teachings of the present 
invention. Likewise, although providing the peelable closure in top wall 
22 is believed to be advantageous at least because of the serving bowl 
function, the peelable closure which fails during microwave cooking to 
provide venting can be formed at other locations such as in portion 26b. 
In particular, after popping the popcorn and while pinching bottom and top 
walls 20 and 22 between the fingers in the consumer's hands, bottom and 
top walls 20 and 22 can be pulled apart to separate any remaining 
securement of portion 26b and to separate portion 26a in an amount as 
desired such as to a circumferential extent allowing the popped popcorn to 
be poured therefrom or completely removing top wall 22 from bottom wall 20 
so that bottom wall 20 performs a serving bowl function. 
Although walls 20 and 22 are interconnected directly together adjacent to 
peripheries 20a and 22a in the most preferred form shown in FIGS. 1-3 and 
8-12, walls 20 and 22 according to the teachings of the present invention 
could be interconnected together by their interconnection to a side wall 
which accordions during the expansion of bag 18 to increase the size of 
the hollow interior of bag 18 in its expanded condition. In an alternate 
embodiment according to the teachings of the present invention, walls 20 
and 22 of bag 18 could be interconnected together by their interconnection 
to gussetted side panels 50 and 52 added on opposite sides of walls 20 and 
22 such as in a manner shown in FIGS. 13-16. In the form shown, gussetted 
side panels 50 and 52 each comprises first and second side panel portions 
50a and 50b and 52a and 52b joined along fold lines 50c and 52c, 
respectively. In the preferred form shown, fold lines 50c and 52c are 
linearly straight. Portions 50a, 50b, 52a, and 52b of panels 50 and 52 
include peripheries 50ad, 50bd, 52ad, and 52bd which are arcuate in shape 
corresponding to the peripheries 20a and 22a of walls 20 and 22. 
Peripheries 50ad and 52ad are interconnected to periphery 20a and 
peripheries 50bd and 52bd are interconnected to periphery 22a such as by 
adhesive strip 26, with fold lines 50c and 52c being in a spaced, parallel 
relation. 
In the preferred form shown, the maximum width of portions 50a, 50b, 52a, 
and 52b between peripheral edges 50ad, 50bd, 52ad, and 52bd generally 
perpendicular to fold lines 50c and 52c is less than one half of the 
maximum diametric size of peripheries 20a and 20b generally perpendicular 
to fold lines 50c and 52c. In fact, as best seen in FIG. 13, the widths of 
gussetted side panels 50 and 52 are substantially less than the widths of 
the pleats of conventional popcorn package and specifically in a manner so 
as to minimize or eliminate extending over susceptor patch 30 and/or the 
charge of popcorn kernels to be popped. Thus, it is not necessary for the 
initial microwave energy to penetrate several layers of material before 
reaching the charge and therefore the microwave energy is generally 
available quicker and in greater amounts to the charge. However, portions 
50a, 50b, 52a, and 52b can have widths of a size relative to the diametric 
size of walls 20 and 22 which is different than shown according to the 
teachings of the present invention. 
Bag 18 of FIGS. 13-16 can be manufactured according to the preferred 
teachings of the present invention in the following manner. Specifically, 
side panels 50 and 52 are folded about fold lines 50c and 50d such that 
the outside surfaces of portions 50a and 52a overlie the outside surfaces 
of portions 50b and 52b. Walls 20 and 22 are positioned with their inside 
surfaces abutting together intermediate fold lines 50c and 52c, with the 
inside surface of wall 20 abutting with the inside surfaces of portions 
50a and 52a and the inside surface of wall 22 abutting with the inside 
surfaces of portions 50b and 52b and with peripheries 20a, 22a, 50ad, 
50bd, 52ad, and 52bd aligned. First, interconnection portion 26a of strip 
26 is suitably activated to interconnect walls 20 and 22 together 
intermediate fold lines 50c and 52c adjacent peripheries 20a and 22a aside 
from second, interconnection portion 26b, to interconnect wall 20 to 
portions 50a and 52a adjacent peripheries 20a, 50ad and 52ad and to 
interconnect wall 22 to portions 50b and 52b adjacent peripheries 22a, 
50bd and 52bd. After activation of first, interconnection portion 26a, bag 
18 according to the teachings of the present invention can be folded, 
filled, sealed, folded, and overwrapped in generally the manner as set 
forth in FIGS. 3-7. 
It should be appreciated that bag 18, including bag 18 having gussetted 
side panels 50 and 52, can be manufactured in other manners according to 
the teachings of the present invention. As an example, a single rollstock 
of microwave bag material could be provided with susceptor patch 30 (if 
desired) and adhesive strip 26 printed in the appropriate locations. The 
edges of the rollstock could be folded inward and lap or fin sealed to 
form a tube, and if desired, the gussets could be folded inward. The tube 
would then be heat-sealed and die-cut into the appropriate round-like 
shape. The preferred location of the lap or fin seal on the tube could be 
opposite to susceptor patch 30 when forming bag 18 of FIGS. 1-6, 8, and 9 
as well as at other locations including along fold line 50c or 52c of 
gusseted side panel 50 or 52. Similarly, each component of bag 18 could be 
formed from separate rollstocks and cut to shape either before or after 
activation of adhesive strip 26. Likewise, although two panel portions 
50a, 50b, 52a, and 52b are provided in each of the gussetted side panels 
50 and 52 in the preferred form shown, it can be appreciated that 
gussetted side panels 50 and 52 can include additional panel portions 
having the same or differing widths. 
In the preferred form shown in FIGS. 13-16, outer peripheries 20a and 22a 
of walls 20 and 22 have round-like shapes in the form of an oval. In the 
most preferred form, peripheries 20a and 22a of walls 20 and 22 and 
peripheries 50ad, 50bd, 52ad, and 52bd of side panels 50 and 52 include 
peripheral extensions 54 which extend beyond the round-like shape of 
peripheries 20a and 22a and adhesive strip 26 adjacent the opposite ends 
of second, interconnection portion 26b. 
Bag 18 shown in FIGS. 13-16 according to the preferred teachings of the 
present invention is similarly advantageous as previously set forth as 
well is advantageous for other reasons. Specifically, during the popping 
of the popcorn kernels and the expansion of bag 18, gussetted side panels 
50 and 52 will unfold along fold lines 50c and 52c so that panel portions 
50a and 50b and panel portions 52a and 52b tend to approach a planar 
condition. However, even with the provision of gussetted side panels 50 
and 52, walls 20 and 22 as the result of the expression of bag 18 expand 
into a bowl, hemispheric or parabolic curve shape from their peripheries 
20a and 22a. Thus, the advantages of the bowl, hemisphere, or a parabolic 
curve shape of inflated bag 18 are obtained according to the preferred 
teachings of the present is invention. In this regard, due to the oval 
shape of peripheries 20a and 22a in a flat condition and the expansion of 
gusseted side panels 50 and 52, bag 18 of FIGS. 13-16 tends to have a 
circular shape in an expanded condition when viewed from the top looking 
down. 
In the preferred form, the peelable closure is formed in the 
interconnection between walls 20 and 22 and intermediate gussetted side 
panels 50 and 52, and bag 18 is opened utilizing a cross pinch-pull 
technique similar to conventional rectangular microwave popcorn bags. In 
particular, portion 26b is formed as a peelable closure which fails during 
microwave cooking to provide venting and to allow ease of separation when 
desired to open bag 18. 
In particular, the corners defined generally at the interconnection of wall 
20 and panel portion 50a (and in the most preferred form at the peripheral 
extensions 54 thereof) is pinched between the thumb and forefinger of one 
of the consumer's hands and the corner defined generally at the 
interconnection of wall 22 and panel portion 52b (and in the most 
preferred form at peripheral extensions 54 thereof) is pinched between the 
thumb and forefinger of the other of the consumer's hands and the corners 
are pulled apart to release adhesive strip 26 between wall 20 and panel 
portion 52a, between wall 22 and panel portion 50b and between walls 20 
and 22. Then, bag 18 is grasped at the opposite corners defined generally 
at the interconnection of wall 20 and panel portion 52a and at the 
interconnection of wall 22 and panel portion 50b (and in the most 
preferred form at peripheral extensions 54 thereof) and the corners pulled 
apart to release adhesive strip 26 between wall 20 and panel portion 50a, 
between wall 22 and panel portion 52b, and between walls 20 and 22. 
Adhesive strip 26 can be opened as little or as much as the consumer 
chooses ie a narrow opening facilitates pouring into a bowl whereas a wide 
opening facilitates easy eating directly out of bag 18. As consumers are 
accustomed to utilizing cross pinch-pull techniques in opening 
conventional rectangular popcorn bags, increased consumer acceptance may 
be experienced with bag 18 of FIGS. 13-16 than with bags 18 which do not 
utilize cross pinch-pull techniques. Also, when the peelable closure is 
formed in the interconnection between walls 20 and 22 as in FIGS. 13-16 as 
well as in FIG. 12, top wall 22 can be formed from a single integral 
component according to the teachings of the present invention and 
specifically without the added expense of fabrication from multiple pieces 
required for fin seal 28 of FIGS. 1, 8 and 9, the layered portions 22d and 
22e of FIGS. 10 and 11 or of fabrication with other manners of peelable 
closures. 
Although openable along peripheries 20a and 22a, bag 18 of FIGS. 13-16 
according to the teachings of the present invention also provides a 
serving bowl function but in a different manner than bags 18 shown in 
FIGS. 1, 8, 9, 11 and 12. In particular, when inflated with popped 
popcorn, walls 20 and 22 intermediate fold lines 50c and 52c extend at a 
relatively large diameter arc generally perpendicular to adhesive strip 
26. Similarly, portions 50a and 50b and portions 52a and 52b which are 
unfolded relative to each other extend at a relatively large diameter arc 
generally parallel to adhesive strip 26 intermediate fold lines 50c and 
52c. Thus, a relatively flat support surface is defined thereby which can 
be placed on a table, counter, or the like to hold bag 18 with walls 20 
and 22 extending generally vertically and in a stable, non-tipping manner. 
Additionally, in the preferred form, the serving bowl function of bag 18 of 
FIGS. 13-16 can be further enhanced by folding walls 20 and/or 22 and/or 
side panels 50 and/or 52 about a fold line above the volume of popped 
popcorn so that the inside surfaces thereof abut in a manner as shown in 
FIG. 15. In this regard, adhesive strip 26 between side panels 50 and 52 
and walls 20 and 22 can be separated by the consumer to an extent 
generally equal to the level of the popped popcorn. When so folded, the 
hand of the consumer would be less prone to rubbing against residual oil 
or grease on the inside surfaces of bag 18 while removing popcorn from bag 
18 as the outer surface of side panels 50 and 52 and walls 20 and 22 would 
be what would be inadvertently touched. It should then be appreciated that 
the peripheral interconnection of walls 20 and 22 and of walls 20 and 22 
and side panels 50 and 52 is especially advantageous in providing this 
enhanced serving bowl function without requiring tearing of bag 18. 
Extensions 42 and 54 provide multiple functions according to the preferred 
teachings of the present invention. First, extensions 54 extend from the 
inflated bag 18 in a generally radial fashion, with both extensions 42 and 
54 creating a visual indication where bag 18 should be opened as 
extensions 42 and 54 have the appearance as handle tabs. Second, 
extensions 42 and 54 provide increased area for grasping and gripping by 
the consumer. Also, as extensions 54 are located outwardly of adhesive, 
strip 26 and the interior of bag 18, extensions 54 do not have the 
tendency to be hot to the touch as other portions of bag 18 which have 
direct contact with the popped popcorn. Thus, extensions 54 provide 
increased consumer safety from contacting hot surfaces. Similar consumer 
safety is also provided by extension 42. It should be appreciated that due 
to the round-like shape of periphery 22g of portion 22e of wall 22 and of 
peripheries 20a and 22a of walls 20 and 22 and the arcuate shape of 
peripheries 50ad, 50bd, 52ad, and 52bd and since walls 20 and 22 and side 
panels 50 and 52 are typically cut from continuous rollstock, extensions 
42 and 54 according to the teachings of the present invention are formed 
from otherwise unused and discarded portions of the rollstock so that no 
additional cost is encountered in providing extensions 42 and 54. 
Extensions 42 and 54 would have similar application to bags 18 according to 
the preferred teachings of the present invention which do not include 
gusseted side panels 50 and 52. As an example, where it is desired to 
provide a peelable closure between peripheries 20a and 22a of walls 20 and 
22 such as to allow pouring of the popped popcorn therethrough, extensions 
54 could be formed on peripheries 20a and 22a for separating adhesive 
strip 26 therebetween. In such applications, extensions 54 could be formed 
as a continuous piece centered on the desired peelable closure. Likewise, 
extensions 56 could be formed on the edges of portions 22b and 26c at fin 
seal 28 such as shown in FIG. 17 for grasping by the consumer in pulling 
the opposite sides of seal 28 when fin seal 28 provides the peelable 
closure. 
Additionally, although the particular manner of manufacture, filling, and 
folding of bag 18 is believed to be advantageous including but limited to 
having a final conventional, rectangular shape for secondary packaging 
purposes, bag 18 can be manufactured, filled and/or folded in other 
manners according to the teachings of the present invention. In this 
regard, it may be desirable to fold or otherwise configure bag 18 to have 
a final shape which is different than other conventional shapes to 
emphasize the uniqueness of bag is in the marketing thereof. 
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.