Patent Publication Number: US-2021177018-A1

Title: Apparatus and related methods for preparing popcorn

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of pending U.S. patent application Ser. No. 15/824326, filed on Nov. 28, 2017, which is a divisional application of U.S. patent application Ser. No. 14/598702, filed on Jan. 16, 2015, which issued as U.S. Pat. No. 9,826,771, both of which are incorporated herein by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to apparatus and methods for preparing popcorn. More specifically, the present invention relates to apparatus and related methods of preparing popcorn using a hot air popper with a removable kernel pitcher. 
     BACKGROUND OF THE INVENTION 
     Popcorn is one of the most universally consumed snacks. Conventional methods for preparing popcorn have utilized heated oil, microwave heating or heated air as the heating medium. One benefit of utilizing heated air is that the popcorn can control the addition of any extra calories or fat as no oil is utilized in the popping process and the addition of butter and/or other flavors or toppings can be accomplished after the popping process is completed. 
     One of the most popular settings for the consumption of popcorn is in movie theaters. Traditionally, theaters have utilized heated oil based systems to pop large volumes of popcorn. During the popping process, popped kernels exit out of a popping tub and are collected on the floor of a popping structure that allows for theater workers to reach in and fill bags or tubs with freshly popped popcorn. Following popping, the theater workers typically rotate the popping tub to an upside down disposition so that any remaining popped and unpopped kernels are emptied onto the floor of the popping structure. 
     The look and style of traditional theater popcorn poppers has been replicated in a smaller fashion so as to fit into a home setting. Generally, these home versions of the theater popcorn popper have a reduced size such that smaller volumes of popcorn are popped and stored for consumption. In addition to having a reduced size, the way in which kernels are popped have been changed from a conventional heated oil arrangement to a hot air arrangement. Using heated air allows for cleaner operation and does not require the user to have oil on hand. In addition, the heated air operation reduces the potential for smoke. 
     While theater style popcorn poppers are available for residential use, it would be advantageous to further improve upon their designs to provide additional functionality and ease of use. 
     SUMMARY OF THE INVENTION 
     A heated air popcorn popper of the present invention provides easy access and clean up through the use of a detachable popping pitcher. Generally, the detachable popping pitcher defines an interior popping volume in which heated air is used to cause unpopped kernels to pop and form popped popcorn. The detachable popping pitcher can comprise a pitcher handle allowing a user to grasp and manipulate the popping pitcher when selectively detaching and attaching the popping pitcher to the popcorn popper. In a theater style, heated air popcorn popper, the detachable popping pitcher is completely removable from a popper housing such that loading unpopped kernels into the popping pitcher is simplified and the user need not be concerned about access being awkward or limited. In a similar manner, the detachable popping pitcher can be fully removed from the popper housing following popping such that any remaining unpopped or popped kernels can be emptied from the detachable popping pitcher and the detachable popping pitcher can be cleaned if so desired. In some embodiments, the detachable popping pitcher can be selectively detached or attached from the popcorn popper with a latching mechanism. In some embodiments, the detachable popping pitcher can include one or more retaining members at an upper portion of the popping pitcher to retain popcorn in a popping volume of the popping pitcher until the level of popcorn rises so as to physically cause the one or more retaining members to open. 
     In one aspect, the present invention is directed to a popcorn popper having a detachable popping pitcher 
     In another aspect, the present invention is directed to a method for loading unpopped kernels into a popcorn popper. 
     In yet another aspect, the present invention can comprise a theater-style hot air popper having a detachable popping pitcher for loading unpopped kernels outside of the theater-style hot air popper. 
     In yet another aspect, the present invention is directed to a method of emptying a popcorn popper by removing a detachable popping pitcher. In some embodiments, the method can further comprise cleaning the detachable popping pitcher. 
     The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A specific embodiment is now described by way of example to further the understanding of the present disclosure, with reference to the accompanying drawings in which: 
         FIG. 1  is a front view of a theater-style popcorn popper according to a representative embodiment of the present invention. 
         FIG. 2  is a side view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 3  is a rear view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 4  is a side view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 5  is a bottom view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 6  is a top view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 7  is a top, perspective view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 8  is a top, perspective view of the theater-style popcorn popper of  FIG. 1  with a door in an open position and a detachable popping pitcher removed from a popper housing. 
         FIG. 9  is a front view of a detachable popping pitcher according to a representative embodiment of the present invention. 
         FIG. 10  is a side view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 11  is a rear view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 12  is a rear view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 13  is a top view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 14  is a bottom view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 15  is a top, perspective view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 16  is a top, perspective view of the detachable popping pitcher of  FIG. 9  having a plurality of retention members in an open disposition. 
         FIG. 17  is a bottom, perspective view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 18  is a partial section view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 19  is a partial section view of the theater-style popcorn popper of  FIG. 1 . 
         FIG. 20  is a top, perspective view of the detachable popping pitcher of  FIG. 9 . 
         FIG. 21  is a front, perspective view of the theater-style popcorn popper of  FIG. 1 . 
     
    
    
     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring generally to  FIGS. 1-8 , a representative embodiment of a popcorn popper  100  of the present invention can comprise a popper housing  102  and a detachable popping pitcher  104 . In some embodiments, popper housing  102  can comprise a theater-style housing  106 . In addition, popcorn popper  100  can also include one or more serving baskets  108 . Popcorn popper  100  is generally fabricated of materials suited for food contact and preparation including metals such as aluminum and stainless steel, plastic polymers such as polycarbonate, glass as well as similar materials and combinations thereof. 
     With reference to  FIGS. 1-8 , popper housing  102  generally includes a pair of side walls  110   a ,  110   b , a rear wall  112 , a front wall  114 , a top wall  116  and a base assembly  118 . Front wall  114  is generally defined by a door assembly  120  and a serving panel  122 . Door assembly  120  generally comprises a transparent door  124 , a door handle  126  and door hinge assemblies  128   a ,  128   b . The base assembly  118  can define a control surface  130  including a control or power button  132  for operably controlling the popcorn popper  100  as well as a removable drip tray  134 . The base assembly  118  further defines an interior floor surface  136  as well as an external bottom surface  138 . Top wall  116  can comprise a tray recess  140  and an air vent  142 . Each of the side walls  110   a ,  110   b  generally comprises a transparent surface  144  having a vent portion  146 . 
     Within an interior portion  150  of the popper housing  102 , the base assembly  118  defines a mounting platform  152  as illustrated in  FIGS. 8, 18 and 19 . Mounting platform  152  can comprise a mounting surface  154  that is supported by an elevated mounting wall  156 . Mounting surface  154  can comprise an airflow screen  158 . The mounting surface  154  can further include a latch receiver  160  oriented toward the front wall  114 . Mounting surface  154  and rear wall  112  can cooperatively define a positioning recess  162 . Mounting platform  152  generally defines an interior mounting area  164 , which can accommodate a fan assembly  166  and a heating member  168 . Fan assembly  166  can generally comprise a fan wheel  170  and motor  172  while heating member  168  can comprise a resistive heating element  174 . Interior mounting area  164  is generally open to an interior base portion  176  that can accommodate controls, wiring and other electrical and safety necessities. 
     As shown in  FIGS. 9-17 , detachable popping pitcher  104  generally comprises a pitcher body  180  defined by a pitcher wall  182 , an upper pitcher opening  184 , a pitcher floor  186  and an interior heating zone  188 . Pitcher body  180  can have a generally circular cross-section as illustrated or alternatively, the pitcher body  180  can have a cross-sectional shape selected from squares, rectangles, triangles and combinations thereof. Generally, the cross-section of pitcher body  180  will substantially resemble a cross-section of the mounting platform  152  to promote positioning and attachment of the pitcher body  180  relative to the mounting platform  152 . Pitcher floor  186  generally includes a pitcher screen  190  formed of a mesh or screen material having apertures significantly reduced in size compared to individual popcorn kernels. Pitcher floor  186  can further define a positioning tab  191 . Pitcher body  180  can further comprise a kernel retention mechanism  192  or means for retaining at the upper pitcher opening  184 . 
     In a representative embodiment, kernel retention mechanism  192  can comprise one or more lid members  194  that are attached to the upper pitcher opening  184  with a corresponding hinge assembly  196 . Lid member  194  can comprise two or more lid members  194 , such as, for example, three lid members  194  as illustrated with the only requirement being that in combination, the lid members  194  cover the entire upper pitcher opening  184 . Each lid member  194  includes a plurality of lid vent openings  198 . Each lid member  194  has a corresponding hinge assembly member  196  such that the lid members  194  are individually capable of transitioning between a covering disposition  200  as seen in  FIGS. 7, 8, 13 and 15  and an open disposition  202  as seen in  FIGS. 16, 20 and 21 . 
     Attached to the pitcher body  180  is a pitcher handle  204 . Proximate the pitcher floor  186 , the pitcher handle  204  can define a latch member  206  having a tapered latch surface  207  as seen in  FIGS. 18 and 19 . Pitcher handle  204  can further comprise a latch actuator  208  that is operably interconnected to the latch member  206  such that depression of the latch actuator  208  changes the position of the latch member  206 . 
     In order to use popcorn popper  100 , popping pitcher  104  must be filled with unpopped kernels  210  as illustrated in  FIG. 20 . Generally, popping pitcher  104  is positioned outside of the popper housing  102  to provide easy access to the upper pitcher opening  184 . If popping pitcher  104  includes kernel retention mechanism  192 , the kernel retention mechanism is first directed to the open disposition  202  so as provide unimpeded access to the interior heating zone  188  through upper pitcher opening  184 . As the unpopped kernels  210  are poured into the interior heating zone  188 , they accumulate on the pitcher floor  186  and are retained by the pitcher screen  190 . Once the desired amount of the unpopped kernels  210  are poured into the popping pitcher  104 , the kernel retention mechanism  192  can be directed to the covering disposition  200  to maintain the unpopped kernels  210  within the interior heating zone  188 . 
     With the popping pitcher  104  filled with the desired amount of unpopped kernels  210 , the user opens the transparent door  124  to allow access into the interior portion  150  of the popper housing  102  as shown in  FIG. 19 . The user directs the popping pitcher  104  proximate the mounting platform  152  and begins to engage the mounting platform  152  by guiding the positioning tab  191  into the positioning recess  162 . With the positioning tab  191  positioned in the positioning recess  192 , the user can lower the popping pitcher  104  such that the pitcher floor  186  sets onto the mounting surface  154 . When the pitcher floor  186  is flush with the mounting surface  154 , the tapered latch surface  207  causes the latch member  206  to slip past the latch receiver  160 , such that the latch member  206  and latch receiver  160  in conjunction with the interaction of the positioning tab  191  and positioning recess  162 , maintain the attachment and alignment of the popping pitcher  104  relative to the mounting platform  152  as shown in  FIG. 18 . With the popping pitcher  104  attached to the mounting platform  152 , the airflow screen  158  and the pitcher screen  190  are aligned so as to allow airflow from the interior mounting area  164  into the interior heating zone  188 . 
     With the popcorn popper  100  assembled through attachment of the popping pitcher  104  to the mounting platform  152 , the user can plug in an electrical cord (not shown) and utilize the control button  132  to begin a popping cycle. Generally, the fan assembly  164  directs air through the heating member  168  and into the popping pitcher  104  through the aligned airflow screen  158  and pitcher screen  190  whereby the heated air interacts with the unpopped kernels  210  within the interior heating zone  188 . Generally, the unpopped kernels  210  are agitated by the heated air and can even be carried upward by the heated air. If unpopped kernels  210  are carried upward, the eventually contact the kernel retention mechanism  192  which prevents the unpopped kernels  210  from exiting the interior heating zone  188 . After a period of time, the unpopped kernels  210  begin reaching an internal temperature of at least 185° C., whereby moisture within the unpopped kernels  210  is converted to steam, thus causing the unpopped kernels  210  to “pop” and become a popped kernel  212 . Each popped kernel  212  is substantially larger in physical volume following popping, thereby causing the internal heating zone  188  to become filled with popped kernels  212 . As the popped kernels  212  accumulate and stack upon one another, eventually an upper level of the popped kernels  212  reaches the kernel retention mechanism  192 . As the upper level of the popped kernels  212  contacts the kernel retention mechanism  192 , the kernel retention mechanism  192  is physically forced upward and caused to transition from the covering disposition  200  to the open disposition  202 , for example, by causing each lid member  194  to flip from the covering disposition  200  to the open disposition  202 . As the kernel retention mechanism  192  transitions to the open disposition  202 , the heated air blows upward through the upper pitcher opening  184  such that the popped kernels  212  begin exiting the internal heating zone  188  and begin to accumulate on the interior floor surface  136  of the base assembly  118 . 
     After a period of time, the unpopped kernels  210  have “popped” and become popped kernels  212 . At that point, the popping cycle is completed and the fan assembly  166  and heating member  168  are deenergized or turned off. At this point, the majority of popped kernels  212  have likely exited the popping pitcher  104  and reside on the interior floor surface  136 . The user can open the door assembly  120  and grasp the pitcher handle  204 . As the user grasps the pitcher handle, the latch actuator  208  can be depressed thereby causing the latch member  206  to retract away from the latch receiver  160 . The user can then begin lifting the popping pitcher  104  away from the mounting platform  152  such that the positioning tab  191  is removed from the positioning recess  162 . With the popping pitcher  104  fully detached from the mounting platform  152 , the user can orient the popping pitcher  104  in an upside down orientation to empty any remaining popped kernels  212  from the interior heating zone  188  as shown in  FIG. 21 . The user can then remove the popping pitcher  104  from the popper housing  102 , whereby the popping pitcher  104  can be reloaded with unpopped kernels  210  or alternatively, the popping pitcher  104  can be cleaned. 
     While a specific embodiment has been described above by way of illustration, it will be appreciated that the described principles are equally applicable to a wide range of popcorn popper products and configurations. More generally, numerous adaptations, modifications, combinations and juxtapositions of the features described above may be made without departing from the principles of the presently disclosed invention.