Abstract:
A potion package with an improved dual compartment configuration for storing, shipping, and stacking food products is provided. The portion package includes three layers of flexible film that define a first compartment and a second compartment. The first compartment is formed by a first and a second layer of flexible film, and the second compartment is formed by the second and a third layer of flexible film. The second layer of flexible film shared by the opposing, superimposed compartments permits movement of the compartments relative to one another. The first compartment is filled with a granular material, such as unpopped popcorn, and the second compartment is filled with a fluid material, such as popcorn oil. The compartments are sized such that when an external force is applied to the container, the granular material and the fluid material are permitted to move within their respective containers, as well as with respect to one another, thereby distributing the external force and inhibiting rupture of the compartments.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a continuation in part of application Ser. No. 09/430,274, filed Oct. 29, 1999. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates to portion packaging, and more particularly, to a portion package to store and transport foods, such as pre-measured units of popcorn and oil.  
         BACKGROUND OF THE INVENTION  
         [0003]    Commercial packages for containing unpopped popcorn kernels and popping oil are well known in the food industry, and are generally referred to by the popcorn industry as “portion packs.” Some portion packs have the unpopped popcorn kernels and salt in one portion and the popping oil in a separate portion located on the side. Still other portion packs have the popcorn kernels in one portion, the salt in second portion, and the popping oil in a third portion, where all the portions are in a side-by-side configuration.  
           [0004]    One of the disadvantages of these existing side-by-side portion packs is oil leakage. When shipping portion packs of popcorn kernels, it is common for the packs to rupture due to the weight and compression on the oil portion of the portion pack caused by the stacking of numerous portion packs atop one another in a packing box. Generally, the rupture occurs along the seal of the portion pack. Once the portion pack is ruptured, the oil can contaminate the surrounding portion packs and boxes.  
           [0005]    To prevent rupture and leakage of oil, many commercial popcorn manufactures have resorted to using popping oils that are solid or semisolid at room temperature. Such oils can better withstand the forces imparted by the other portion packs during shipping. Thus, the type of oils used to make popcorn is largely controlled by packaging considerations. However, an important disadvantage to this solution is that most solid or semisolid oils are hydrogenated oils which are known to be less healthy than unsaturated popping oils.  
           [0006]    Therefore, a need exists for improved packaging for portion packs such as those used to contain popcorn and popping oil that are less susceptible to rupture during shipment, and which also allow the use of healthier popping oils.  
         SUMMARY OF THE INVENTION  
         [0007]    The present invention is directed to a container having two compartments that are adjacent to one another and share a common interface, but contain separate materials. The container and two compartments are formed by three layers of flexible film. A first and a second layer of flexible film form a first compartment, and the second and a third layer of flexible film form a second compartment. The first compartment contains a granular material and the second compartment contains a fluid material. Thus, the second layer of flexible film separates the granular and fluid materials in the first and second compartments.  
           [0008]    The first and second compartments are sized to permit movement of the granular material and the fluid material within their respective compartment. Additionally, the configuration of the two compartments allows the compartments to move with respect to one another. When an external force is applied to the container, the granular material and the fluid material move within the first and second compartments and distribute the external force by moving relative to one another, thereby inhibiting rupture of the compartments. In order to permit adequate movement of the materials in the compartments, the total amount of granular material and fluid material that is placed in the container should occupy less than about 80% of the total capacity of the container, which is defined by the sizing of the first and second compartments. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    [0009]FIGS. 1 and 2 show prior art portion packs;  
         [0010]    [0010]FIG. 3 is a perspective view of the three flexible film layers of the present invention;  
         [0011]    [0011]FIG. 4 is a perspective view of the present invention with the three film laminate layers sealed together at the sides and bottom;  
         [0012]    [0012]FIG. 5 is a top view of a sealed portion pack of the present invention including the food materials secured within the portion pack and an easy-open top seal; and  
         [0013]    [0013]FIG. 6 is a side view in section showing the portion pack of FIG. 5 taken along line  6 - 6 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0014]    Referring to FIG. 1, common portion packs used in today&#39;s market are in a side-by-side configuration. There is one compartment  40  for the kernels and salt and another compartment  42  for oil. An alternate configuration of existing portion packs is shown in FIG. 2, where one portion  44  stores the kernels, a second portion  46  holds the salt, and a third portion  48  holds the oil all in a side-by-side configuration.  
         [0015]    As shown in FIG. 3, the portion pack  10  of this invention preferably has three layers of flexible film which together form two compartments. The layers of flexible film can be produced by arranging one or more sheets of flexible film, preferably to form two rectangular compartments. In one embodiment, a single sheet of flexible film can be folded several times to create multiple layers. In another embodiment, separate sheets of flexible film can be layered on top of each other. The function and utility of this invention does not rely on the method used to achieve the multiple layers of film. Rather, it is the configuration of the three layers in relation to the contents placed into the portion pack that makes this invention an improvement over existing portion packs.  
         [0016]    The flexible film used to produce the portion pack  10  can be made from any composition including plastics suitable for food packaging, such as polypropylene, polystyrene, or a polyester. Preferably, a heat sealing film laminate is used. The most preferred embodiment uses a polyester film coated with a heat sealable material, such as polyethylene.  
         [0017]    According to the preferred embodiment, the first layer of film laminate  12  and the third layer of film laminate  14  each have a coating of heat sealable material on their inside surfaces  16   a  and  16   b , respectively. The second layer of film laminate  18 , is positioned substantially between the first layer of film laminate  12  and the third layer of film laminate  14 , and has coatings of heat sealable material on both of its surfaces,  20   a  and  20   b . This configuration of layers allows all three layers to be heat sealed together. Despite the preferred use of heat sealing, it is recognized that alternative methods of sealing the multiple layers can be used. For example, adhesives or other materials can be used to seal the layers into compartments, so long as secure seals are created.  
         [0018]    As shown in FIGS. 4, 5, and  6 , the first, second, and third layers of film laminate are preferably heat sealed along a first side  22 , a second side  24 , and a bottom  26 . The preferred temperature for creating an effective seal is in the range of between about 240° and 400° F. After sealing the three surfaces, a first compartment  28  and a second compartment  29  are defined by the sealed films. The first compartment is formed by the first layer of film laminate  12  and the second layer  18 , and the second compartment is formed by the second layer of film laminate  18  and the third layer  14 . Thus, the second layer of film laminate  18  serves as a partition between the first layer  12  and the third layer  14 , and as a common interface shared by the first compartment and the second compartment. This use of a common interface between the two superposed compartments  28 ,  29 , has several advantages. The two compartments are then filled and a top seal  30  is formed to close the top openings of the two compartments.  
         [0019]    One advantage is that the structure of the portion pack  10  of the present invention is that the structural integrity is enhanced by having the first compartment  28  and the second compartment  29  superimposed upon one another. The second layer  18  defines a flexible common interface that allows a pressure applied to one compartment to be distributed broadly across both compartments. When the compartments are filled with a desired amount of product, there remains a substantial flexibility in the portion pack in that the layers of film flex and conform to the shape of the contents when an external force is applied to the portion pack. Furthermore, the contents of the portion pack are allowed to shift or travel within their respective compartments to areas under less pressure. The degree of movement permitted in the compartments depends largely on the relationship between the amount of contents placed within each compartment and the geometry of the compartment.  
         [0020]    As shown in FIG. 6, in the preferred embodiment, the unpopped popcorn kernels are placed in the first compartment  28  and the oil is placed in the second compartment  29 . In one preferred embodiment each of the two containers defined by the portion pack is a rectangle that is about 3½ inches wide and 7½ inches long, surrounded by a seal that is about ¼ inch wide. Such a portion pack ideally contains about 6¼ ounces of popcorn kernels and ¼ ounce of salt in the first compartment and 1½ ounces of popping oil in the second compartment. This is the proper amount of popcorn kernels and oil for use with 6 to 8 ounce commercial popping machines.  
         [0021]    According to the present invention, it is important that the compartments not be filled to their maximum capacity. For the portion pack described above, if the first compartment were filled to capacity with popcorn kernels leaving the second compartment empty, it would hold about 10 to 11 ounces of kernels. Similarly, if the second compartment of such a portion pack were filled to capacity with popping oil with the first compartment empty, it would hold about 10 to 11 ounces of popping oil. In the preferred embodiment, the compartment of the portion pack holding the granular material, in this case popcorn kernels, should only be filled to about 50 to 60% of the total capacity. Similarly, in the preferred embodiment, the compartment of the portion pack holding a fluid material, in this case popping oil, should only be filled to about 10 to 20% of the total capacity. Together, the granular solid and fluid should occupy less than about 80% of the total capacity. In the most preferred embodiment, the filled capacity should be less than about 75% of the total capacity.  
         [0022]    This configuration permits the filled portion pack to better withstand the external forces commonly encountered in shipping and storage. This is due to the ability of the contents of the first and second compartments to shift and move both within their respective compartments and with respect to one another, distributing the external forces over the entire portion pack. More particularly, when an external force such as the compressive force caused by a stack of other packages above the given portion pack, is exerted on the second compartment of the portion pack containing the oil, the oil shifts within the second compartment, transferring the force to the first compartment which contains the popcorn kernels. Similarly, the popcorn kernels are able to distribute or move within the first compartment and absorb the force applied to the oil, thus reducing the pressure on the oil compartment. Additionally, the flexibility of the second sheet of film  18  allows the contour of the film to match that of the popcorn kernels in the first compartment, creating voids  31  in the second compartment into which the oil can flow. In addition to occupying the voids, the oil occupies the perimeter region  33  of the second compartment. The result is that the popcorn kernels support the majority of the external forces, preventing the pressure of the second compartment from building to the point where the second compartment is susceptible to rupture. Because the popcorn kernels so effectively support the external forces, the amount of weight that can be stacked on the portion pack without rupture of the pack is increased. This not only makes storage and shipping more convenient, it also permits the use of healthier unsaturated popping oil rather than the commonly used hydrogenated oils that are solid or semisolid at room temperature.  
         [0023]    While described for portion packs of the type containing popcorn kernels and popping oil, this structural advantage is equally applicable to other variations of contents placed in the portion pack  10 . For example, the portion pack of the present invention provides advantages for any package in which a granular solid such as popcorn kernels and a fluid such as popping oil are packaged in a compartmentalized package. Examples of other granular solids used in the food industry include grains such as rice, or dried beans or vegetables. Examples of fluids other than popping oil include, other types of oils, oil and water mixtures, aqueous solutions, aqueous or oil slurries of solids, gels, or even powders or other solid particles that tend to flow like a fluid, and which tend to cause the package to be susceptible to rupture. Where two compartments are filled with predetermined amounts of different substances with different characteristics, the compartments should be sized as set forth above to permit sufficient movement with respect to one another and within the respective compartments to exhibit the advantage of the present invention.  
         [0024]    Another advantage of the portion pack  10  of the present invention is that it is more compact than a prior art side-by-side configuration. Its compact nature allows it to be manufactured at lower cost than prior art portion packages. Additionally, the portion pack of the present invention is more efficient to stack, store and ship. Unlike a side-by-side configuration which tend to have compartments with different thicknesses and tolerances to pressure, the new portion pack has the appearance of a single compartment and has only one overall outer thickness. Consequently, when a large number of prior art portion packs are placed in a box, the portion packs should be carefully stacked to best distribute the forces in order to avoid possible rupture of any of the portion packs. However, for the portion pack of the present invention, the portion packs can be packed in a box with less care since the portion packs themselves are able to withstand the external forces without complicated packing procedures.  
         [0025]    Another advantage is that the new portion pack will allow the ingredients, such as popcorn kernels, salt, and oil, to be poured into the popcorn kettle faster and easier by merely cutting the top seal  30 . Many kettle temperatures are kept at a range of 400° to 500° F. and, therefore, can severely burn an operator&#39;s hands. However, with the present invention, the operator can easily cut the top seal  30  of the portion pack and pour all the contents into the kettle quicker and easier, thereby avoiding injury to the operator. Furthermore, the present invention includes an optional easy-open top seal which allows the portion pack to be opened without the assistance of any accessory utensil.  
         [0026]    As illustrated in FIG. 5, the easy-open top seal  40  is positioned along the top seal  30  of the portion pack and comprises a notch tab  42 , a notch margin  44 , and a rip guide  46 . The notch tab  42  is positioned substantially flush with the large top seal  30  of the portion pack, and is actually part of the top seal, but has been separated from the portion pack at its side surface. The notch margin  44  is positioned immediately below the notch tab and comprises a portion of the top seal that tapers upwardly. The rip guide  46  is positioned between the notch tab  42  and the notch margin  44 , and when pulling the notch tab, the notch tab separates from the notch margin along the rip guide and opens the portion pack along the top seal. Thus, the portion pack will be open to pour out all of the contents of the two compartments simultaneously.  
         [0027]    This invention also provides a preferred method for preparing the portion packs. A first roll of film laminate is placed above a second roll of film laminate such that when the film laminates are rolled out, the first layer of film laminate is placed above the second layer laminate. It is preferred that the first layer of film laminate be half the width of the second film laminate, such that when the second layer of film laminate if folded in half, it will cover the entire first layer of film laminate. This creates the three layers of the portion pack and the two compartments of the portion pack. However, the second layer of film may be longer at the top to allow for the ease in opening the compartments to place food or any other objects into them.  
         [0028]    Once the first layer of film laminate and the second layer of film laminate are laid out, the film laminates are heat sealed at a temperature range of about 240° to 400° F. on the first side, the second side, and the bottom thereby forming the first compartment and the second compartment. The portion packs are then cut on a first side to divide the portion packs from the layer of film, and the food or desired contents are then placed within the first and second compartments. Once placed within the compartments, the portion pack is heat sealed on the top to secure the contents within the portion pack.  
         [0029]    The shape, width, height, and thickness of the portion pack can be varied depending on the user&#39;s needs. For example, rather than forming a portion pack with a rectangular shape, the portion packs may be circular or triangular. Furthermore, this invention has been described by reference to specific examples and embodiments, which will bring alternative embodiments, modifications and variations to the minds of those skilled in the art. The appended claims are intended to encompass all such alternatives, modifications, and variations.