Patent Description:
Popcorn is often made in bags pre-packaged with popcorn that are then heated in a microwave, or in difficult-to-use machines that require manual loading of kernels, flavoring, and oils. Both solutions are less than ideal and achieve inadequate results. For example, it is difficult, if not impossible, to achieve even popping or flavoring of all kernels in microwavable bags. A user must stand next to the microwave to listen for particular popping patterns to try to guess when most of the kernels have popped. As a result, microwaving popcorn results in a high number of unpopped kernels, uneven flavoring, and burning. The interior of the bag is also covered in oil and flavoring, making it undesirable and messy to eat directly from the bag. Portion sizes are also unnecessarily large, which often results in wasted, uneaten popcorn. Existing countertop popping machines are complex to use, requiring manual measuring and loading of ingredients. They are difficult to clean because several parts must be dismantled to clean the entire machine after each use. Finally, because they use bulk flavoring and cooking of kernels, flavor can be uneven and, like microwave popcorn, existing countertop machines frequently result in unpopped kernels, uneven flavoring, and burning. <CIT> discloses a system for popping popcorn including a housing, a container positioned in the housing, a cartridge containing unpopped popcorn kernels removably supported in the container, wherein the cartridge includes ferromagnetic material, a coil that creates an oscillating magnetic field that interacts with the ferromagnetic layer of the cartridge and generates an amount of heat in the cartridge, a vibrator coupled to the container for vibrating the container and the cartridge, and a receiving vessel for receiving popped popcorn positioned adjacent the container. <CIT> discloses a device and a method to pop corn while preventing any unpopped kernels from mixing with the popped corn and further preventing the already popped corn from burning. Each corn kernel is placed into an individual cell on a cassette. When the kernel is popped, it pops out of the cell and falls off of the cassette and is thus removed from the heat source. The unpopped kernels remain in the cassette where they will later be disposed of. <CIT> discloses a cooking system that utilizes vibration to improve the convenience of preparing food and the quality of the finished product. The system uses a vibrating device coupled to a cooking vessel with a pad and/or isolation blocks disposed between the vibrator and the vessel. The cooking system can be adapted to prepare specific foods in specific quantities, such as popcorn in pre-packaged containers.

The present invention resolves the myriad problems associated with existing popcorn popping systems and methods. A grain-popping machine is described that is configured to receive a pod. Each pod includes a plurality of cells, with each cell preferably containing a single grain kernel or seed, flavoring, and a cooking medium such as oil or shortening. In an example, the pod is loaded into the grain-popping machine through a slot so that it is held in position below a heating element. The heating element is activated to begin a popping sequence. When each grain kernel or seed in the pod reaches popping temperature, it absorbs the flavoring in its cell and ejects through the bottom cover of the pod into a bowl positioned in a receiving area of the grain-popping machine. The pod is then removed and disposed of.

The system and methods described herein therefore are easier to use and clean than existing methods of popping grains, avoid burning grains, and provide even flavoring for all grains in the pod. Advantageous examples of the present disclosure are the subject-matter of the dependent claims. Further examples not falling under the scope of the present invention are also given in the description.

Turning now to the drawings, in which like reference characters indicate corresponding elements throughout the several views, <FIG> is a perspective view of a grain-popping machine <NUM> according to an example not according to the claimed invention. Grain popping machine <NUM> has an upper chamber <NUM>. Upper chamber <NUM> includes a pod slot <NUM>, which can be located at various positions on grain popping machine <NUM>. <FIG> illustrates two locations on grain popping machine <NUM> on which pod slot <NUM> can be formed. While <FIG> illustrates two pod slots <NUM>, it is understood that, in most examples, only one pod slot <NUM> would be required. Thus, if the upper location of pod slot <NUM> is chosen, the lower location would generally not be included. Pod slot <NUM> can receive grain pods of various shapes and sizes, as will be described in further detail herein.

In the example shown in <FIG>, pod slot <NUM> is rectangular. The slot could be in various other shapes in accordance with examples not falling under the scope of the present invention. For example, the slot could be square, oval, or circular. Pod slot <NUM> can also be formed in different lengths and widths, regardless of the shape. In other examples, pod slot <NUM> is formed in different locations on upper chamber <NUM>. For example, pod slot <NUM> could be formed higher or lower on the front face of upper chamber <NUM> or could be positioned on the side of upper chamber <NUM>. In other examples, pod slot <NUM> is formed on the top surface of upper chamber <NUM>. Pod slot <NUM> can be configured so that pods can be introduced horizontally into the grain-popping machine <NUM>. In other examples, pod slot <NUM> is angled slightly upward so that pods are introduced into grain popping machine <NUM> at an angle. Angling pod slot <NUM> and interior guiding system for the pods allows for gravity to pull the pod down to the desired position within grain popping machine <NUM>, and can also isolate heating elements inside the grain-popping machine <NUM> from exposure to the pod slot <NUM>. Pod slot <NUM> can also be formed on the top of grain popping machine <NUM>, and the pod can be inserted vertically, horizontally, or at an angle into the pod slot. Gravity or automated mechanism can be used to pull the pod into the appropriate position within upper chamber <NUM> in such examples, as explained in further detail herein.

A pod dock, not shown, is preferably included inside upper chamber <NUM> to receive grain pod <NUM> after the pod has been inserted into upper chamber through pod slot <NUM>. When a grain pod has been inserted into upper chamber <NUM> through pod slot <NUM>, it is received in the pod dock either through a user pushing the pod fully through the pod dock. Grain popping machine <NUM> can signal to a user that the pod has been fully received in the correct position in the pod dock through a variety of feedback mechanisms. For example, grain-popping machine can include haptic or audio feedback, for example, a mechanical click or other sound. Visual feedback, for example, a light indicator, could also be provided. Any combination of visual, audio, and haptic feedback can be used. Grain popping machine <NUM> can also include automatic means of positioning the pod properly in the pod dock. For example, an automated guide can be included inside upper chamber <NUM>. When a user inserts a pod into pod slot <NUM>, grain popping machine <NUM> senses that a pod has been inserted and activates the automated guide, which mechanically moves the pod into the proper position in the pod dock by, for example, actuating a clamp that grabs the pod and moves it to the proper position.

In other examples, a door or tray is provided in upper chamber <NUM> instead of pod slot <NUM>. Upon activation by a user, the door or tray opens, exposing a pod dock. A user then inserts the pod into the pod dock. When the door or tray is pushed fully closed, the pod dock will be in the proper location in upper chamber <NUM> below or above a heating element, as discussed in further detail herein. The pod dock may also be positioned to the side of a heating element or in any other orientation, but is preferably positioned adjacent to a heating element. The door or tray may slide out horizontally from upper chamber <NUM>, may swing open vertically, or may swing open pivoting on the lower or upper edges of the door.

Grain popping machine <NUM> also includes a dock area <NUM>. A receiver <NUM> is preferably provided with grain popping machine <NUM>. Receiver <NUM> can be a bowl or cup as shown in <FIG>, and is designed to receive popped grains exiting from upper chamber <NUM>, as will be described in further detail. The receiver could be made out of various materials and can be disposable or reusable. In some embodiments, receiver <NUM> is a disposable cup or bowl made of a paper or plastic material. In other embodiments, receiver <NUM> can be formed of a ceramic or other type of reusable material. Grain popping machine <NUM> further includes a base <NUM> and an activation button <NUM>. In a preferred embodiment, activation button <NUM> is centered along the front top edge of grain popping machine <NUM>. However, it is understood that activation button <NUM> can be located at other locations on grain popping machine <NUM>. Activation button <NUM> can physically displace when pressed, providing tactile feedback. In other embodiments, activation button <NUM> can be a static button that senses touch and provides haptic, visual, or audio feedback when touched. Preferably, grain-popping machine <NUM> is configured so that activation button <NUM> is the only physical button on the machine in order to provide for streamlined operation. Grain popping machine <NUM> can automatically turn on when a grain pod is inserted into pod slot <NUM>, or pressing the activation button <NUM> can turn on the machine. In either case, pushing activation button <NUM> after a grain pod has been inserted into pod slot <NUM> can initiate a popping sequence.

Grain popping machine <NUM> may not feature any physical buttons and can both power on and initiate a popping sequence by sensing, either mechanically or through motion sensing technology, when a grain pod has been inserted into pod slot <NUM>. A physical button as described above can be included to power on the grain popping machine <NUM> and the popping sequence can be initiated when a grain pod is inserted into pod slot <NUM>. Grain popping machine <NUM> can also trigger start up or power on when a pod door opens or closes, or when a plunger is activated.

Grain popping machine <NUM> is operated by inserting into pod slot <NUM> a pod of kernels or seeds of various types of poppable grains (corn, for example) or puffable grains (rice, for example). Pod slot <NUM> is heated inside upper chamber <NUM> by a heating element, as described in further detail herein. Once the desired heat is reached, the kernels and seeds in the pod pop or puff and can be released from the pod in various ways. The popped grains exit upper chamber <NUM> through outlet <NUM> into receiver <NUM> for consumption by a consumer. As mentioned previously, various types of grains can be popped in grain popping machine <NUM>. In a preferred embodiment, the grain to be popped in grain popping machine <NUM> is popcorn, however, other types of grains can be popped or puffed in the machine, including quinoa, wheat berries, barley, amaranth, millet, sorghum, rice, and any other grain that pops or puffs at heat or by any other activation method. As used herein, a grain is an individual fruit, kernel, grist, or seed of a cereal or grass crop, whether cultivated or wild.

Grain popping machine <NUM> can provide lighting and other feedback to guide and optimize the user experience. For example, grain popping machine <NUM> can be provided with various lighting sources that illuminate in different patterns, different colors, and at different times to signify certain events in the operating cycle of grain popping machine <NUM> or to signal to a user that action is required. One type of lighting source that can be included on grain popping machine <NUM> is a horizontal array <NUM> of light-emitting diodes stretching across the front of grain popping machine <NUM>, as illustrated in <FIG>. Other types of lighting can be used in place of the light-emitting diodes, as one skilled in the art would appreciate. Activation button <NUM> and dock area <NUM> can also be provided with light-emitting diodes or other light sources. Grain popping machine <NUM> can also include a power switch, which can be provided at various locations on the machine.

As one example of a user experience guided by light sources on grain popping machine <NUM>, a user first switches the power switch to an on position. Powering grain popping machine <NUM> on results horizontal array <NUM> lighting up to display, for example, blue flashing lights that indicate that grain popping machine <NUM> is running a self-diagnostic start-up procedure. Horizontal array <NUM> can also progressively illuminate from left to right or right to left to indicate the progress made during the self-diagnostic start-up procedure. Activation button <NUM> may also light up in, for example, a white light. When the self-diagnostic procedure is complete, activation button <NUM> and horizontal array <NUM> illuminate in green to signal to the user that grain popping machine <NUM> is ready for further interaction. Activation button <NUM> can flash in either green or white light to draw the user's attention. Prior to a user pressing activation button <NUM>, pod slot <NUM> may be rendered inoperative to prevent insertion of a grain pod therein. A door may be provided to cover pod slot <NUM>, with the door remaining closed until the machine is ready to accept a grain pod. Other pod receiving methods can be utilized. For example, a slidable tray can be inserted into pod slot <NUM>. The slidable tray can be automatically and mechanically operated by grain popping machine to slide out to receive a grain pod and slide back inside grain popping machine <NUM> once a pod has been inserted into the appropriate slot on the slidable tray.

When the user presses the flashing activation button <NUM>, pod slot <NUM> becomes available to the user by, for example, an access door opening to provide access to pod slot <NUM> for insertion of a pod or a slidable tray sliding out of grain popping machine <NUM> to accept a grain pod. Pod slot <NUM> can also be provided with light sources that illuminate green or another color to indicate that grain popping machine <NUM> is ready for a grain pod to be inserted into pod slot <NUM>. Once a grain pod is inserted into grain popping machine, horizontal array <NUM> can flash or progressively light from left to right to indicate that grain popping machine <NUM> is performing an analysis of the inserted grain pod prior to beginning the popping sequence. This analysis can include checking to ensure that the grain pod has been inserted properly, confirming that the grain pod is authentic and not a generic version of a grain pod, and analyzing various coding included on the pod that can provide, for example, popping instructions unique to the particular type of grain pod inserted.

If the pod analysis confirms that the inserted grain pod is permitted to and ready to be popped, horizontal array <NUM> can present green lighting to indicate that the machine is ready to begin the popping sequence. Activation button <NUM> can also flash green to indicate readiness to begin popping sequence. If receiver <NUM> is properly positioned in dock area <NUM>, a user can press activation button <NUM> to begin the popping sequence. If receiver <NUM> is not positioned in dock area <NUM>, a light source illuminating dock area <NUM> can flash or otherwise illuminate dock area <NUM> and horizontal array <NUM> can flash to indicate to the user that receiver <NUM> should be placed in dock area <NUM>. Once receiver <NUM> is properly positioned, the light source in dock area <NUM> and horizontal array <NUM> can show a solid, non-flashing color to indicate that the missing receiver <NUM> is now recognized. A weight or visual sensor can be included in dock area <NUM> to detect the presence or absence of receiver <NUM>. The user can press activation button <NUM> to begin the popping sequence.

Once the popping sequence has begun, horizontal array <NUM> can progressively light from left to right or right to left to indicate the progress of the popping sequence. Horizontal array <NUM> can also blink in increasing or decreasing frequency to indicate popping progress. During the popping sequence, activation button <NUM> may display a red light, blinking or otherwise, which indicates that a user can press activation button <NUM> to cancel or pause the popping sequence. Once the popping sequence has completed, horizontal array <NUM> may blink to indicate such to the user. The light source in dock area <NUM> can also blink or display a green light to indicate that receiver <NUM>, containing the popped grain, can be removed. Horizontal array <NUM> can display blue lights, progressive, blinking, or solid, to indicate that grain popping machine is cooling. Once cooling has completed, all or some portion of the light sources including on grain popping machine <NUM> can display a green light indicating that the used grain pod can be removed and that grain popping machine <NUM> is ready to begin the next popping sequence. While the user interface as described herein references specific colors and lighting patterns, it is understood that the various lighting techniques, lighting combinations, and lighting colors described herein can be used to indicate and stage the user experience.

<FIG> shows top view <NUM> of grain popping machine <NUM>. As shown in <FIG>, the top <NUM> of grain popping machine <NUM> has heat and aroma vents <NUM>, formed therein. The vents <NUM> can take various forms. In a preferred embodiment, shown in <FIG>, the heat and aroma vent <NUM> forms a circle on the outside of top <NUM>. In other embodiments, the entire top <NUM> of grain machine <NUM> could have venting slots formed therein. Vents <NUM> can be formed in various shapes, for example, in the center of the top or along the outer edge of top <NUM>. Vents <NUM> could also be formed in addition to or in place of vent <NUM> on the sides of grain popping machine <NUM>. Vent <NUM> allows heat to escape the upper chamber <NUM> and also allows popcorn aroma to escape upper chamber <NUM>. In some embodiments, filters are included inside grain popping machine <NUM>, preferably between any heating elements included therein and vents <NUM>. The filters reduce escaping aroma, which is useful in environments where there is a concern that the aroma of popped grains would be distracting. Insulation is also included inside upper chamber <NUM> in some embodiments. Including insulation reduces the considerable heat generating during popping by isolating the exterior of grain popping machine from heating elements and lowering the temperature of heat escaping through vents <NUM>.

In an example not according to the claimed invention, grain-popping machine <NUM> includes sensors (not shown) for sensing various parameters that could affect popping. For example, grain-popping machine <NUM> preferably includes an atmospheric pressure sensor that can provide feedback to the grain popping machine <NUM> so that cooking times can be adjusted as necessary based on the altitude at which a particular popping sequence is initiated. Other sensors included in grain popping machine <NUM> include temperature sensors for both ambient air and internal temperatures. Grain popping machine <NUM> can also include a processor, timer, database, and associated hardware for interpreting and acting on the information provided by the various sensors. The processor is preferably in communication with a network allowing for remote updates to software provided with the processor. This can include a wireless Internet network or cellular network. The processor can include a storage medium and machine-executable instructions stored thereon that cause the grain popping machine <NUM> to perform various actions, for example, shortening or lengthening popping time, based on pre-set instructions and taking into account information about the surrounding environment gathered by the various sensors. The processor can also include instructions that cause the grain popping machine <NUM> to vary the heat applied to grain pod <NUM> by a heating element, the length of time heat is applied to grain pod <NUM>, etc., based on indicators included on the pod or manually or remotely entered by a user. Examples of such indicators and methods of communicating the indicators to grain popping machine <NUM> are provided below. Grain popping machine <NUM> can also include audio sensors and corresponding machine-readable instructions to monitor when and how many kernels have popped and adjust the cooking temperature or time based on that audio feedback. Machine learning and artificial intelligence programs can be used to optimize the various sensors.

<FIG> shows a preferred embodiment of a grain pod <NUM>. Grain pod <NUM> includes kernels or seeds of one or more types of grains, as described previously. Although not shown in <FIG>, according to the invention the grains are contained in individual cells inside grain pod <NUM>. Grain pod <NUM> has a top cover <NUM>, a bottom cover <NUM>, and a sidewall <NUM>. Grain pod <NUM> can be formed of various materials. In a preferred embodiment, grain pod <NUM> is formed of a high temperature tolerant plastic. In alternate embodiments, grain pod <NUM> can be formed of various metals, preferably a lightweight metal, for example, aluminum. Grain pod <NUM> could also be formed of a non-flammable, paper-based material or any other natural or manufactured material that is resistant to high temperatures. In one embodiment, grain pod <NUM> is between <NUM> and <NUM> millimeters tall as measured from the top cover <NUM> to bottom cover <NUM>. In other embodiments, grain pod <NUM> is either <NUM> or <NUM> millimeters tall between top cover <NUM> and bottom cover <NUM>. Grain pod <NUM> can also be formed with additional insulating material between millimeters tall between top cover <NUM> and bottom cover <NUM>. The insulating material can aid in stacking the pods for storage and shipment and helps to reduce the heat transmitted to the outside of grain pod <NUM> when it is removed from grain popping machine after a popping sequence has concluded. Grain pod <NUM> can also be formed with extended tabs on its periphery to aid in handling grain pod <NUM>.

Top cover <NUM> of grain pod <NUM> is preferably formed of a heat conductive material. In a preferred embodiment, the top cover <NUM> is formed of a thin aluminum material or other heat conductive material. Although grain pod <NUM> is shown in a circular shape, it is understood that various pod shapes could be used to achieve similar results. For example, grain pod <NUM> could take a square or oval or rectangular form instead of the circular form showed in <FIG>. Grain pod <NUM>, as shown in <FIG>, also includes a channel <NUM> between a raised outer lip <NUM> and an inner wall <NUM>. Both top cover <NUM> and bottom cover <NUM> are sealed to grain pod <NUM> in order to seal in the grain kernels, flavoring, cooking medium (for example, cooking oils, shortening, lard, etc.) and other edible materials contained inside grain pod <NUM>, as will be shown in further detail herein. Various methods can be used to seal top cover <NUM> and bottom cover <NUM> to grain pod <NUM>. For example, the covers can be sealed to grain pod <NUM> by friction welding, including horizontal friction welding, sonic welding, radio frequency (RF) welding, application of heat, horizontal scrubbing, gluing, folding connecting taps, or spindling, among other methods known in the art, can be used.

Grain pod <NUM> can include numerous combinations of poppable or puffable grains and various flavorings, or can include kernels or seeds of only one particular type of grain. In preferred embodiments, grain pod <NUM> includes text, coloring, or graphics, or a combination thereof, to indicate the particular grain or grains inside the grain pod <NUM> and the flavoring and cooking medium included therein. In other embodiments, grain pod <NUM> includes a variety of grains, with each grain included having the same flavoring or with different grains in the grain pod <NUM> having different flavorings. Although not shown in <FIG>, grain pod <NUM> may include machine-readable indicators that can communicate to grain popping machine <NUM> the type of grain or grains in grain pod <NUM>, the flavor or flavors included in grain pod <NUM>, and the type or types of oil, shortening, or other cooking medium included in grain pod <NUM>. In a preferred embodiment, grain pod <NUM> includes a bar code, QR code, or other type of machine-readable coding pattern that serves as the machine-readable indicator discussed previously. In such embodiments, grain popping machine <NUM> includes a reader (not shown) for reading the coding pattern included on grain pod <NUM>. The reader can be positioned inside upper chamber <NUM> or at the entry to pod slot <NUM>. In other embodiments, the reader can be positioned on the outside of grain popping machine <NUM> so that a user can scan the code on the reader prior to inserting grain pod <NUM> into grain popping machine <NUM>. The code can be printed on the grain pod <NUM>, can be a textured pattern elevated off the surface of grain pod <NUM>, or could simply be a color pattern on the grain pod. It is understood that the machine-readable code can be positioned anywhere on grain pod <NUM>. However, in a preferred embodiment, the machine-readable code is formed on the bottom of grain pod <NUM>.

In other embodiments, grain pod <NUM> includes spaced notches or indentations along the periphery thereof that serve as an indicator to grain popping machine <NUM> of the type of grain or grains in grain pod <NUM>, the flavor or flavors included in grain pod <NUM>, and the type or types of oil, shortening, or other cooking facilitator included in grain pod <NUM>. The notches or indentations can be provided on grain pod <NUM> in a particular number, with specific distances between each notch or indentation, or in different widths, depths, or shapes, all of which, or a combination of which, can serve as the indicator discussed previously. Similar to the previous embodiment, grain-popping machine <NUM> can include a reader configured to read and interpret the machine-readable code formed by the notches or indentations, either mechanically, optically, or using any of a variety of sensing methods.

In still other embodiments, grain pod <NUM> could be formed in different shapes, thicknesses, diameters, widths, and lengths. Small variations in these variables can indicate to a reader on or inside grain popping machine <NUM> the type of grain or grains in grain pod <NUM>, the flavor or flavors included in grain pod <NUM>, and the type or types of oil, shortening, or other cooking facilitator included in grain pod <NUM>. Alternately, or in addition to, using machine-readable indicators as described above, grain pod <NUM> can be formed with a simple human-readable code thereon. A human-readable code could also be provided on the packaging of a group of grain pods <NUM> and recorded at a central website or user guide provided with grain pod <NUM>. In such embodiments, grain-popping machine <NUM> includes a user interface that allows a user to enter the human-readable code. Alternately, a mobile device application or remote control is provided to allow a user to interface with grain popping machine <NUM>. The mobile device application or remote control could allow the user to perform a variety of functions, including powering on/off grain popping machine <NUM>, initiating a popping sequence, emergency power off, indicating the type of grain or grains in grain pod <NUM>, the flavor or flavors included in grain pod <NUM>, and the type or types of oil, shortening, or other cooking facilitator included in grain pod <NUM>, ordering additional grain pods <NUM>, submitting a help request, submitting a service call, etc..

<FIG> shows an exploded view of grain pod <NUM> with the top cover <NUM> hovering above the grain pod <NUM>. As shown in <FIG>, numerous cells <NUM> are formed on the interior of grain pod <NUM>. Each cell <NUM> is designed to hold a kernel or seed of a grain, for example, corn. In addition to the kernels, cells <NUM> hold flavoring and a cooking medium to facilitate popping of the corn when exposed to heat for a prolonged period. As shown in <FIG>, cells <NUM> are formed in a generally honeycombed pattern at even distances from each other. As will be described in other embodiments herein, cells <NUM> could also be formed in circular, square, oval, polygonal, or other shapes. <FIG> also shows cell walls <NUM>, which separate cells <NUM>. In other embodiments, cell walls <NUM> could be thinner or thicker than shown in <FIG>. In addition, grain pod <NUM> could be formed without cells and cell walls and instead have one layer of kernels or seeds distributed roughly equally across the interior surface area of grain pod <NUM>. For example, grain pod <NUM> could be formed with a flat chamber therein to hold kernels in a single layer or multiple layers inside grain pod <NUM>. During manufacturing, grain kernels are placed within cells <NUM> along with flavoring and cooking medium and any other desired ingredient to enhance the flavor, appearance, or popping qualities of the grain. Once the kernels are inside cells <NUM>, the top <NUM> is sealed onto grain pod <NUM>.

In a preferred embodiment, grain pod <NUM> includes approximately <NUM> to <NUM> tablespoons of grains or kernels, with each cell including a single kernel or grain. More preferably, each grain pod <NUM> includes <NUM> tablespoons of grains or kernels, with that result that each popping sequence produces between <NUM> and <NUM> grams (between <NUM> and <NUM> ounces) of popped grains. However, in other embodiments larger or smaller pods containing additional or fewer kernels or grains can be provided while still retaining the benefits of pod-based popping.

<FIG> shows an exploded view from below grain pod <NUM>. As shown in <FIG>, bottom cover <NUM> has not yet been affixed to grain pod <NUM>. Bottom cover <NUM> can be formed of a variety of materials. In a preferred embodiment, bottom cover <NUM> is formed of a high temperature compatible paper that will allow for easy exit of popped kernels from cells <NUM>. In other embodiments, bottom cover <NUM> is formed of a lightweight metal foil, preferably aluminum foil. As described in further detail herein, bottom cover <NUM> can be formed with perforations or other mechanically weakened points to facilitate escape of popped kernels from grain pod <NUM>. Bottom cover <NUM> could also be formed of a material that weakens as it gets hotter so that the material is weakened once grains reach a certain temperature, thereby allowing the grains to escape from cells <NUM>. As shown in <FIG>, the sidewall <NUM> of grain pod <NUM> may have an inner lip <NUM> formed on the bottom side thereof. Grain pod <NUM> may also include a notch <NUM> on the bottom side of sidewall <NUM>. The mechanical use of inner lip <NUM> and bottom <NUM> will be explained in further detail herein.

<FIG> shows a heating element <NUM> positioned above a grain pod <NUM>. Heating element <NUM> can be formed of a metal ceramic polymer or composite material. Heating element <NUM> could also be formed of a combination of any of the previously mentioned types of heating elements. In an example not according to the claimed invention, heating element <NUM> is formed of a metal material such as nichrome. In other examples not according to the claimed invention, heating element <NUM> can be formed of metal such as kanthal or cupronickel. Heating element <NUM> may also be formed of an etched foil. While heating element <NUM> is shown as a solid circular slab in <FIG>. in some examples not according to the claimed invention, heating element <NUM> could be formed as a collection of wires, ribbons, or strips. Heating element <NUM> can be covered or sandwiched between layers of materials selected from the mica group of sheet silicates to provide insulation. Heating element <NUM> can also be or include cartridge heaters. Heating element <NUM> can be provided in a variety of orientations relative to grain pod <NUM>, i.e., below, above, side-by-side, at an angle etc., provided that heating element <NUM> is in close enough proximity to grain pod <NUM> to transfer heat thereto.

Heating element <NUM>, regardless of the material from which it is made, can also be formed in different shapes. For example, it can be formed in a square shape, a rectangular shape, a polygon shape, oval shape, or any non-symmetric shape, and can be formed in various thicknesses. Preferably, the shape of heating element <NUM> matches that of grain pod <NUM>. This configuration allows for even heating across the surface of grain pod <NUM>, resulting in more even popping of the kernels or grains therein. In addition, heating element <NUM> could be formed to wrap around grain pod <NUM> so that grain pod <NUM> nests within heating element <NUM>, or a second heating element could be provided underneath grain pod <NUM> for all or a portion of the popping sequence. In such examples not according to the claimed invention, the second, lower heating element could be automatically removed at a designated time or point during the popping sequence so as not to interfere with the popped kernels or grains as they exit grain pod <NUM>. The second heating element can be formed with holes aligning with the cells <NUM> of grain pod <NUM>. When the second heating element is formed with such holes, it can be left in place for the duration of the popping cycle, as the popped grains can pass through the holes in the second heating element and into the receiver <NUM>. It is also understood that more than two heating elements can be used, and that heating elements can be applied from a variety of distances from grain pod <NUM> and can be positioned at a variety of angles to the grain pod <NUM>.

When two heating elements are included, they can be positioned in a clamshell configuration, such that one or both of the heating elements can pivot at an angle to the other heating element at one or more stages of the popping process. When a clamshell configuration is used, the two heating elements can be physically hinged together or can be held in place relative to each other by other mechanical or vacuum structures inside grain popping machine <NUM>. For example, when the clamshell configuration is implemented such that the two heating elements and grain pod <NUM> are positioned horizontally within grain popping machine <NUM>, the top heating element can pivot upwards from one point or side to an angle relative to the position of the bottom housing element when the grains are sufficiently heated to a popping temperature or close thereto. When this configuration is used, the popped kernels exit from the top of grain pod <NUM>, deflect off the bottom surface of the top heating element, and down into the receiver <NUM>. Alternately, the bottom heating element in such a configuration can pivot while the grain pod <NUM> and the top heating element remain in a roughly horizontal position, such that the kernels can exit down from the grain pod <NUM> and into receiver <NUM>. Similarly, the two heating elements and grain pod <NUM> can all be positioned at an angle relative to the surface on which grain popping machine <NUM> sits, and one or both of the heating elements can hinge open when the kernels have reached a desired temperature or when heat has been applied for a predetermined time.

Heating element <NUM> can also be formed with cavities corresponding to and aligning with the cells <NUM> of grain pod <NUM>. The cavities are of a size and shape that allow each cell <NUM> to partially or completely nest within a cavity formed in the surface of heating element facing grain pod <NUM>. This configuration applies heat to the grains inside cells <NUM> from a variety of angles instead of only from above or below. Heating element <NUM> with cavities can be positioned underneath or above grain pod <NUM>. When heating element <NUM> with cavities is used, grain pod <NUM> is preferably formed such that the cells <NUM> protrude at least partially from the body of the pod. One example of such a pod construction is detailed herein with respect to <FIG>. When heating element <NUM> with cavities is positioned above the grain pod <NUM> inside grain popping machine <NUM>, grain pod <NUM> is preferably formed such that the cells <NUM> protrude upward instead of downward when positioned inside grain popping machine <NUM>.

In other examples not according to the claimed invention, heating element <NUM> is formed of ceramic heating element such as molybdenum disilicide or various PTC ceramic elements. Heating element <NUM> could also be formed of polymer PTC heating elements including PTC rubber materials. Heating element <NUM> may also be a radiative heating element, such as a high-powered incandescent lamp or other type of radiant or infrared heating elements, for example, an R40 reflector lamp or similar lamps. In operation, heating element <NUM> is placed directly above or in contact with top cover <NUM> of grain pod <NUM>. As heating element <NUM> heats to an appropriate temperature depending on the type of grain and other factors, the kernels inside grain pod <NUM> heat, eventually heating to a temperature at which the specific grain pops and the grains then exit the grain pod <NUM>. In some examples not according to the claimed invention, a conductor material, for example, copper, is positioned between heating element <NUM> and grain pod <NUM>. The conductor material ensures that heat from heating element <NUM> is evenly applied across the top surface of grain pod <NUM>, and also helps moderate the speed at which maximum cooking temperature is reached.

Positioning heating element <NUM> above grain pod <NUM> and configuring grain pod <NUM> so that popped grains escape grain pod <NUM> through the bottom cover <NUM> provides several advantages. For example, allowing the popped grains to exit the bottom cover <NUM> directly into receiver <NUM> greatly reduces the surface area of grain popping machine <NUM> that requires cleaning. Only the relatively small portion of upper chamber <NUM> between the bottom of grain pod <NUM> and receiver <NUM> is contacted by popped grains. That portion of upper chamber is easily reached for cleaning without disassembling grain popping machine <NUM>. In contrast, in prior art systems using free loaded grains instead of pods, the heating element was placed below the grains, so that when the grains popped they would exit up and around a heating element to fall into a bowl. In doing so, the grains contact almost the entire interior surface area of a machine, which must then be dismantled regularly for detailed cleaning and disinfecting. In addition, positioning grain pod <NUM> below heating element <NUM> ensures that no popped grains fall back into or on top of grain pod <NUM> after being popped, thereby reducing the risk of overcooked or burnt kernels, which negatively affect a user's experience. Popped grains exit their particular cell <NUM> immediately upon popping and are removed from the area of heating element <NUM> to receiver <NUM>, reducing the chance of overcooking or burning and accommodating for slight variances in popping times between individual grains.

<FIG> shows grain-popping machine <NUM> with heating element <NUM> and grain pod <NUM> positioned within upper chamber <NUM>. The circular opening shown in <FIG> is included as a window to the inside of upper chamber <NUM> for purposes of illustration. In examples not according to the claimed invention, only pod slot <NUM> is formed on the exterior of upper chamber <NUM> so that heating element <NUM> and grain pod <NUM> are not visible from the exterior of upper chamber <NUM>. As shown in <FIG>, heating element <NUM> is positioned directly above, and in some embodiments, in contact with the top of grain pod <NUM> inside upper chamber <NUM>. As heating element <NUM> heats the kernels inside grain pod <NUM> to a target temperature for a prolonged time, both of which vary depending on the type of grain used, flavoring, cooking medium, and other environmental conditions such as pressure and altitude, the kernels pop and the popping of the kernels causes them to eject from the bottom of grain pod <NUM> through bottom cover <NUM>, out of upper chamber <NUM>, and into receiver <NUM>. By having the kernels exit grain pod <NUM> through the bottom, the surface area of upper chamber <NUM> contacted by popped grains and liquids is kept at a minimum because the popped kernels do not contact any of the other surfaces of upper chamber, which reduces cleaning time and difficulty and makes grain popping machine <NUM> operate more cleanly than prior art machines. After popping, grain pod <NUM> is ejected from grain popping machine <NUM> and can be disposed of in a trash receptacle so that the machine is immediately able to receive another grain pod. The popped kernels can be removed from the grain-popping machine by removing receiver <NUM>, which can serve as a bowl for serving the popped kernels. Preferably, each grain pod <NUM> includes only enough popped kernels to form a single serving of the particular popped grain chosen. As detailed above with respect to <FIG>, the popped kernels exit upper chamber <NUM> through outlet <NUM>, which is open to the bottom of grain pod <NUM>.

Ideal cooking times and temperatures for a particular grain pod <NUM> vary based on the types of grains, flavorings, and cooking medium included in cells <NUM>, as well as ambient temperature, pressure, altitude, and other variables. As detailed above, grain popping machine <NUM> can include a processor and associated hardware and software to account for these variables and automatically alter cooking times and temperatures accordingly. However, in examples not according to the claimed invention, heating element <NUM> is heated to between approximately <NUM> degrees Celsius and <NUM> degrees Celsius (<NUM> and <NUM> degrees Fahrenheit) and more preferably to a constant temperature of <NUM> degrees Celsius (<NUM> degrees Fahrenheit) with a variance of plus or minus <NUM> degrees. In other examples not according to the claimed invention, heating element <NUM> can vary temperatures during the popping sequence to achieve a max temperature earlier or later in the sequence.

Temperature sensors can also be provided to directly sense the temperature inside cells <NUM> and the processor can include instructions to dynamically alter the temperature of heating element <NUM> during a popping sequence to optimize the temperature reached by grains in the cells <NUM> and ensure that no grains are overcooked or burned. Humidity sensors can also be included in grain popping machine <NUM>, either to measure ambient humidity outside or inside upper chamber <NUM>, or more preferably to measure humidity inside cells <NUM> to determine whether a predetermined cooking time and temperature should be altered to optimize popping of grains in a particular grain pod <NUM>. In an example not according to the claimed invention, the entire popping sequence is completed in less than one hundred and twenty seconds. More preferably, the popping sequence from insertion of grain pod <NUM> to the time at which all grains have popped and entered receiver <NUM> is completed in approximately sixty seconds, or less. In other examples not according to the claimed invention, the popping sequence is completed in approximately one hundred and eighty seconds, that is, one hundred eighty seconds plus or minus thirty seconds to accommodate for variables.

<FIG> shows an alternate example not according to the claimed invention, of grain popping machine <NUM>. In this example, heating element <NUM> is positioned below grain pod <NUM>. The circular opening shown in <FIG> is included as a window to the inside of upper chamber <NUM> for purposes of illustration. As heating element <NUM> reaches the temperature to pop the kernels in grain pod <NUM>, the kernels pop and exit the grain pod <NUM> and are funneled back down by gravity through outlet <NUM> and into receiver <NUM>, as shown by the arrows in <FIG>.

Popping grains requires high temperatures, which presents issues for a countertop consumer device. Various methods are contemplated to address this safety issue. For example, whatever configuration of heating elements is chosen, grids or gates can be provided inside grain popping machine <NUM> to prevent children from contacting the surface of the heating elements if they insert their fingers through pod slot <NUM> or any other opening to the interior of grain popping machine <NUM>. A safety interlock can also be provided such that a door to pod slot <NUM> or other pod insertion opening on grain popping machine <NUM> can only be opened when a pod is being inserted, with no extra space for insertion of fingers or other body parts. Child proof safety switches can also be provided to prevent access to or operation of grain popping machine when the safety switch has not been manipulated into a position that allows such access or operation. All openings to the interior of grain popping machine <NUM> can also be automatically disabled when the temperature inside the machine is above a safe level, and the opening can be automatically made functional again once the temperature has dropped below a safe level. Various methods can be used to more quickly cool grain popping machine <NUM> and heating elements <NUM> after a popping cycle. For example, heat sinks or heat pipes can be used to remove heat from heating elements <NUM>. Cooling fluid can also be circulated over or around heating elements <NUM> to accelerate cooling. Because grain popping machine <NUM> may be heavier towards the top than at the bottom, a heat sink can be positioned under the receiving tray to balance the weight distribution while providing cooling.

<FIG> illustrates popped kernels <NUM> exiting through bottom cover <NUM> of grain pod <NUM>. The orientation of heating element <NUM> above grain pod <NUM> is similar to the orientation shown in the grain-popping machine of <FIG>. Because each cell <NUM> contains a single kernel, each kernel is free to pop when that particular kernel reaches the appropriate temperature for the particular kernel. This allows for slight variations in the popping time for different kernels in the same grain pod <NUM> so that kernels that might pop earlier than other kernels are not burned by being kept in contact with a heat source after popping.

<FIG> illustrate a preferred embodiment of grain pod <NUM>. As shown in <FIG>, grain pod <NUM> is formed in a generally circular or cylindrical shape with cells <NUM> and cell walls <NUM>. The cells of the grain pod shown in <FIG> are formed in a hexagonal shape similar to a honeycomb. In a preferred embodiment, the cells <NUM> shown in <FIG> are sized to hold a single grain seed or kernel in addition to any desired flavoring or cooking medium. As the kernels heat and pop, they absorb the flavoring placed in the cells. The cooking medium can be an oil infused with a flavor or combination of flavors, or dry flavoring can be added separately to the cell prior to sealing. Instead of or in addition to providing flavoring inside each cell <NUM>, flavoring can be added as or after the popped grains exit cells <NUM>. The post-exit flavoring can be achieved by a misting or spraying device that ejects flavoring, either dry or liquid, onto the popped grains as they exit the pod or after they have been received in receiver <NUM>. The misting or spraying device can be automatic, i.e., it can operate without user intervention, or controls can be provided to allow a user to active the device to add the desired flavoring. Flavoring shakers or packets can also be provided separately with grain popping machine <NUM> to allow a user to customize flavoring.

<FIG> shows a cross-section of <FIG>, showing the vertical shape of cell walls <NUM>. As shown in <FIG>, each cell is formed so that it is narrower towards the top cover <NUM> of grain pod <NUM> and becomes wider moving towards bottom cover <NUM>. As the kernel is heated by heating element <NUM> and eventually reaches its popping temperature, the kernel expands, or pops. As the kernel expands, the shape of cells <NUM> in <FIG> apply pressure to the portion of the kernel towards top cover <NUM>, thereby ejecting the popped kernel through the bottom cover <NUM> of grain pod <NUM>. The change in diameter or width of cells <NUM> from the top of grain pod <NUM> to the bottom of grain pod <NUM> can be altered to achieve more or less pressure on the kernel in the pod upon popping. The vertical angle of cell walls <NUM>, shown in <FIG>, are preferably between <NUM> and <NUM> degrees. More preferably, the angle is between <NUM> and <NUM> degrees, and most preferably approximately <NUM>-<NUM> degrees. The angling of cell walls <NUM> direct much of the energy created by a popping grain towards the bottom cover <NUM> to increase the pressure on the material forming bottom cover <NUM>. In addition to or in place of angling, the shape of the cells can include a conical section, a conical section with the flat bottom, a parabola with the wider portion positioned toward bottom cover <NUM>, or any combination of the above. The angling can be reversed for grain pods where exit through top cover <NUM> is desired. Cells <NUM> can also be formed to have the same, or substantially the same, that is, within acceptable manufacturing variations, diameters and widths from the top of the grain pod <NUM> to the bottom of grain pod <NUM>.

<FIG> also illustrates an alternate embodiment of sidewall <NUM>. As shown in <FIG>, raised lip <NUM> of sidewall <NUM> extends upward from the top of grain pod <NUM>. Sidewall <NUM> is formed with a notch <NUM> towards the bottom thereof. When grain pods <NUM> are stacked in a package containing multiple grain pods, upper lip <NUM> rests inside notch <NUM> to secure the stacked grain pods together and to provide a resting surface for the pods so that the top and bottom covers of grain pods <NUM> stacked together in a package remain slightly apart from each other. This helps prevent breakage or damage to of the top and bottom cover during shipping, delivery, and storage of grain pods <NUM>.

<FIG> illustrate another embodiment of grain pod <NUM>. As shown in <FIG>, the cells <NUM> are circular when viewed from the top. Cell walls <NUM> divide the cells <NUM>. <FIG> shows a cross-section of the grain pod <NUM> illustrated in <FIG>. As with the grain pod <NUM> shown in <FIG>, the cells <NUM> of the <FIG> grain pod are wider towards the bottom of the grain pod than they are at the top. The cell walls <NUM> are slightly curved so that each cell is generally in the shape of an inverted U with the open part of the U facing the bottom of grain pod <NUM> and being wider than the diameter of the bottom of the U, which is positioned near or in contact with top cover <NUM> of the grain pod. As with the embodiments shown in <FIG>, the grain pod <NUM> shown in <FIG> feature a raised upper lip <NUM> and a notch <NUM> in the bottom of the sidewall. These features, as described above, aid in stacking packaging and delivering the grain pods.

<FIG> illustrates a cross-section of another embodiment of grain pod <NUM>. The grain pod shown in <FIG> is similar to the previously described grain pods, with the exception that the cells are approximately half as high as the cells of the previous embodiments. As a result, the grains or kernels placed in each cell protrude, at least partially, from the cell out from the bottom of the grain pod <NUM>. The grains are still sealed into the cells by a bottom cover, but in this embodiment the bottom cover is, preferably, a flexible membrane <NUM> that holds the grain kernels in their cells <NUM> and seals each cell off from other cells <NUM>, but that conforms to the shape of the kernels protruding from the cells <NUM>. The grain pod <NUM> shown in <FIG> also features an extended inner lip <NUM>, which extends slightly beyond the lowest point of flexible membrane <NUM>. The extended inner lip <NUM> rests on the top of the sidewall so that when the pods are stacked, the membrane cover <NUM> does not make contact with the top cover <NUM> of grain pod <NUM>. In doing so, the extended inner lip <NUM> prevents unwanted tearing or damage to the flexible membrane <NUM> or top cover <NUM> during packaging, shipment, delivery, and storage. Configuring the cells so that they are less deep than the height required to accommodate a full kernel aids in ejecting the kernels from the cells as they pop. Because they are already partially out, the pressure created by the open cells facilitates the kernels breaking through the flexible membrane <NUM> as they pop. Ideally, fifty percent or more of the kernel protrudes from cells <NUM>. Configuring grain pod <NUM> such that between sixty and seventy-five percent of the kernel protrudes from cell <NUM> further aids ejection of the kernels from the cells and can also provide heating advantages, as discussed elsewhere herein. The cells <NUM> may also be shaped so that they have a wider diameter towards the flexible membrane <NUM> of grain pod <NUM> than towards the top cover <NUM>. It is understood that various cell shapes and sizes can be used with the flexible membrane shown in <NUM>, and that various materials and manufacturing methods, as discussed elsewhere herein, can be used to form the grain pod <NUM> illustrated in <FIG>.

<FIG> illustrates another embodiment of grain pod <NUM>. As shown in <FIG>, the cells <NUM> have a bulbous shape, but still with the top portion of the cells <NUM> closest to top cover <NUM> being narrower than the bottom portion of cells <NUM>. Again, as in previous embodiments, this encourages the kernel to exit the pod downward as it pops. Also shown in <FIG> are a series of perforations or weakened areas <NUM> in the bottom cover <NUM> of grain pod <NUM>. In a preferred embodiment, these perforations allow the bottom cover <NUM> to tear as the kernel pops and exits the bottom cover <NUM>. As shown in <FIG>, for example, the bottom cover is easier to pierce by the kernel than if it did not have a perforation. Embodiments of these weakened areas will be described in further detail with respect to <FIG>. Also shown in <FIG> is an alternate embodiment of the stacking and mating systems described earlier. As seen in <FIG>, inner lip <NUM> extends downward, creating a male mating end, and channel <NUM> on the top portion of grain pod <NUM> is adapted to receive the inner lip <NUM>.

<FIG> illustrates various methods of weakening bottom cover <NUM> of grain pod <NUM> so that the kernels can more easily break through the bottom cover <NUM>. The kernel designated as <NUM> has exited through the bottom cover <NUM>. The portion of bottom cover <NUM> next to the cell that kernel <NUM> is exiting from has been weakened, either mechanically or by other means, approximately in the center of the cell <NUM>, so that when the kernel breaks through bottom cover <NUM>, the bottom cover <NUM> splits approximately in the middle of the cell and the edges of the bottom cover <NUM> remain attached to the top of cell walls <NUM> so that the material that forms the bottom cover <NUM> does not exit into the receiver <NUM>. The material of the bottom cover <NUM> thereby stays attached to the grain pod <NUM> instead of falling into the receiver <NUM> with the popped grain. Similar results are achieved if a flexible membrane <NUM> is used.

In another embodiment, as shown with reference to kernel <NUM> in <FIG>, the bottom cover <NUM> can be weakened, for example, by physical perforations or other weakening, along only one side or portion of a cell <NUM>. In operation, this is similar to the perforation described with respect to kernel <NUM>, except that instead of the ripped pieces of the bottom cover <NUM> remaining attached to all sides of the cell walls <NUM>, the bottom cover <NUM> may be held to only a portion of the top of cell walls <NUM>. For example, one half of the bottom cover corresponding to a particular cell <NUM> may remain attached to the cell walls <NUM>, while the other half may be pre-perforated or otherwise weakened so that it breaks off, easily allowing the kernel to escape when it pops. Although thus far discussion of weakening the bottom cover <NUM> has focused mostly on physical perforation of the bottom cover <NUM>, that is merely one example of potential ways to weaken portions of the bottom cover <NUM> to facilitate escape of a kernel. Instead of perforating at particular locations, the bottom cover could be formed of a thinner material at those particular locations or it could be formed of a different material at those locations that weakens faster than the main body of bottom cover <NUM> as temperature increases. In other embodiments, the material that fastens bottom cover <NUM> to the top of cell walls <NUM> may be varied at certain locations in order to facilitate breaking of the bottom cover <NUM>. For example, a portion of the material bonding bottom cover <NUM> to the cell walls <NUM> could be a different bonding material than other portions. The bonding material in the weakened portions might be chosen so that it melts and creates a weaker bond at higher temperature than other portions of the bonding material to achieve similar results to perforation or mechanical weakening. For embodiments that feature mechanical perforation, or some other type of mechanical weakening of bottom cover <NUM>, various methods can be used to achieve that perforation. For example, the bottom cover <NUM> could be pre-perforated during manufacturing and before shipment. In alternate embodiments the grain-popping machine <NUM> can be formed with a mechanical perforator or weakener inside, so that when a user inserts grain pod <NUM> into grain popping machine <NUM>, the bottom cover <NUM> of grain pod <NUM> is perforated in grain popping machine <NUM> or during insertion into the grain-popping machine <NUM>.

<FIG> illustrate alternate examples not according to the claimed invention, of grain popping machine <NUM>. In <FIG>, grain pod <NUM> is positioned inside grain popping machine <NUM> so that it is above heating element <NUM> instead of below heating element <NUM>. Grain pod <NUM> is flipped from the configuration shown in previous examples where the kernel exits from the bottom of grain pod <NUM>. In the embodiment shown in <FIG> of the grain pod <NUM>, the kernels exit towards the top of the grain-popping machine <NUM> instead of straight down. As heating element <NUM> heats the kernels within grain pod <NUM> to the appropriate temperature for that particular grain, the grains would pop; exiting the grain pod <NUM>, and gravity causes the popped kernels to fall down into receiver <NUM>, as shown in step <NUM>. In the example shown in <FIG>, a fan, preferably a silent fan, could be used to help the kernels exit the grain pod <NUM> and filter down to receiver <NUM>. Once the receiver <NUM> is full of the popped grains, it can be removed from dock <NUM> as shown in step <NUM>.

<FIG> shows another example not according to the claimed invention, of grain popping machine <NUM>. In the example in <FIG>, grain pod <NUM> is positioned inside the machine above heating element <NUM> instead of below. As shown in step <NUM>, grain pod <NUM> is configured so that as the grains pop, the grain pod expands and the sidewall <NUM> of the grain pod expands. Once the grains have popped, the heating element is mechanically removed, preferably automatically, from underneath grain pod <NUM>. The bottom of grain pod <NUM> is pulled with heating element and the popped kernels are pulled by gravity into the receiver <NUM> and can then be removed from the dock <NUM>, as shown in step <NUM>.

<FIG> shows another example of grain popping machine <NUM> not according to the present invention. In <FIG>, grain pod <NUM> is inserted into grain popping machine <NUM> so that it is positioned above heating element <NUM>. As heating element <NUM> heats the kernels in grain pod <NUM> to the popping temperature, grain pod <NUM> expands into a bucket shape. The bucket formed by the grain pod <NUM> in this example serves as a receiver <NUM> and grain pod <NUM> itself, in its bucket shape, can be removed from grain popping machine <NUM> for serving the popped grains. As shown in step <NUM>, heating element <NUM> is mechanically moved, in some examples, from the bottom of grain pod <NUM>, and a cooling fan cools the expanded grain pod <NUM> so that it is safe for handling by a consumer. It is understood that grain pod <NUM> shown in <FIG> could take various shapes on expansion and is not strictly confined to the shape shown in <FIG>.

<FIG> illustrates a portion of a portion of a grain pod insert <NUM>. Grain pod insert <NUM> is preferably formed of a thermoplastic polymer, although other materials compatible with use in the food industry can be used. Various types of polymers are contemplated for grain pod insert <NUM>, including natural polymers and synthetic thermoplastic polymers, including but not limited to nylon. Additives can be included in the polymers used to form grain pod insert <NUM>.

Grain pod insert <NUM> includes cells <NUM> and cell walls <NUM> similar to those described with respect to other embodiments of the present invention. As shown in <FIG>, cells <NUM> are formed with a generally circular cross section and a rounded bottom. However, it is understood that cells <NUM> could be formed in a variety of cross-sectional shapes, including, but not limited to, the hexagonal and square cross-sectional shapes described with respect to other embodiments herein. Cells <NUM> could also be formed with a flat bottom instead of the rounded bottom shown in <FIG>. Because grain pod insert <NUM> is preferably formed of a polymer, e.g., a nylon material, it can be formed by heating a flat sheet of polymer to a temperature at which the polymer can be stretched into the form shown in <FIG> by application of mechanical force to the polymer sheet. For example, grain pod insert <NUM> can be formed partially or completely through the use of thermoforming. Grain pod insert could also be formed by directly applying the polymer sheet to an array of grains. When this method is used, the polymer sheet stretches closely around the shape of each individual grain. When top cover is applied over the stretched polymer sheet, closed cells <NUM> are formed around the grain, with little, if any, airspace within the cells. Vacuum sealing could be used to remove all air from cells <NUM> formed in this manner. Forming grain pod insert <NUM> in this manner simplifies manufacturing. In addition, polymers such as nylon are known to weaken as they are heated, and through polymer compounding, which involves mixing or blending polymers and additives to alter certain properties of the resulting material, the polymers can be engineered to reach a desired weakness at desired temperatures. As a result, a grain pod <NUM> constructed with grain pod insert <NUM> does not require a bottom cover <NUM>. The cells <NUM> of grain pod insert <NUM> are closed at the bottom portion thereof, which serves to retain grains, flavoring, and cooking medium within the cells <NUM>. The polymer forming grain pod insert <NUM> is engineered to weaken to near breaking point at the ambient temperature at which grains contained in cells <NUM> will being to pop. As a result, the popping grains can easily break through the bottom of cells <NUM>, while unpopped grains remain in their cell <NUM> until they begin to pop.

It is understood that grain pod insert <NUM> and grain pod <NUM>, which is described with reference to other figures herein, could also be formed using extrusion or injection molding. Formable foils can also be used to form grain pod insert <NUM>, with similar benefits to those described with respect to <FIG>. For example, cold formable foils, e.g., cold formable aluminum foil, can be used to form grain pod insert <NUM> and grain pod <NUM>. Foils can allow for more efficient heat transfer between heating element <NUM> and grains in cells <NUM>. The thickness of the foil can be chosen such that the force of the popping grain tears the foil, permitting the popped grain to escape through the foil. The use of formable foils can eliminate the need for a bottom cover on grain pod insert <NUM> or grain pod <NUM>. Grain pod insert <NUM> and grain pods <NUM> described herein could also be made from thermoforming, aluminum stamping, or other suitable methods of manufacture.

<FIG> is a cross-sectional view of a grain pod <NUM> formed with grain pod insert <NUM>. After it is formed, grain pod insert <NUM> can be attached to a sidewall <NUM> by various methods known in the art. Grain pod <NUM> as shown in <FIG> can also be formed as a single piece using the same methods detailed with respect to grain pod insert <NUM>, that is, by heating and mechanically manipulating a polymer, or by extrusion or injection molding. Attaching grain pod insert <NUM> to a separately formed sidewall <NUM> in order to form grain pod <NUM> allows for a different material to be used for the sidewall <NUM>. It can be desirable to use a stronger and less heat-sensitive material for the sidewall <NUM>, which is subject to forces during shipping and user manipulation that grain pod insert <NUM> may not experience. <FIG> is a top perspective view of the grain pod <NUM> described with respect to <FIG> and <FIG>. As noted above, grain pod insert <NUM> may be formed separately and attached to sidewall <NUM>, or the entire grain pod <NUM> can be formed as a single unit. As shown in <FIG>, grain pod <NUM> can include a tab <NUM> formed with or attached to sidewall <NUM>. Tab <NUM> facilitates user handling of grain pod <NUM>.

<FIG> illustrates grain pod <NUM> as described with respect to <FIG> with a heating element <NUM>. As shown, heating element <NUM> has protrusions <NUM> extending from its bottom surface. Protrusions <NUM> provide targeted heating to cells <NUM>. Preferably, protrusions <NUM> match the cross-sectional shape of cells <NUM>, here, a circular shape. In addition, protrusions <NUM> are arranged on heating element <NUM> such that, when grain pod <NUM> is positioned in a pod dock, described herein, protrusions <NUM> are positioned so that each protrusion <NUM> is centered on a cell <NUM>, thereby providing targeted heat to the opening at the top of each cell <NUM>. In operation, heating element <NUM> can be mechanically lowered onto the top of grain pod <NUM> so that protrusions <NUM> press down onto top cover <NUM> (not shown). Heating element <NUM> and grain pod <NUM> can also be held together by applying a vacuum, thereby ensuring a firm seal. The portions of top cover <NUM> directly above each cell <NUM> can be formed to depress into the cell <NUM> as the protrusions <NUM> on heating element <NUM> apply pressure to top cover <NUM>. This provides more focused and direct heat transfer from heating element <NUM> because heat is applied in closer proximity to the grains and cooking medium in each cell <NUM>. The contents of cells <NUM> can also be vacuum sealed, so that heat from protrusions <NUM> transfers directly through top cover <NUM> and is applied directly to the grains and cooking medium in the cells <NUM>.

<FIG> illustrates heating element <NUM> positioned above grain pod <NUM>, with the top cover <NUM> covering the top of cells <NUM>. However, heating element <NUM> with protrusions can also be positioned below grain pod <NUM>, and two heating elements, one positioned above and one positioned below the grain pod <NUM>, can be used, with one or both having protrusions or cavities.

Instead of protrusions extending from the main body of heating element <NUM>, as depicted in <FIG>, a plurality of separate, unconnected, heating elements can be used. For example, each protrusion <NUM> could be a separate heating element, such that each cell <NUM> can be heated by an individually-controllable heating element. Such an array of heating elements allows for pinpoint heating control depending on variables such as position of the cell <NUM> in the cell array. For example, cells <NUM> on the interior of grain pod <NUM> may heat faster than cells <NUM> on the periphery of grain pod <NUM> when the heating element <NUM> and grain pod <NUM> are arranged horizontally inside grain popping machine <NUM>. Using individually-controllable heating elements allows more control of temperature distribution. For example, the temperature of each individual heating element can be pre-programmed to vary during each popping cycle such that the grains in interior cells are heating at roughly the same rate and to roughly the same temperature as the grain in peripheral cells, helping to ensure even popping and prevent burning of the grains. Similarly, the plurality of individual heating elements can each be formed with a cavity, as with the unitary heating element with cavities described above with respect to <FIG>. In such configurations, the cavities can be formed to roughly approximate the shape of cells <NUM> such that each cell <NUM> is at least partially inside a cavity during the popping process.

<FIG> illustrates a grain pod <NUM> formed from a metal. Preferably grain pod <NUM> is formed of a malleable metal foil, for example, aluminum foil, copper foil, or tin foil, though other foldable metals and metal foils can be used. The cells <NUM> of this grain pod <NUM> are formed as separate pockets of the same material, each made to receive one grain. Cells <NUM> are independent of each other, and each is preferably formed by folding or forming a single piece of foil into a shape that is sufficient to hold a single grain. The single piece of foil used to form each cell <NUM> is preferably circular in shape, though by overlapping portions of the piece of foil the desired cell shape and dimensions can be achieved by folding a sheet of foil that was originally other shapes, e.g., rectangular, square, polygonal, triangular, etc. Cells <NUM> can be formed by using a press and mold, whereby pressure on the piece of foil around the preformed mold causes the foil to bend around the mold into the desired shape. While <FIG> illustrates cells <NUM> in a roughly conical shape, cells <NUM> can be formed in a variety of shapes consistent with the purposes of grain popping machine <NUM>. The cells can be more or less rounded at the lower ends thereof compared to cells <NUM> as illustrated in <FIG>. For example, cells <NUM> could be squared off at the bottom thereof, or could be formed in a semi-sphere shape. Moreover, while cells <NUM> as shown in <FIG> are circular in horizontal cross-section, they can be formed with a square, rectangle, or polygonal cross-section or any other cross-sectional shape and dimension discussed herein with respect to other grain pod forms. The foil forming cells <NUM> is selected such that the force of a grain expanding inside each cell <NUM> is sufficient to tear the foil open, allowing the grain to escape as or immediately before it pops.

During assembly, the individual cells <NUM> shown in <FIG> are placed into a docking tray <NUM>. Openings <NUM> are formed in docking tray <NUM>. Each opening <NUM> is sized to receive a cell <NUM>. Preferably, the horizontal cross-sectional diameter of cells <NUM> increases from the bottom portion <NUM> to lip <NUM> of the cell such that an entire cell <NUM> cannot pass fully through the opening <NUM>, but instead hangs from docking tray <NUM>. Lip <NUM> of cell <NUM> can have a larger diameter than the body of cell <NUM> so that when cell <NUM> is placed through opening <NUM> bottom first, the lip rests on the top surface <NUM> of docking tray <NUM>, as shown in <FIG>. Lip <NUM> can be sealed or attached to the top surface <NUM>, which is also preferably formed of a metal, e.g., aluminum foil, by a variety of methods described elsewhere herein. In addition to, or instead of, attaching lip <NUM> to top surface <NUM>, a separate sealing sheet <NUM> can be used to sandwich lips <NUM> between docking tray <NUM> and sealing sheet <NUM>. Sealing sheet <NUM>, which is also preferably formed of a metal, e.g., aluminum foil, can be attached to lips <NUM> or docking tray <NUM>, or both, by a variety of methods described elsewhere herein. Sealing sheet <NUM> can be formed with openings <NUM> corresponding to openings <NUM> on docking tray <NUM>. Grain pod <NUM>, as shown in <FIG>, can also be formed without sealing sheet <NUM>. A top cover, which is also preferably formed of a metal, e.g., aluminum foil, is attached to sealing sheet <NUM> or directly to docking tray <NUM>, and functions in the manner described herein with respect to other top covers for grain pods <NUM> described herein. Sheets <NUM> formed of high temperature pressure sensitive adhesive, for example, acrylic adhesives, silicone, or other high temperature adhesives, can be used to attach the various layers of metal, e.g., aluminum, together, as shown in <FIG>. High temperature pressure sensitive adhesive sheets <NUM> can also be used to attach metal layers in the other grain pods described herein.

<FIG> illustrates a top view of docking tray <NUM> as described with reference to <FIG>. As shown in <FIG>, lips <NUM> of formed cells <NUM> rest on the top surface of docking tray <NUM>. Lips <NUM> can be attached to docking tray <NUM> by friction welding, including horizontal friction welding, sonic welding, radio frequency (RF) welding, application of heat, horizontal scrubbing, gluing, folding connecting taps, or spindling, among other methods known in the art, can be used. As discussed above with reference to <FIG>, a sealing sheet <NUM> or top cover <NUM> can be used instead of or in addition to direct attachment of lips <NUM> to docking tray <NUM>. <FIG> is a side view of grain pod <NUM> as described with reference to <FIG> and <FIG>. As shown in <FIG>, individual cells <NUM> hand from docking tray <NUM>.

<FIG> illustrates a clamshell type grain pod <NUM>. As shown in <FIG>, top cover <NUM> is attached to the top surface of tray <NUM> along one side. Cells <NUM> are formed or provided in tray <NUM> according to any of the various methods described herein, and grain pod <NUM> can be formed of any of the various materials discussed herein with reference to other figures. For example, cells <NUM> could be formed integrally with tray <NUM> or could be individual pod cells as described herein with reference to <FIG>. The clamshell design of grain pod <NUM> facilitates manufacturing by simplifying the process of sealing top cover <NUM> to the top surface of tray <NUM>.

<FIG> illustrates a grain pod <NUM>. As shown in <FIG>, grain pod <NUM> includes a top cover <NUM>, cells <NUM>, which are formed or provided in tray <NUM> according to any of the various methods described herein. Grain pod <NUM> can be formed of any of the various materials discussed herein with reference to other figures. For example, cells <NUM> could be formed integrally with tray <NUM> or could be individual pod cells as described herein with reference to <FIG>. Cells <NUM> are fully cylindrical in construction, with approximately the same diameter from top to bottom of each cell. Cells <NUM> can be manufactured by forming the cylindrical walls <NUM> out of one piece of material and then fixing an end cap <NUM> to one end of the cylindrical walls <NUM> to close off that end.

<FIG> illustrates a half shell type grain pod <NUM>. As shown in <FIG>, grain pod <NUM> is formed of a top piece <NUM> and bottom piece <NUM>. Unlike most of the other grain pods described herein, which have full cells formed or affixed to a tray, the cells of grain pod <NUM> are formed when top piece <NUM> is attached to bottom piece <NUM>. Each piece is formed with a plurality of partial cells <NUM> that align with corresponding partial cells <NUM> on the other piece such that when top piece <NUM> is aligned with and affixed to bottom piece <NUM>, a plurality of cells are formed, each large enough to receive a grain, flavoring, and a cooking medium. In manufacture, a grain is placed in each of the partial cells of bottom piece <NUM> along with flavoring and a cooking medium, and then top piece <NUM> is affixed to bottom piece <NUM> to enclose the grain, flavoring, and cooking medium and form a full cell. At the time when top piece <NUM> is affixed to bottom piece <NUM>, grains <NUM> can be protruding from partial cells <NUM> in bottom piece <NUM>, as shown in <FIG>. <FIG> shows a side view of an assembled grain pod <NUM>, in which top piece <NUM> has been affixed to bottom piece <NUM>, thereby creating full cells <NUM> composed of partial cells <NUM> from each of top piece <NUM> and bottom piece <NUM>. As illustrated in <FIG>, each full cell <NUM> is comprised of two evenly sized partial cells <NUM>, one from bottom piece <NUM> and one from top piece <NUM>, hence the reference to a half shell grain pod. However, it is understood that the size and volume of partial cells <NUM> on bottom piece <NUM> can be larger or smaller than the size and volume, respectively, of partial cells <NUM> on top piece <NUM>. For example, partial cells <NUM> formed in bottom piece <NUM> could form three quarters of the full volume of each full cell <NUM>. It is also understood that full cells <NUM> can be formed in a variety of shapes and dimensions, as described herein with reference to other grain pods. It is also understood that bottom piece <NUM> and top piece <NUM> can be formed from any of the materials disclosed herein for forming the various described grain pods, and can be affixed to each using the various methods described herein with respect to other grain pods. For example, partial cells <NUM> can be formed separately from aluminum or other foils and then attached to bottom piece <NUM> and top piece <NUM>.

<FIG> illustrates a partial grain pod <NUM>. As with other grain pods described herein, partial grain pod <NUM> includes a plurality of cells <NUM> adapted to receive grains, flavoring, and a cooking medium. In partial grain pod <NUM>, cells are formed by creating a grid <NUM> of a metal material, preferably aluminum foil. Grid <NUM> is formed by cutting the foil into strips and folding the strips to form walls that, when combined with other strips to form a generally honeycomb shape as shown in <FIG>, form cells <NUM>. A bottom cover <NUM> closes off the bottom of cells <NUM>, and a top cover, not shown, closes off the top of cells <NUM>. Grid <NUM> can be formed from other materials instead of metals. For example, grid <NUM> can be formed of paper-based materials, plastics, etc. Bottom cover <NUM> and any top cover provided with partial grain pod <NUM> can be formed of any of the materials disclosed herein with reference to other grain pods, and can be formed of a different material than grid <NUM>.

<FIG> shows a grain-popping machine <NUM> according to a preferred embodiment of the invention, that is similar the grain popping machine shown in <FIG>, but with a different heating system. Instead of heating element <NUM>, grain-popping machine <NUM> uses a heating chamber <NUM> to apply heat to grain pod <NUM>. According to the invention, the grain pod <NUM> comprises a plurality of cells <NUM> having an open end and a closed end, the plurality of cells each containing one or more grains, wherein the grain pod <NUM> has a bottom cover <NUM> that seals the open end of the plurality of cells when attached to the grain pod <NUM>. Grain pod <NUM> can be inserted into grain-popping machine <NUM> in a variety of ways, as described previously. Grain pod <NUM> can be inserted into grain-popping machine <NUM> such that the majority of grain pod <NUM> is positioned inside heating chamber <NUM> and only, or substantially only, a bottom cover <NUM> of grain pod <NUM> extends from the bottom of heating chamber <NUM>. Grain pod <NUM> can include lips <NUM> that contact the lower exterior surface <NUM> of heating chamber <NUM>. Such a construction aids in preventing energy from escaping heating chamber <NUM> during the popping process.

Lower exterior surface <NUM> of heating chamber <NUM> can be formed with holes sized to receive cells <NUM>, such that each cell <NUM> extends through an individual hole in the lower exterior surface <NUM> instead of all cells <NUM> extending into heating chamber <NUM> through a single large opening. For example, grain pod <NUM> can be formed in the manner described with respect to <FIG> and <FIG> herein. Docking tray <NUM> can be inserted into grain popping machine <NUM> such that each cell <NUM> is disposed completely, or substantially completely, inside heating chamber <NUM>, with only the surface of the docking tray <NUM> being positioned outside heating chamber <NUM>. In this manner, energy is applied evenly throughout each cell <NUM> during the cooking cycle. Grain pod <NUM> can also be formed consistent with other grain pods described herein. In addition to faster and more even heating, the use of heating chamber <NUM> with the described hearing methods results in a pod surface that is cooler to the touch and therefore safer for consumers. Grain pod <NUM> can be mated with heating chamber <NUM> using a variety of mechanisms, both automated and manual, as described herein with reference to other constructions of grain popping machines.

Heating chamber <NUM> can be heated by a variety of heat sources. For example, a resistive heating source, also known as a Joule or Ohmic heating, can be used. The heating source can also be electromagnetic, radio frequency, inductive, microwave, or dielectric heating. These heating sources can heat kernels <NUM> to the required popping temperature faster than other heat sources and can also provide more even heating of grains <NUM>. These heating sources can be located external to heating chamber <NUM>, and a variety of methods can be used to transmit energy from the heating sources into heating chamber <NUM>. For example, energy from the sources can be transmitted into heating chamber <NUM> by mechanical waveguide, antenna, or electrodes. If electrodes are used, they can be positioned in parallel or not in parallel.

Claim 1:
A grain popping system comprising:
a housing, wherein the housing is at least partially enclosed to define an interior space, and
wherein the housing comprises a top and a bottom:
a heating chamber (<NUM>) positioned in the interior space, the heating chamber (<NUM>) having a top and a bottom, and wherein the bottom of the heating chamber (<NUM>) is positioned toward the bottom of the housing and the top of the heating chamber (<NUM>) is positioned toward the top of the housing;
a grain pod (<NUM>) comprising a plurality of cells (<NUM>) having an open end and a closed end, the plurality of cells each containing one or more grains, wherein the grain pod (<NUM>) has a bottom cover (<NUM>) that seals the open end of the plurality of cells when attached to the grain pod (<NUM>);
wherein a plurality of holes are formed through the bottom of the heating chamber, and
wherein each of the plurality of holes is adapted to receive one of the plurality of cells therethrough,
wherein the bottom cover of the grain pod (<NUM>) faces the bottom of the housing when the plurality of cells are positioned in the bottom of the heating chamber (<NUM>),
wherein heating the grain pod (<NUM>) heats the one or more grains in the plurality of cells, thereby causing the one or more grains to exit the grain pod (<NUM>) by piercing the bottom cover of the grain pod (<NUM>).