Microwave Popcorn Bag

Abstract

A microwave popcorn bag for containing and heating popcorn kernels in a microwave oven. The bag is constructed of a laminated fibrous material and comprises a base panel, top panel, side panels, and interior space. The side panels have gussets with fold areas and fold lines that are adjacent to the base panel and that enable the bag to expand. An oil-resistant microwave susceptor film is laminated with the fibrous material and extends laterally across the base panel and the fold lines into the fold areas. Microwave interactive material is confined to the base panel. As the popcorn is heated, the bag expands and the microwave susceptor film forms a tray structure that collects oil and resists it penetrating through the fibrous material.

What is claimed is: 
     
         1 . A construct for heating a food item, comprising:
 a base panel;   a first panel adjacent to the base panel, wherein the first panel includes a first expandable portion comprising a first panel portion adjacent the base panel;   a second panel that is adjacent to the base panel and opposed to the first panel, wherein the second panel includes a second expandable portion comprising a second panel portion adjacent the base panel;   wherein the base panel, the first panel and the second panel are comprised of a fibrous material; and   a microwave susceptor film within the base panel, wherein the microwave susceptor film is comprised of an oil-resistant material;   wherein the microwave susceptor film extends across the base panel into the first panel portion and the second panel portion to resist oil penetrating through the fibrous material;   wherein when the first expandable portion and the second expandable portion are expanded the microwave susceptor film forms a tray structure having a bottom within the base panel, a first side within the first panel portion and a second side within the second panel portion.   
     
     
         2 . The construct of  claim 1 , wherein the first panel includes a first fold line and the second panel includes a second fold line, wherein the microwave susceptor film extends across a portion of the first panel portion to at least near the first fold line of the first panel, and wherein the microwave susceptor film extends across a portion of the second panel portion to at least near the second fold line of second panel. 
     
     
         3 . The construct of  claim 1 , wherein the first panel includes a first fold line and the second panel includes a second fold line, wherein the microwave susceptor film extends across the first fold line of the first panel, and wherein the microwave susceptor film extends across the second fold line of second panel. 
     
     
         4 . The construct of  claim 1 , further comprising a first end portion and a second end portion, wherein the second end portion is spaced apart from and is opposite the first end portion, wherein the first panel and the second panel both extend substantially an entire distance between the first end portion and the second end portion, and wherein the microwave susceptor film extends along the first panel and the second panel substantially the entire distance between the first end portion and the second end portion. 
     
     
         5 . The construct of  claim 1 , including a fourth panel between the first panel and the second panel, wherein the fourth panel is opposite of the base panel. 
     
     
         6 . The construct of  claim 1 , wherein the first panel includes an area where a surface of the fibrous material has an oil-resistant substance and the microwave susceptor film is not present. 
     
     
         7 . The construct of  claim 1 , wherein the fibrous material comprises an inner layer and an outer layer, and wherein the microwave susceptor film is between the inner layer and the outer layer. 
     
     
         8 . The construct of  claim 1 , wherein the oil-resistant material comprises a biodegradable cellulose material. 
     
     
         9 . The construct of  claim 1 , wherein the microwave susceptor film comprises a microwave interactive material, wherein the microwave interactive material is only present in the base panel. 
     
     
         10 . The construct of  claim 9 , wherein the microwave interactive material has a first side substantially facing the first panel and a second side substantially facing the second panel, and wherein the first side is tapered toward the base panel until no microwave interactive material is present at the first panel, and the second side is tapered toward the base panel until no microwave interactive material is present at the second panel. 
     
     
         11 . A construct for heating a food item, comprising:
 a base panel;   a top panel substantially opposite to the base panel;   a first side panel between the base panel and the top panel, wherein the first side panel comprises a first gusset comprising a first panel portion adjacent the base panel;   a second side panel between the base panel and the top panel, wherein the second side panel is substantially opposite to the first side panel, wherein the second side panel comprises a second gusset comprising a second panel portion adjacent the base panel;   wherein the base panel, the top panel, the first side panel and the second side panel are comprised of a fibrous material; and   a microwave susceptor film within the base panel, wherein the microwave susceptor film comprises an oil-resistant film with a microwave interactive material;   wherein the oil-resistant film extends across the base panel into the first panel portion of the first gusset and into the second panel portion of the second gusset to resist oil penetrating through the fibrous material;   wherein the microwave interactive material is present only in the base panel;   wherein the microwave susceptor film forms a tray structure with a bottom within the base panel, a first side within the first side panel and a second side within the second side panel.   
     
     
         12 . The construct of  claim 11 , wherein the first side panel includes a first fold line and the second side panel includes a second fold line, wherein the microwave susceptor film extends across a portion of the first panel portion to at least near the first fold line of the first side panel, and wherein the microwave susceptor film extends across a portion of the second panel portion to at least near the second fold line of second side panel. 
     
     
         13 . The construct of  claim 11 , wherein the first side panel includes a first fold line and the second side panel includes a second fold line, wherein the microwave susceptor film extends across the first fold line of the first side panel, and wherein the microwave susceptor film extends across the second fold line of second side panel. 
     
     
         14 . The construct of  claim 11 , wherein the oil-resistant film extends into the first side panel substantially an entire distance between the base panel and the top panel, and wherein the oil-resistant film extends into the second side panel substantially the entire distance between the base panel and the top panel. 
     
     
         15 . The construct of  claim 11 , comprising a first end portion and a second end portion, wherein the second end portion is spaced apart from and is opposite the first end portion, wherein the first side panel extends along the base panel substantially an entire distance between the first end portion and the second end portion, wherein the oil-resistant film extends along the first side panel substantially the entire distance between the first end portion and the second end portion, wherein the second side panel extends along the base panel substantially the entire distance between the first end portion and the second end portion, and wherein the oil-resistant film extends along the second side panel substantially the entire distance between the first end portion and the second end portion. 
     
     
         16 . The construct of  claim 11 , wherein the first side panel and the second side panel each includes an area where a surface of the fibrous material has an oil-resistant substance and the microwave susceptor film is not present. 
     
     
         17 . The construct of  claim 11 , wherein the fibrous material comprises an inner layer and an outer layer, wherein the microwave susceptor film is between the inner layer and the outer layer. 
     
     
         18 . The construct of  claim 11 , wherein the oil-resistant film comprises a biodegradable cellulose material. 
     
     
         19 . The construct of  claim 11 , wherein the microwave interactive material has a first side substantially facing the first side panel and a second side substantially facing the second side panel, and wherein the first side is tapered toward the base panel until no microwave interactive material is present at the first side panel, and the second side is tapered toward the base panel until no microwave interactive material is present at the second side panel. 
     
     
         20 . A construct for heating a food item, comprising:
 a first panel;   a second panel adjacent to the first panel;   a third panel that is adjacent to the first panel and opposed to the second panel;   a fourth panel between the second panel and the third panel, wherein the fourth panel is opposite of the first panel;   wherein each of the second panel and the third panel has an expandable portion;   wherein the first panel, the second panel, the fourth panel and the fourth panel are comprised of a fibrous material; and   a microwave susceptor film within the first panel, wherein the microwave susceptor film comprises an oil-resistant material, and wherein the microwave susceptor film extends across the first panel into the second panel to resist oil penetrating through the fibrous material;   wherein the microwave susceptor film extends across the first panel into a portion of the expandable portion of each of the second panel and the third panel;   wherein when the expandable portion of each of the second panel and the third panel is expanded the microwave susceptor film forms a tray structure with a bottom within the first panel, a first side within the second panel and a second side within the third panel.