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Disclosed are microwave popcorn articles which upon microwave heating provide popcorn of reduced fat content, better fat distribution and improved taste as well as methods for the preparation of such articles. The articles comprise any conventional microwave popcorn bag and an improved popcorn/fat charge. In addition to unpopped popcorn kernels and fat, the charge further essentially includes minor amounts of salt, color and/or flavors. The present method involves the spraying of a fat/salt slurry at the same time as and at an angle to a falling cascade of unpopped popcorn kernels as they are charged to the upper open end of the microwave popcorn bag. The angle of the fat/salt spray is such as to intersect with the falling popcorn cascade within the popcorn bag below the top seal area. By applying the fat/salt slurry to a falling cascade of unpopped popcorn kernels during bag filling, improved distribution of the slurry over the popcorn is achieved. Such improved slurry distribution yields organoleptic improvements in the popped product in that fat perception is increased even at low fat levels as well as more uniform distribution of flavor, salt and color.
1. A method for filling a microwave popcorn bag with unpopped popcorn kernels coated with a fat or fat/salt slurry evenly dispersed thereon having improved evenness of coating of the kernels with the fat, comprising the steps of:
A. providing a microwave popcorn (12) having a sealed bottom end (28), an open sealable top end (30) defining an upper orifice and a transversely extending seal area (31) in an open configuration and in a vertically aligned orientation;
B. filling the bag with a quantity of unpopped popcorn kernels (13), and slurry (15) comprising the substeps of:
1. dispensing a quantity of unpopped popcorn kernels in an airborne stream; and concurrently
2. spraying a quantity of a fat or fat/salt slurry into the airborne popcorn stream to coat the popcorn kernels with the slurry as the popcorn kernels are charged into the bag, wherein the slurry is fluid and has a temperature ranging from about 114� to 130� F., and wherein the weight ratio of popcorn kernels to slurry ranges from about 5 to 30:1; and
C. sealing the open top end of the popcorn bag (12).
2. The method of claim 1
wherein the spray is oriented to spray the slurry in the direction of and into the airborne popcorn stream and at an angle of about 0� to 90� relative to the popcorn stream to form an intersection between the spray and the popcorn stream.
3. The method of claim 2
wherein the popcorn is dispensed in the form of a cylindrical cascade defining a stream diameter;
wherein said bag is formed of a flexible tubular sheet material having a sealed bottom and an open sealable upper end; and
wherein the spray angle ranges from about 8� to 15�, and said intersection is within the popcorn bag (12) below the seal area (30).
4. The method of claim 3
wherein the spray is in the form of a fan spray having a width at the intersection equal to the diameter of the popcorn cascade and wherein the cascade falls vertically into the bag.
5. The method of claim 4
wherein the fat or slurry has a spray temperature of between about 114� to 130� F. (45� to 54.5� C.) and the fat is a material selected from the group consisting of low melting point fats, partially hydrogenated oils, fluid fats, and mixtures thereof.
6. The method of claim 5
wherein the popcorn quantity ranges from about 80% to 97%;
wherein the fat quantity ranges from about 2% to 15%; and
wherein the spray additionally includes about 1% to 4% of salt.
7. The method of claim 6
wherein the bag has first and second major rectangular face panels each having parallel transversely extending top and bottom edges and parallel vertically extending side edges and sections of interconnecting folded gusset material projecting centrally between the side edges of the face panels with the centrally projecting gussets approaching each other enough to divide the bag into first and second collateral tubes; and
wherein the popcorn and fat or slurry are charged to only one collateral tube.
8. The method of claim 7
wherein the bag includes a lower transverse fold defining an intermediate tube portion and the bag is maintained with the lower fold portion folded against the bag body; and
wherein the first collateral tube has a microwave susceptor layer defining a microwave collateral tube.
9. The method of claim 8
wherein the slurry is applied entirely to the cascade from bottom to top.
10. The method of claim 9
wherein the first major face panel is smaller in width than the second major face panel defining a minor microwave susceptor collateral tube and a major susceptor-free collateral tube; and
wherein the angle ranges from about 8� to 15�.
11. A method for filling a microwave popcorn bag with unpopped popcorn kernels coated with a fat and salt slurry having improved evenness of coating of the kernels with the fat and salt, comprising the steps of:
A. providing a microwave popcorn bag having a sealed bottom end and an open sealable top end defining an upper orifice;
B. advancing the bag to below a fill station means for dispensing unpopped popcorn kernels in a falling cylindrical cascade, and a means for spraying an edible fat and salt slurry, said spraying means being oriented to spray the slurry into the falling popcorn cascade and at an angle of about 0� to 15� relative to the cascade to form an intersection between the fat and slurry spray and the popcorn cascade;
C. opening the microwave bag to have its upper orifice in an open configuration and to have a vertically aligned orientation;
D. dispensing a quantity of unpopped popcorn kernels to fall in a cascade into the open bag upper orifice and concurrently spraying a quantity of fat and slurry into the falling popcorn cascade to coat the unpopped popcorn kernels with the fat and slurry while falling
wherein the intersection between the cascade and the spray is within the bag;
E. closing the microwave bag; and
F. sealing the open end of the popcorn bag.
12. The method of claim 11
wherein the popcorn is dispensed from a cylindrical filling tube, funnel or filling horn with a circular dispensing hole to form a cylindrical cascade.
13. The method of claim 12
wherein said bag is formed of a flexible tubular sheet material having a sealed bottom and an open sealable upper end.
14. The method of claim 13
wherein the fat and slurry is sprayed in the form of a horizontally oriented fan spray having a width at said intersection equal to the diameter of the popcorn cascade.
15. The method of claim 14
wherein the slurry has a temperature of between about 115� to 130� F. and includes a fat material selected from the group consisting of low melting point fats, partially hydrogenated oils, fluid fats, and mixtures thereof.
16. The method of claim 15
wherein the popcorn quantity ranges from about 90% to 97%,
wherein the fat quantity ranges from about 2% to 5%, and
wherein the salt quantity ranges from about 1% to 4%.
17. The method of claim 16
wherein the bag is maintained in an open position by suction pulling apart the first and second major face panels.
18. The method of claim 17
wherein the bag has first and second major rectangular face panels each having parallel transversely extending top and bottom edges and parallel vertically extending side edges and sections of interconnecting folded gusset material projecting centrally between the side edges of the face panels with the centrally projecting gussets approaching each other enough to divide the bag into first and second collateral tubes, and
wherein the popcorn and slurry are charged to only one collateral tube.
19. The method of claim 18
wherein the first collateral tube has a microwave susceptor layer defining a microwave collateral tube.
20. The method of claim 19
wherein the first major face panel is smaller in width than the second major face panel defining a minor microwave susceptor collateral tube and a major susceptor-free collateral tube.
21. The method of claim 20
wherein Step C includes the substep of directing at least one air jet against a gusset face panel of the bag.
22. The method of claim 19
wherein the first and second tubes are of equal size.
This is a division of application Ser. No. 08/086,607, filed Jul. 2, 1993, now abandoned.
The present invention relates to packaged food products. More particularly, the present invention relates to microwave popcorn product articles, to fat coated popcorn used therein and to methods for filling such articles.
Popcorn is a highly popular snack food item. In the past, the at-home preparation of popcorn by the consumer involved adding kernel popcorn plus a cooking oil to a covered pot and heating until the popcorn kernels popped to make popcorn. As used herein, "kernel popcorn" refers to unpopped popcorn. The noun "popcorn" or synonymously "popped popcorn" refers herein to popped kernel popcorn. The adjective "popcorn" can refer to either.
More recently, microwave popcorn products have become extremely popular. At present, in the U.S., over 70 different brands of microwave popcorn products are available. In general, the more popular microwave popcorn products comprise an expandable paper bag containing a charge of kernel popcorn, fat and salt. The microwave popcorn article is adapted to be heated in a microwave oven for three to five minutes to produce the popped popcorn. More recently, improved microwave popcorn articles have been fabricated employing a metallized susceptor which facilitates the heating of the popcorn-fat charge and which, in turn, leads desirably to increases in popcorn volume and decreases in unpopped kernels. Microwave popcorn articles of this type are described in detail in, for example, U.S. Pat. No. 4,450,180 (issued May 22, 1984 to J. D. Watkins and incorporated herein by reference).
While extremely convenient and popular, microwave popcorn articles are not without certain disadvantages. Notwithstanding the wholesome and nutritious nature of popcorn per se, known microwave popcorn products typically are formulated with relatively high amounts of fat. Conventional full fat products generally contain about 25% to 35% fat. Since fats have more calories per gram than popcorn, it is not uncommon that more than 50% of the calories associated with the popcorn are derived from the fat. It is generally accepted that diets should be modified so as to significantly reduce the fat contribution to total caloric intake.
In view of the high fat content of conventional microwave popcorn and in light of health concerns, there have been formulated microwave popcorn products of reduced fat content. These products are manufactured in the same manner as full fat products but simply with less fat being added. Unfortunately, these products, upon preparation provide microwave popped popcorn that is organoleptically deficient in view of the perceivably reduced fat content. The present invention provides an improved product of reduced fat content by improving the fat perception by improving the evenness of the fat distribution. The improvement results from the present improved method of filling.
Some reduced fat products are about one half the fat of full fat product, some one third, some one fourth, etc. As the amount of fat is progressively reduced, the importance of the evenness of distribution of the little fat still employed progressively increases.
Microwave popcorn articles, of course, comprise a microwave popping bag and a charge of popcorn, fat, and, usually, salt. Certain early patents taught the addition of popcorn, fat and salt in the form of a prefabricated toroid or doughnut shaped piece. The piece was fabricated by mixing the popcorn, salt and melted fat to form a blend and the blend was allowed to cool and harden into the toroid shape desired. These circular pieces were then dropped into the desired chamber of the popcorn bag prior to final sealing. (See for example U.S. Pat. No. 4,450,180, issued May 22, 1984).
Contemporary methods of filling microwave popcorn bags, however, employ a different filling process and technique. (See, for example, U.S. Pat No. 4,604,854 entitled Machine For Forming, Filling and Sealing Bags, issued Aug. 12, 1986 to D. W. Andreas). The microwave bags having an unsealed open end are advanced to a first popcorn filling station. While being maintained in an open position, the popcorn is charged to the desired channel. Thereafter, the bags are advanced to the next station at which the fat/salt slurry is added to the bag. Typically, the slurry is added in the form of a vertically dispensed pencil jet (i.e., a confined stream) of the slurry. The bags now containing both popcorn and slurry are then advanced to a sealing station where the bags are provided with a top seal to complete the closure of the bag. The sealed popcorn bags are advanced to subsequent finish packaging operations which complete the folding of the bags, providing the bags with an overwrap, and inserting appropriate numbers of the bags into cartons, etc.
The contemporary method for filling popcorn bags involving the sequentially filling (i.e., not at the same time and station) of popcorn and then the slurry is well suited for those microwave popcorn products which can be characterized as "full fat" products. Such products typically have about 25% to 35% of fat. When such high fat amounts are used, the products have ample fat to provide the desired organoleptic attributes. The fat exists in sufficient quantities to more or less completely cover the popcorn and uniform distribution of the fat is not a concern.
While useful in connection with full fat microwave popcorn articles, there is a present need for reduced fat or low fat products comprising about 2% to 15% fat. When such low fat microwave products are prepared using the conventional sequential filling step process, there is an insufficient amount of fat to coat all the popcorn kernels. Upon microwave heating, a relatively few popped popcorn pieces can contain a disproportionate amount of the small amount of fat present. As a result, a large number of popped popcorn are perceived as being dry and thus organoleptically deficient.
Also, such low fat products do not have sufficient amounts of fat to bind the popcorn together in the disc form described in the '180 patent for simultaneous addition as thereon described. While other coating techniques might provide popcorn having small quantities of fat evenly coated therein as herein, the most difficult problem is how to handle the sticky fat-laden popcorn and fill uniform amounts thereof into microwave popcorn bags at high speed.
Given the state of the art as described, there is a continuing need for new and improved microwave popcorn articles of reduced fat content. Accordingly, it is an object of the present invention to provide new and improved microwave popcorn articles.
It is a further object of the present invention to provide a microwave popcorn article having a reduced fat charge, which upon microwave heating can provide popcorn of reduced fat content.
It is a further object of the present invention to provide microwave popcorn articles which upon microwave heating yield a popcorn of reduced fat content which nonetheless provides the organoleptically desirable attributes of higher fat content popcorns.
It is a further object of the present invention to provide microwave popcorn articles which upon microwave heating produce popcorn having fat distributions which are relatively more uniform than conventionally prepared low fat microwave popcorn.
It is a further object of the present invention to provide microwave popcorn packaged food products which upon microwave heating yields popped popcorn substantially free of popcorn pieces disproportionately high in absorbed fat.
Still another object of the present invention is to provide improved commercially practical filling methods for use in manufacturing microwave popcorn products of reduced fat content.
Another object of the present invention is to provide improved methods of filling microwave popcorn bags with popcorn and fat that improve the evenness of fat distribution over the popcorn.
Still another object is to provide a popcorn more evenly coated with reduced quantities of fat that upon microwave popping provide improved organoleptic properties.
Still another object is to provide microwave popcorn articles which upon microwave heating produce popcorn having relatively more uniform distribution of flavor, salt and/or color.
It has been surprisingly discovered that the above objectives can be realized and that superior microwave popcorn articles can be provided. In the preferred embodiment, the present invention resides in part in the simultaneous filling of popcorn and fat involving the spraying of fat/salt slurry at an angle to a falling cascade of popcorn as it is being charged to the upper open end of the microwave popcorn bag. The angle of the fat/salt spray is such as to intersect with the falling popcorn cascade within the popcorn bag below the top seal area. By applying the fat/salt slurry to a falling cascade of popcorn during bag filling improved distribution of the slurry over the popcorn is achieved. Such improved slurry distribution yields organoleptic improvements in the popped product in that fat perception is increased even at low fat levels.
FIG. 1 is a diagramatic view of one method of filling a microwave popcorn bag in accordance with the invention.
FIG. 1A is a perspective view of an unsealed, folded microwave popcorn bag.
FIG. 2 is a plan sectional view taken along lines 2--2 of FIG. 1 with sealing jaws in retracted position shown in dotted relief.
FIG. 3 is an enlarged cross sectional view partially cut away of the popcorn and fat filling step taken along lines 3--3 of FIG. 1.
FIG. 4 is a greatly enlarged sectional view partially broken away of the filling step taken along lines 4--4 of FIG. 3.
FIG. 5 is an enlarged sectional view partially broken away of the filling step taken along lines 5--5 of FIG. 4.
FIG. 6 is a sectional view taken along lines 6--6 of FIG. 5.
In its article aspect, the present invention relates to improved microwave popcorn articles. The present microwave popcorn articles essentially comprise a microwave popcorn bag and a charge of kernel popcorn having reduced quantities of fat and salt more uniformly dispersed upon the popcorn. In the preferred embodiment, the popcorn charge is characterized by a low fat content reduced by 70% to 80% relative to a conventional full fat product. The kernel popcorn component essentially comprises about 90% to 98% of the charge. The fat component essentially comprises about 2% to 8% of the charge. The charge further comprises about 1% to 4% salt. The fat is distributed such that 80% to 90%+ of the popcorn kernels have at least 80% of their surface coated with the fat.
In its method aspect, the present invention resides in methods for filling a microwave popcorn bag with popcorn kernels coated with a fat and salt slurry having improved evenness of coating of the kernels with the fat and salt. The present methods comprise the steps of:
A. providing a microwave popcorn bag having a sealed bottom end and an open sealable top end defining a seal area in an open configuration and in a vertically aligned orientation;
B. filling the bag with a quantity of popcorn, fat and, salt, comprising the substeps of:
1. dispensing popcorn kernels in an airborne stream by gravity in a falling cascade; and concurrently,
2. spraying a quantity of a fat or fat and salt slurry into the airborne popcorn stream to coat the popcorn with the fat or slurry while airborne, said spraying being oriented to spray the slurry into the falling popcorn cascade and at an angle of about 8� to 15� relative to the stream to form an intersection between the slurry spray and the popcorn cascade said intersection being within the popcorn bag below the seal area; and
C. sealing the open top end of the popcorn bag.
The present invention relates to improved microwave popcorn articles of reduced fat content and improved volume and to their methods of preparation. The present microwave popcorn articles essentially comprise a microwave popcorn bag, a charge of a quantity of 1) popcorn, and 2) a quantity of a fat and/or fat/salt slurry uniformly dispersed upon the popcorn. Each of these article components as well as methods of filling, product use and attributes are described in detail below.
Throughout the specification and claims, percentages are by weight and temperatures in degrees Fahrenheit unless otherwise indicated.
Microwave Bag
The present microwave popcorn articles essentially comprise a conventional microwave popcorn popping bag. Useful herein for the microwave popping bag are a wide variety of microwave bags available commercially or known in the art. Useful microwave bags herein can include any conventionally useful bag for microwave popcorn products. For example, a suitable bag widely used commercially and preferred for use herein is described in the U.S. Pat. No. 4,450,180 patent which is incorporated herein by reference. A generally similar bag is described in U.S. Pat. No. 4,548,826. Generally, the bag comprises and is fabricated from a flexible sheet material having two collateral tubular sections. The sections are parallel longitudinally extending that communicate with each other at the center of the package.
Referring now briefly initially to FIG. 1A, there is shown an embodiment of a microwave popcorn article 10 composed of a microwave bag 12 formed from flexible sheet material such as paper and being of collateral tubular configuration, that is to say, being composed of a pair of parallel longitudinally extending tubes 14 and 16 which communicate with one another along a central longitudinal opening 18. The two parallel tubes 14 and 16 are separated by longitudinally extending side indentations 20 and 22. When the package comprises a paper bag, the bag can be composed of first and second face panels 24 and 26 respectively and the indentations 20 and 22 comprises gussets. The bag has bottom seal 28 and initially an open top or orifice 30 but a sealable seal area 31. After being filled, the top 30 is also sealed conventionally by means of heat or a suitable adhesive to provide a top seal in the top seal area 31.
The bag material is generally fabricated with multiple plies including an outer ply 33 which is generally paper, a grease-proof or resistant inner ply 34 (preferably grease proof) and microwave susceptor film member or ply 35 (see FIG. 4) intermediate these inner and outer paper layers. However, in preferred embodiments the microwave susceptor 35 is present only on one major face panel.
While tubes (or chambers, or channels) 14 and 16 can be of equal size, conventionally the susceptor channel 14 is generally slightly smaller. In such a configuration, the gussets include major left gusset face 36, minor left gusset face 37, major right gusset face 38 and minor right gusset face 39. The bag 12 can be provided with a lower transverse fold 40 to define an intermediate portion or pocket 41.
Although in the present description, a particular description is given to this preferred microwave bag, the present invention is also useful in connection with, for example, flat bottomed bags, bags with or without a bottom fold, with a straight bottom seal or other more complex bottom seal designs.
The present article 10 further essentially includes a quantity of kernel popcorn 13. Conventionally, microwave popcorn formulations are now expressed based upon the weight of the entire popcorn and fat charge. This convention is followed in the present description of the invention. Broadly, the popcorn can range from about 80% to 98% of the popcorn charge. Typically, about 80 to 90 g of popcorn is added to the bag, preferably about 80 to 85 g. In general practice, the amount of popcorn is set and the other ingredients are varied to provide reduced or low fat, and/or salted or no-salt embodiments. Thus expressed, in the preferred low fat embodiments of the present invention, the present microwave popcorn articles comprise a charge essentially comprising about 90% to 98% kernel popcorn (for non-salt embodiments, 97% for salted products), preferably 91% to 95%, and for best results about 93%. For less preferred, reduced fat embodiments the popcorn comprises about 80% to 87% popcorn.
Conventional kernel popcorn varieties can be used herein. Highly preferred for use herein are relatively larger kernel popcorn varieties. Preferred for use herein are those larger varieties having a kernel count of about 40 to 80 kernels per 10 g, preferably 50 to 65, which are commercially available.
The present articles additionally essentially comprises a quantity or charge of an edible fat designated generally by reference numeral 15. Generally, the present methods are useful in connection both with reduced-fat and with low-fat embodiments. As noted, the present invention finds particular suitability for use in connection with low-fat microwave products. Low fat products have an even lower fat content than reduced fat embodiments. Reduced fat products have a fat content of about 8% to 15% fat. All fat percentages are descriptive of added fat and are not meant to include fat which may be included in the finished product from other ingredients, e.g., the fat from the popcorn. Thus, broadly, the fat can range from about 2% to 15% and about 8% to 15%, (preferably 10% to 14%) for reduced fat embodiments. In the preferred low fat embodiments the charge essentially comprises about 2% to 8% fat, preferably 3% to 4% fat and for best results about 3.5%.
The fat, preferably semi-solid or solid fat, can be from any conventional, suitable fat(s) or oil(s) or mixtures thereof from vegetable or animal sources including from soybean, cottonseed, safflower, corn, peanut oil(s), butter oil and mixtures thereof. The oils can be partially hydrogenated. Preferred for use herein are fats which are partially hydrogenated soybean and/or corn oil. Also useful herein are tropical oils such as coconut oil and palm kernel oil, although present consumer trends disfavor utilization of such oils.
Microwave popcorn articles additionally conventionally comprise salt in the popcorn/fat charge. However, certain line extensions of popular microwave popcorn brands include no-salt or low salt embodiments. In those salt bearing articles, the salt is simply physically admixed in with the fat component to form a fat and salt "slurry." The term slurry is used herein as is common in the microwave popcorn art to refer to any coating applied to the popcorn. The term "slurry" as used generally herein thus includes fat alone; fat and salt; fat, salt, flavors and/or color or sweetener(s); as well as any other variation or combination of ingredients used as an addition to the popcorn herein.
The slurry can additionally optionally comprise minor amounts of other materials conventionally employed to make the microwave popcorn more aesthetically or nutritionally or organoleptically appealing. Such adjuvant ingredients can include, for example, sugar(s), minerals, vitamins, colorants, preservatives and flavors. If present, each of these constituents can comprise from about 0.01% to about 2% (or more for sugar, cheese solids) by weight of the fat slurry. Especially popular for use herein is a butter flavor. The flavors can be either in liquid, fat soluble forms and/or in dry powder forms such as a liquid oil absorbed onto a particulate carrier, e.g., gum arabic, starch, silicon dioxide, or dehydrated cheese solids.
In those salt containing embodiments herein, the charge additionally essentially comprises about 1% to 5% salt, preferably about 2% to 4% and for best results about 2.5%. Of course, both salt free reduced fat and salt free low fat embodiments are contemplated herein as well.
The fat with the salt dispersed therein is prepared simply by admixing the fat (in a fluid or melted state) together with any optional ingredients with salt and blending the mixture to form a stable dispersion or slurry. The fat or slurry, while still warm (114� to 130� F.; 45� to 55� C.), is then sprayed onto the popcorn while filling the bag as described in detail below.
Method of Preparation
Now referring to FIG. 1, there is seen a schematic of the method of preparation preferred for use herein generally designated by reference numeral 50. The drawing shows a conventional microwave packaging line and depicts three stations thereof designated generally by reference numbers 52, 53 and 54. In upstream stations, (not shown) the tubular bag material is cut into desired lengths, and is provided with the bottom seal 28. Additionally, in upstream stations, the bags 12 are folded to have their bottom third folded up as depicted in first station 51 of FIG. 1 to provide the first lower transverse fold 40 so that the popcorn and fat charge can be positioned within the bag in the desired middle portion 41 thereof. The bags 12 are advanced from station to station (left to right) by suitable drive means such as the endless drive chain 54 depicted having bag engagement clips 55. Packaging line speeds range from about 50 to 100 bags per minute. Also, the bottom third of the bags are maintained in the closed position by appropriately spaced parallel guide bars 56 and 58.
In the conventional method of filling microwave popcorn bags, the first station 51 would be a popcorn filling station. The fat and salt addition would be charged to the bag at a second separate station. However, as illustrated, in the present method of filling popcorn bags, the popcorn filling and fat addition are performed at the same time and at the same station rather than in sequential separate steps.
Thereafter, the bags being maintained in the upright, folded orientation depicted in FIG. 1 are advanced to the popcorn and fat filling station 52. The bag 12 is then filled as described in detail below.
Once filled, the bags are then advanced to the third sealing station 53 wherein the top orifice 30 is sealed such as by retractable heat sealing jaws 82 which impart a seal in the heat seal area. Also at the third station can be an upper set of parallel guide bars 84 which causes the bags to close for top sealing. The filled and sealed microwave popcorn bags are then advanced to subsequent downstream packaging operations (not shown). Such subsequent downstream packaging operations include folding the bags again to provide a three-folded bag, i.e., to provide a second upper transverse fold, overwrapping the folded bags with an overwrap or moisture barrier layer, and inserting desired numbers of the packaged article into cartons.
As depicted in FIG. 1, the filling station 52 can employ a popcorn dispensing and fat spray apparatus 60. Generally, however, the filling station 52 includes a means for dispensing a measured quantity of popcorn such as the dispensing wheel 61 depicted. The dispensing wheel 61 discharges at timed intervals a measured quantity (e.g., 80 to 90 g) of the popcorn into a vertically oriented filling horn or funnel 62. The funnel 62 causes the popcorn to fall by gravity in the form of an airborne stream or cascade of a defined width or diameter suitable for the size of the bag's orifice, e.g., cylindrical. The apparatus 60 further includes an applicator 64 for spraying the fat/salt slurry 13 (e.g., commercially available from Hibar Systems Limited, Ontario, Canada) that is supplied by slurry supply means 66. The slurry supply means 66 includes a conventional positive displacement reciprocating metering pump 68 having a piston 70 and a pressurized slurry inlet 72. The pump 68 precisely pumps metered amounts of the fat/salt slurry to the applicator 64 at closely controllable time intervals.
Still referring to FIG. 1, the filling station 52 is further provided with a means for opening the popcorn bag 12 for filling which essentially includes at least one and preferably a pair of reciprocating suction cups 74 and 76. Suction cups 74 and 76 engage the first and second face panels 24 and 26 to open the bag 12. In highly preferred embodiments, the bag opening means additionally includes a means for opening the bag such as an opposed pair of air jets 78 and 80 or other mechanical bag opening devices directed towards panels 36 and 38 to facilitate opening of the popcorn bag for filling. Air jets 78 and 80 are cycled to be directed against gusset faces 36 and 38 respectively so as to cause the bag to open to allow more easily the dispensing of the popcorn and fat into tube 14 as depicted in FIG. 5.
FIG. 1 further depicts at the third station 43 a means for closing the filled bag such as closure bars and a means for top sealing the now filled popcorn bags such as the set 82 of retractable electrically operated heat sealing jaws.
Reference is now made again to FIG. 2. Initially, the bag 12 at the first station 51 is maintained in a closed vertically aligned position. FIG. 2 also shows better that the bag 12 is opened by suction cups 78 and 79 which engage panels 26 and 24 respectively and pull the bag open as the cups retract in the opposite direction indicated. The filling spout or funnel 62 is positioned immediately above the bag such that its bottom end is aligned with the upper open end of the small tube with just enough clearance to insure smooth operation. FIG. 2 further shows at the third station 53 the retractable movement of heat seal jaws 82.
The cross sectional profile of the falling popcorn cascade is shown in dotted relief as 86.
Reference is now made briefly to FIG. 5. In FIG. 5, it can be seen that the slurry is dispensed in the preferred embodiment in the form of a fan-type spray 90. Such a fan spray application is obtained by providing the applicator 64 with a spray nozzle tip 65. Generally, a spray nozzle that provides a fan type spray pattern is selected so as to disperse the fat or fat/salt slurry with a fan width equal to the diameter or width of the falling popcorn cascade at their line of intersection. In the preferred embodiment a 65� fan nozzle tip 65 is used having a 2 gal/min rating (7/64" opening). The 65� distribution angle specification, of course, is for a water spray. Since the fat/salt slurry has viscosity characteristics different from water, the actual angle of the slurry spray is modestly less than the full 65� distribution angle achieved by water. In actual practice the fan nozzle angle 65 specification can range from 40� to 75�, preferably about 45� to 65�, and for best results about 65�. FIG. 5 further shows that the funnel axis and the applicator axis are aligned to be in the same plane so that their respective product streams' direction or vector are correspondingly coplanar.
While a fan spray is preferred for use herein, equivalents thereof in terms of dispensing the slurry across the popcorn stream can also be used. For example, a multiplicity of very fine jet streams, e.g., 3-12, or a sparge can be used to achieve the desired dispersion hereunder. Also, other spray types, (e.g., a cone spray, or a mist spray) are useful herein, especially when used within the funnel. However, great care must be taken in selecting such useful alternatives so as to avoid getting slurry in the bag seal area. In other embodiments, the spray can be gas assisted, e.g., air, steam, or inert gas.
Reference now is made to FIG. 4 which shows that the intersection 91 of the falling popcorn cascade 88 with the fat spray is importantly below the upper seal area 31. It is important to avoid the inadvertent spotting of the fat in the seal area 31 since the presence of fat in the seal area adversely affects the integrity of the seal in the later sealing step. Even minor gaps in the seal can greatly adversely affect the performance of the microwave popcorn bag upon microwave popping. Gaps in the seal can lead to steam loss which in turn can lead undesirably to reductions in popped corn volume or premature venting. Such a concern about avoiding the inadvertent deposition of minor amounts of fat in the seal area is not a problem in the conventional method of microwave popcorn bag filling since the conventional practice is to dispense the fat in a thin pencil jet in a downward vertical direction (e.g., about 0.2 mm in diameter).
Still referring to FIG. 4, it is seen that in the most preferred embodiment the angle of the slurry is at an angle of about 8� to 15� from vertical, preferably about 12� from vertical. Such a slight angle is desirable so as to cause the fan spray of slurry to intersect with the downwardly directed falling popcorn cascade. The angle is also important to achieving the desired intersection of the slurry with the popcorn within the microwave popcorn bag, importantly below the upper seal area. The angle is adjustable by the lateral movement of the applicator 64 about pivot pin 92 as position nut 94 is secured to threaded rod 95. The fat or slurry discharge and popcorn fall are timed to coincide while the popcorn falls. More particularly, the slurry shots must be timed such that they intersect with the beginning of the popcorn charge and continue through the end of the popcorn charge from bottom to the top of the popcorn cascade. The continuous intersection of slurry and popcorn throughout the charge is important to ensure a uniform distribution of the slurry.
In preferred embodiments, the bag 12 has a microwave chamber (i.e., wherein one major face panel has an intermediate microwave susceptor layer between the inner and outer bag layers) and, for cost considerations, a microwave susceptor-free chamber. In the preferred practice, the popcorn fat and salt are charged to the microwave channel. Conventionally, the microwave panel is the lesser channel (i.e., being formed by the smaller major face 24) and the greater channel is the microwave free channel. Such a configuration minimizes the amount of relatively expensive microwave susceptor material required while nonetheless providing the needed expansion volume upon microwave popping.
By selecting a fan-type of spray and by orienting the spray at a small angle relative to vertical, an intimate mixing of the slurry with the popcorn is achieved while the popcorn is still falling. The mixing and tumbling action of the popcorn and the slurry while still falling surprisingly achieves a highly uniform distribution of the fat over substantially all of the popcorn surface area.
The popcorn and fat mixture obtained by the methods of the present invention is thus importantly characterized by the fat being uniformly dispersed over the surface of the popcorn. More specifically, in the present invention, the present popcorn and the microwave popcorn articles containing such popcorn are essentially characterized by at least 80% (preferably 90%) of the popcorn kernels having substantially all (at least 80%) of their surface area coated by the popcorn. In contrast, using conventional filling techniques (e.g., a thin pencil jet of slurry) at equivalent popcorn and fat usage levels, fewer than 75% of the popcorn kernels have substantially all of their exterior surface coated with the fat. Otherwise stated, there is a substantial reduction (from about 25% to less than 10%) in the number of popcorn kernels that are not substantially completely covered by fat. This increase in the uniformity of fat distribution surprisingly disproportionately leads to an increase in the perception of fat. Such a result is highly desirable in such low fat embodiments containing such modest levels of fat.
Another aspect of the present invention is that the fat is preferably applied to the popcorn outside of the funnel 62. While less preferred, it is possible to apply the fat or slurry in the form of at least one fan spray to the popcorn as the popcorn is falling through the funnel and achieve the benefits of the present invention. In those embodiments, the angle of the spray can range from 0� to 180�, preferably 0� to 90�, and more preferably >60� relative to the popcorn stream. For example, the application can be positioned to be parallel to and preferably concentric with the popcorn stream (i.e., 0� angle relative to the popcorn stream). In another variation, the spray can be through a hole in the funnel into its interior. The spray can be at 90� to the popcorn stream or at an acute angle thereto. However, it has been discovered that the preferred practice herein of applying the spray of slurry to the popcorn outside of the funnel leads unexpectedly to desirable increases in filling speeds.
The skilled artisan will appreciate that the cycle time of the bag in the popcorn and fat filling station is very brief. At line speeds of 60 bags per minute, the entire filling cycle is on the order of one second. Of course, at higher line speeds, the cycle time must correspondingly be less. When the slurry is charged to the popcorn within or above the filling funnel, the coated popcorn tends to be momentarily held up in the funnel. While the duration of the impediment is extremely brief, it is of sufficient duration so as to reduce achievable line speeds substantially. Thus, it is an advantage of the present invention that by applying the slurry in the present preferred manner, (i.e., exterior to the funnel) unexpected increases in line speeds are obtained. Additionally, applying the spray within the funnel, if unheated, can lead to fat build up therein which requires more frequent cleaning. In those embodiments wherein the spray is applied within the funnel, it is preferable to heat the funnel, more preferably to above the melting point of the fat. Such heating can be done by warm air or by electrical heating tape applied to the funnel exterior.
It will be appreciated that another advantage of the present method is that the popcorn is uniformly dispersed with the fat without the presence of any additional coating material such as a film material that might tend to interfere with the popcorn puffing performance or the popped product's organoleptic attributes.
As mentioned briefly above, the present invention broadly resides in the provision of a microwave popcorn article which upon microwave heating provides microwave popped popcorn having three principal advantages. First, the popped popcorn has a reduced fat content but nonetheless exhibits the perceived organoleptic attributes of higher fat content popcorns. Second, the fat distribution is superior, notwithstanding the reduction in fat content. Moreover, the popped popcorn exhibits better flavor and appearance.
While not wishing to be bound by the proposed theory, the present invention resides in part in the appreciation that in the microwave preparation of popcorn, the fat upon heating initially liquefies and tends to collect at the bottom of the microwave bag. As microwave heating continues, some kernels pop first. Surprisingly, these popped kernels appear to disproportionately absorb the liquefied oil. As a result, relatively less oil is available to coat and flavor the remaining popcorn pieces. Thus, the finished popped popcorn is characterized by a relatively few number of popcorn pieces having relatively large amounts of fat with the vast majority of the popcorn pieces having much less. Indeed, it has been speculated herein that about 3% to 5% of the popcorn pieces believed to be the initially popped pieces can contain up to 40% of the overall fat.
Surprisingly, it was discovered that the initial undesirable excessive fat absorption by earlier popped pieces could be minimized or substantially reduced by providing the fat more evenly distributed upon the popcorn. Provision of such a more evenly distributed fat thereby avoids pooling of the fat in the bag bottom which in turn desirably avoided the excessive initial fat absorption by the early popped pieces.
The avoidance of excessive initial fat absorption allows for a substantial reduction in overall fat content to be achieved without sacrificing desirable organoleptic attributes. However, the more even distribution of the then reduced fat content allows even further reductions in overall fat content without sacrificing organoleptic attributes.
It was surprisingly discovered that such a fat component could be provided by spraying the slurry into a falling cascade of popcorn while the popcorn is being charged to the microwave popcorn bag.
Furthermore, in those embodiments wherein the charge additionally includes added flavor, e.g., supplemental butter flavor, or seasonings, the present invention provides an added benefit; namely, superior distribution of the added flavor, salt and color.
Product Use
The microwave popcorn products prepared as described can be used in a conventional manner for the at-home preparation of popcorn by microwave heating. Upon microwave heating, the popcorn exhibits more uniform coating of the fat and salt, more uniform fat distribution, excellent organoleptic attributes, and in the preferred low fat embodiments, a reduced fat content.
The present invention finds suitability for use in the provision of a mass market, shelf stable consumer food item adapted to prepare oiled, flavored popcorn upon microwave heating.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative and not limitative of the remainder of the disclosure. It will be appreciated that other modifications of the present invention, within the skill of the microwave popcorn art, can be undertaken without departing from the spirit and scope of the invention.
An improved microwave popcorn article of the present invention comprising a microwave popcorn bag was prepared having the popcorn/fat charge of the composition indicated below. The microwave popcorn bag is fabricated substantially in accordance with the teachings of U.S Pat. No. 4,450,180. Microwave popcorn articles comprising microwave popcorn bags of this type are available under the brand name Betty Crocker™/Pop Secret™. The popcorn fat charge had the following composition:
______________________________________Ingredients Weight %______________________________________Popcorn 93.8Fat1 3.3Salt 2.8Artificial butter flavor 0.1 100.0%______________________________________ 1 An hydrogenated soybean oil available from Honey Mead Products Co. under the trade name HM608.
A supply of the fat and salt were prepared to form a warm slurry (about 122� F.; 50� C.).
A quantity of microwave popcorn bags were filled as follows:
About 82.6 g of popcorn was dispensed by the dispensing wheel into the funnel. The applicator was timed to dispense about 5.5 g of the slurry as the popcorn cascade exits the bottom of the filling funnel to disperse the slurry in the form of a fan spray. The duration of the spray was about 0.5 seconds. The slurry intersected the popcorn within the microwave popcorn bag below the seal area. The bags were then heat sealed to form finished, low fat microwave popcorn articles of the present invention.
Disposed within the articles were slurry coated popcorn of the present invention.
A number (50) of microwave popcorn articles were opened to test for evenness of the slurry in coating the popcorn. The bags were opened and the popcorn removed for testing. The fat coated popcorn was then stained with a lipophobic dye. The stained fat coated popcorn was then visually examined for extent of coverage.
The results of such testing was that about 92% of the individual popcorn kernels had at least 90% coverage by the fat.
The results of such testing indicate that the methods of the present invention were surprisingly effective in evenly distributing minor amounts of fat on the popcorn.
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When looking for a custom, vintage, or rare vehicle, not many can compete with this original 1980 Apollo Verona Concept car. Billed as "Cobra... More
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2002 Maserati Coupe Cambiocorsa. 25,000 miles Blue with beige leather interior. 4.2L 390HP Ferrari built V8 engine, six speed "F1" Cambiocorsa gearbox with paddle... More

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text:
NASA Curiosity Rover Live Stream: Will.i.am Song Live On Mars Through Speakers [NASA Live Stream]
Will.i.am will broaden his fan base on an intergalactic level. NASA's Curosity rover will play Black Eyed Peas' lead singer Will.i.am's single, "Reach for the Stars," through their speakers on the planet Mars on Tuesday, Aug. 28. NASA will live stream Curosity playing the single from the surface on the Red Planet at 1pm (PST) or 4PM (EST) as part of an educational event for students.
Will.i.am will broaden his fan base on an intergalactic level.
NASA's Curiosity rover will play Black Eyed Peas' lead singer Will.i.am's single, "Reach for the Stars," through their speakers on the planet Mars on Tuesday, Aug. 28.
NASA will live stream Curiosity playing the single from the Red Planet at 1 p.m. (PST) or 4 p.m. (EST) as part of an educational event for students.
Students will hear the song while attending the event at NASA's Jet Propulsion Laboratory in Pasadena, Cali. NASA's team that helped the landing of Curiosity on Mars will speak with students about their first mission on Aug. 5 and the technology behind it.
Watch the livestream of NASA's Curiosity rover playing Will.i.am's song "Reach For The Stars" on planet Mars here.
The song, "Reach for the Stars," was inspired by Will.i.am's passion for science, technology and space exploration. He created the song exclusively for the fact-finding mission, in which Curiosity travels around Mars to collect any new data while 780 million miles away.
The Curiosity rover - with no humans inside- landed on Mars the evening of Aug. 5 PST (morning of Aug. 6 EST) ending a 36-week flight. A few hours later, NASA released the first image of the Red Planet taken by the rover.
NASA's Curiosity became the largest rover ever to land on another planet and marked the beginning of an ambitious goal set by the United States to send humans to the Red Planet in the 2030s.
"[The landing] marks an unprecedented feat of technology that will stand as a point of national pride far into the future. It proves that even the longest of odds are no match for our unique blend of ingenuity and determination," President Barack Obama said in a statement.
The Curiosity rover is expected to stay two years on the Red Planet to assess whether Mars ever had an environment able to support life forms.
The vehicle, which is about the size of an SUV, immediately began sending back pictures of the landscape with its "fisheye" hazard avoidance cameras, and the photos have amazed NASA and the general public.
NASA will further explore Mars when it launches Mars Atmosphere and the Volatile Evolution (MAVEN) orbiters next year.
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text:
Plan a visit to the OPP Museum!
Just minutes from downtown Orillia, The OPP Museum is located right inside Ontario Provincial Police General Headquarters (GHQ).
As this is a secure police facility, please bear in mind the following policies are in place:
- All visitors to OPP GHQ must check in with security personnel upon arrival. You may be required to present photo Identification. This includes bus tours or other large groups, so please ensure that you plan enough time to sign in upon arrival.
- Children aged 17 and under do not require identification but must be accompanied by an adult with appropriate identification.
- If photo identification is requested, acceptable identification includes one of the following:
- driver's licence,
- Ontario photo card (or other provincial issue equivalent), or
- passport (Canadian or international)
- Individuals who do not possess one of these "normally accepted" forms of identification may still be granted access under certain circumstances. Please check with the security officer on duty when you arrive.
- Please note that security reserves the right to refuse entry to OPP GHQ to any persons. If you would like further clarification on building access, please call OPP General Headquarters Security directly at 705 329-6111 during regular business hours.
When you arrive, you can pick up a guide to General Headquarters and a Museum Exhibit Guide, free of charge.
In addition to exploring the museum, visitors are welcome to stroll along "Public Street", the long corridor at the front of GHQ where you will find vintage vehicle displays, information exhibits on the OPP Auxiliary program, OPP Awards, and the OPP Veterans' Association. You are also welcome to visit The Off Duty ShOPP (705) 329-6280, where you will find a wide variety of OPP branded clothing and merchandise for sale. You may also wish to pause for refreshments at The Steak-Out Cafeteria (705) 329-6523. Major exhibits are featured in the museum's main gallery that include interactive games, and provides a learning experience for people of all ages. Community Services Officers, teachers and group leaders are encouraged to use the museum as a learning resource.
Visit www.oppmuseumfriends.ca to download a copy of our Educators' Resource Guide for more ideas on how you can make the most of your visit to The OPP Museum.
Hours & Admission
Admission to The OPP Museum is always free! The Museum is open year-round, Monday to Friday from 8:30 a.m. to 4:30 p.m. but is closed on weekends and statutory holidays.
Free visitor parking is located at the front of GHQ in the large circular drive, including accessible permit parking spaces near the entrance doors.
There is no bus parking available at GHQ, however, bus drivers can drop/off and pick-up visitors at the front doors to GHQ. An Orillia city bus stop is also located on Memorial Avenue in front of GHQ.
Location & Directions
777 Memorial Avenue
Orilllia, Ontario, Canada
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text:
Feel free at our free ringtones website, where it's possible to download killer ringtones for your mobile phone. Today we have a ringtone of "In The End" by Black Veil Brides as well as 737 other ringtones by Black Veil Brides. "In The End" is a top-rated song from the "Wretched and Divine: The Story of the Wild Ones" album that was composed by Black Veil Brides at their label together with other 18 tracks. You can listen to all 102 Black Veil Brides – "In The End" ringtone variations available here and download it for free to your computer. You can also get other 4 albums produced by Black Veil Brides for all time. "In The End" is referred to , and we bring you a huge amount of videos absolutely for free. And finally, we have collected lyrics for this track and you can view it here as well. So feel free to browse, listen, download ringtones at Audiko.net. Make your phone sound cool!
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text:
Washer Magic Washing Machine Cleaner
Part #: WX10X10201
In Stock
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Single-use bottle.
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text:
A clean, high efficieny, low pressure drop, adsorptive filter material that is porous and includes an acidic functional group. The filter can include, for example, a non-woven filter composite has a porous sulfonated divinyl benzene styrene copolymer beads having sulfonic acid functional side groups. The non-woven filter is used to remove molecular bases, including ammonia, organic amines, inides, aminoalcohols, alcoholoamines from the atmosphere used in semiconductor fabrication and other processes that require uncontaminated gaseous environments of high quality.
1. A method of filtering air for a semiconductor processing facility needing uncontaminated air, comprising the steps of:
providing a filter including a non-woven carrier material having thermo-plastic fibers and having distributed therein adsorbent particles of a sulfonated divinyl benzene styrene
flowing air through the filter with the surfaces of said distributed adsorbent particles being exposed for contact with passing air; and
removing the base contaminants from the passing air with the sulfonated material.
2. A method for filtering molecular base contaminants from air in semiconductor processing equipment comprising passing air through a filter element comprising alternating layers of a powder material and a binder.
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The present application is a divisional of U.S. patent application Ser. No. 09/378,180, filed Aug. 20, 1999, now U.S. Pat. No. 6,447,584, which claims the benefit of U.S. Provisional Application No. 60/097,215, filed on Aug. 20, 1998, the entire teachings of which are incorporated herein by reference.
In this age of increased air pollution, the removal of chemicals from the air we breathe is a concern of everyone. In addition, in the fabrication electronic materials and of devices such as semiconductors, there is a requirement for uncontaminated air of high quality.
Gas phase filtration is commonly accomplished using activated carbon manufactured in various ways. One approach uses a carbon/adhesive slurry to glue the carbon to the substrate. The adhesive decreases carbon performance by forming a film on its surface.
A second approach involves carbonizing an organic based web by heating, followed by carbon activation. This material is expensive and has relatively low adsorption capacity.
A third approach involves forming a slurry of carbon powders and fibers into sheets by a process analogous to a wet papermaking process. This material has a medium-to-high cost, and has an undesirable high pressure drop. Moreover, chemically impregnated carbon particles cannot be efficiently used in conjunction with an aqueous process, as the aqueous nature of the process either washes away the chemical used to impregnate the carbon, or reacts undesirably with the impregnating or active chemical groups thereby rendering it inoperative. In general, however, filter materials which do not incorporate chemically active groups perform far less effectively than those which do include chemically active groups.
None of these approaches fully achieve the desired properties which provide a clean, cost effective, high efficiency, low pressure drop, adsorptive composite.
The present invention comprises a clean, cost effective, high efficiency, low pressure drop, adsorptive, filter comprising a high surface area, highly acidic chemically impregnated adsorbent. A preferred embodiment of the invention can employ a non-woven composite material having acidic functional groups that bind to airborne bases. The invention can be used in lithography systems which employ materials that are sensitive to impurities, such as molecular bases present in the air circulating through semiconductor wafer processing equipment. A large number of bases including ammonia, NMP, triethylamine pyridine, and others, can be maintained at concentrations below 2 ppb in a tool cluster filtered with the present invention. The invention also includes methods for forming the filter comprising, for example, the dry application of an active adsorbent to a non-woven carrier material, which is then heated and calendered with cover sheets.
In a preferred embodiment of this invention the non-woven carrier materials can be polyester non-wovens, and the adsorbent can include sulfonated divinyl benzene styrene copolymer. Another preferred embodiment employs carboxylic functional groups. The acidic groups have at least 1 milliequivalent/gram acidity level or higher and preferably at least 4.0 milliequivalents/gram or higher. The polymers used are porous, preferably having a pore size in the range of 50-400 angstroms and a surface area of 20 m2/g or higher.
The dry processing of a non-woven polyester batting allows for even distribution of adsorbent particles throughout the depth of the polyester batting. This provides an increased bed depth at a very low pressure drop, which is highly desirable since a twofold increase in bed depth can increase the filter's breakthrough time (time to failure) fourfold when using these thin fabric based sulfonic beds.
Thus, the invention provides a clean, cost effective, high efficiency, low pressure drop, adsorptive non-woven filter composite, and a method for forming said composite. The novel filter composite is'particularly useful for the removal of base contaminants in an air stream, which contaminants can be gaseous or vaporous. Particulates will also be removed if greater than the pore size of the filter. The filter has a service life of at least 12 months with a pressure drop to reduce power consumption and minimize impact on the systems operation. For example, a high pressure drop filter can require a longer time for a lithography system to equilibrate the temperature and humidity after filter replacement.
In an alternative embodiment, the filter uses both sulfonated divinyl benzene styrene copolymer and an activated carbon as the adsorbent. Activated carbon is discussed in greater detail in U.S. Pat. No. 5,582,865 entitled "Non-Woven Filter Composite", issued Dec. 10, 1996 with Rezuke, et al. as inventors. The entire contents of this patent is incorporated herein by reference. The filter in this preferred embodiment has two (or more) layers, one of activated carbon and one of sulfonated divinyl benzene styrene copolymer beads. Additionally, two or more materials can be mixed to provide the filter system of the present invention.
In another preferred embodiment a synthetic carbon material, such as that described in U.S. Pat. No. 5,834,114 entitled "Coated aborsbent fibers", issued Nov. 10, 1998 with Economy, et al. as inventors, the contents of which are incorporated herein by reference, can be coated with the materials of the present invention to provide a porous acidic filter in accordance with the invention.
A detection system and method of use for determining when the filter needs to be replaced by detecting base contaminants in air is described in U.S. Pat. No. 6,207,460 entitled "Detection of Base Contaminants in Gas Samples", issued Mar. 27, 2001 with Oleg Kishkovich, et al. as inventors. Also U.S. Pat. No. 6,096,267 entitled "Detecting of Base Contaminants", issued Aug. 1, 2000 with Oleg Kishkovich, et al. as inventors and U.S. Pat. No. 6,296,806 entitled "Protection of Semiconductor Fabrication and Similar Sensitive Processes", issued Oct. 2, 2001 with Oleg Kishkovich, et al. as inventors can also be used with the present invention. These patents disclose the protection of a DUV lithography processes using chemically amplified photoresists which are sensitive to amines in the air. These patents are incorporated in the present application in their entirety by reference.
A preferred embodiment of a method of fabricating a filter element having a large surface area and the desired flow characteristics involves the use of a powdered material that is deposited in sequential layers one on top of the other. Following the deposit of each layer of powdered material, a binder material is delivered onto each layer of powdered material using a printing technique in accordance with a computer model of the three dimensional filter element being formed. Following the sequential application of all of the required powder layers and binder material to form the part in question, the unbound powder is appropriately removed, resulting in the formation of the desired three dimensional filter element. This technique provides for the fabrication of complex unitary or composite filter elements having high surface area that are formed with a very high degree of resolution.
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a perspective view of the apparatus of this invention before heating and calendaring;
FIG. 2A is a perspective view of the apparatus of this invention after heating and calendaring;
FIG. 2B is a perspective view of the apparatus of this invention after heating and calendaring with a cover sheet;
FIG. 3A is a perspective view of the apparatus of this invention in a square or rectangular containment structure showing the creases of the pleated structure;
FIG. 3B is a top view of the apparatus of this invention showing its pleated structure;
FIG. 4 is a top view of the apparatus of this invention with a high first pass efficiency multi-pleat pack panel filter in a square or rectangular containment structure;
FIG. 5A is a top view of the apparatus of this invention in a radially pleated cylindrical containment structure;
FIG. 5B is top view of the apparatus of this invention in a media-wrapped cylindrical filter; and
FIG. 6 is a perspective view of a process of producing a filter of the invention.
FIG. 7 is a pleated filter made in accordance with the invention.
FIG. 8 is a graphical illustration comprising the base removal efficiency of filters previously available and a filter made in accordance with the invention.
FIG. 9 is a process for fabricating a filter in accordance with a preferred embodiment of the invention.
FIG. 10 illustrates an example of a three dimensional filter fabricated in accordance with the process.
Referring to FIG. 1, a portion of a composite 16 is shown. The composite 16 has a cover sheet 66 and a middle layer 62. In a preferred embodiment, the cover sheet 66 is a polyester non woven having a binder to fiber ratio of 55/44 and a thickness of 0.024 inches. The middle layer 62 is air-laid polyester non woven having a thickness of 0.25 inches and binder to fiber ratio of 35%/65%. The composite is impregnated with a porous acidic polymer material that binds readily with molecular bases in air flowing through the filter.
The structure of FIG. 2A can be used directly in this form as the composite filter element. The composite 16, in a preferred embodiment employs a second cover sheet 80, provided on the surface of middle layer 62, opposite to the first cover sheet 66 backing 12, as shown in FIG. 2B. Alternatively, a second cover sheet 14 a, can be provided over the backing layer 12, as shown in FIG. 2C. The cover sheet can be a filtering or non-filtering non-woven polyester, polyamide or polypropylene material or other similar materials. If the cover sheet is a filtering material, it serves to provide some filtering of the air entering the composite structure for removal of particulate materials in the air stream. The cover can also serve to retain the porous acidic polymer material such as a sulfonated divinyl benzene styrene copolymer, which can be in bead form, within the middle layer or batting 62. The cover sheets can also be chemically inert materials such as polypropylene.
The composite 16, can be contained within any suitable container or frame work for installation in an intended position for filtering operation, typically in the form of a removable or replaceable filter element. For many purposes, it is preferable to increase the surface area of the filter material exposed to an incident air flow, and for this purpose the composite can be pleated to provide the increased surface area.
One embodiment is shown in FIG. 3A, in which the composite material forms an air filter 15 or 17. The filter material is pleated into an accordion like structure 19 as shown in FIG. 3B, contained within a square or rectangular container 18, having a front 21, and back 23, which are open to an air stream shown by arrow 22. The pleating 20 is substantially perpendicular to the air flow. FIG. 3A shows the structure in a front or back view. FIG. 3B shows a cutaway top view of a filter structure.
An alternative embodiment is shown in FIG. 4 wherein a plurality of pleated composite elements 24, are sequentially disposed within container 18, to provide a multi-stage filter through which the air can pass. As in the above embodiment, the pleats 20, of the elements 24, are substantially perpendicular to the direction of air flow 22.
A further embodiment is shown in FIG. 5A, wherein the composite structure 16, is disposed in a cylindrical configuration and retained within a cylindrical container 28. The pleats 20, are as described above, substantially perpendicular to a radially directed air flow. A further embodiment is shown in FIG. 5B wherein the composite structure is wound in a spiral configuration 30, contained within a generally cylindrical container 28.
In a preferred embodiment, adsorbent particles are evenly distributed throughout the non-woven or fiber matrix or polyester batting. An example of an adsorbent particle includes but is not limited to sulfonated divinyl benzene styrene copolymer.
In a preferred embodiment, the ion exchange strongly acidic preliminary catalyst has the important properties including a particle size of between 0.3 and 1.2 mm, a porosity of approximately 0.30 ml/g, and an average pore diameter of 250 Å. The catalyst preferably has a higher porosity of up to 300 ml/g, or, higher. In addition in a preferred embodiment has the properties of concentration of acid sites of approximately 1.8 meq/ml and surface area of 45 m2/g. One such catalyst is sold under the tradename AMBERLYST� 15DRY or AMBERLYST� 35DRY by Rohm and Haas.
Overall, the dry processing of the fiber matrix, which includes the combination of the fluidized bed sulfonated divinyl benzene styrene copolymer deposition process, the inherent stratification of the batting's density, and the even distribution of the sulfonated divinyl benzene styrene copolymer particles as well as stratification of the sulfonated divinyl benzene styrene copolymer particle size, allows for a fabric architecture having an increased bed depth at a very low pressure drop, which is highly desirable due to its high first pass efficiency coupled with its low operating cost.
The term "efficiency" as employed herein is defined by the formula X-Y/X wherein X is the upstream concentration of pollutant, and Y is the downstream concentration of pollutant.
It is recognized that the filter can have a mix of an activated carbon and the preliminary catalyst material discussed above. This combination has sufficient porosity and strongly acidic groups to provide easy permanent removal of medium and strong bases and sufficient retention of weak bases from the airborne base contaminants. The filter can also include a porous polymer material.
The filter as described is employed in filtering the air in environments such as semiconductor fabrication systems where there is a requirement for uncontaminated air of high quality.
Referring to FIG. 6, the middle air-laid polyester non woven lay 62 is collated to a cover sheet 66. The adsorbent particles 60 are positioned on a fiber matrix 62 from a fluidized bed 64. The sulfonated divinyl benzene styrene copolymer particles 60 are evenly stratified throughout the depth of the batting 62. As discussed above, an increased bed depth of adsorbent particles distributed throughout the batting is highly desirable as it increases residence time, increases exposure of the adsorbent particle surfaces, provides a low pressure drop, as well as substantially increasing the lifetime of the filter.
The adsorbent particles 60 distributed in the matrix 62 are then heated, preferably using two zones 68, 70 of infrared energy at different wavelengths. The batting 62 is heated to an overall average temperature of between 250� and 350� F.
The infrared energy causes the adsorbent particles to adhere to the batting at points where the particles contact the batting. This procedure avoids the necessity of raising the temperature of the entire batting to a point at, or near, the melting point of the polyester batting, which could cause the batting to melt and collapse thereby encasing the particles and destroying their chemical activity.
The batting 62 is then calendared using a pair of calender rolls 76,78. The first of these rolls 76 (Heated Steel Roller) can be temperature controlled which allows the heating and calendering steps to be carried out at a steady temperature of around 140�, and prevents overheating and subsequent melting of cover sheet and prevents over calendering of the fabric. The second roll, roll 78, is a rubber roll having a durometer that avoids crushing of the adsorbent particles.
In FIG. 6, Middle Layer (62) can have the following specifications: Air-Laid Polyester Non Woven 100% 15 Denier Fiber. The Binder consists of a Fiber Ratio of 35% to 65%, Binder to Fiber. The weight is 6.5 oz. per linear yard at a 52 inch width. The thickness is 0.25 inches.
The cover sheet (66 and 80) can have the following specifications: Polyester Non Woven 100% 2.25 Denier Fiber. The Binder consists of a Fiber Ratio of 55 g/45 g. The thickness is 0.024 inches and the weight is 1.75 oz./yd2.
Furthermore, when the temperature controlled roller 76 is used, the pressure at which the batting is 2000 pounds across the 26 inch distance. Higher calendaring pressures can crush the particles particularly when those particles are activated carbon based, thereby forming dust, which cannot be retained in the filter composite and can consequently pass into the gas stream.
In addition, a synthetic non-woven cover sheet 80, which helps to maintain the sulfonated divinyl benzene styrene copolymer in the batting, may be calendared with the batting 62, as discussed above. After the filter is formed, gussets or spacers are placed in the filter. The filter is sealed into a metal box.
Optionally, the material may be conducted over an upper roller 84 to facilitate cooling the material prior to further processing. The method of manufacture for an activated carbon filter is described in detail in U.S. Pat. No. 5,582,865 titled "Non-Woven Filter Composite". The entire contents of this patent is incorporated herein by reference.
While the above described method is a preferred method of creating the filter, it is recognized that other techniques can be used. Some of these techniques include those developed by Hoechst such as that described in U.S. Pat. No. 5,605,746, the entire contents of which is incorporated herein by reference or KX Media. The common feature in all these methods are the incorporation of a chemically active sorbent into a porous media structure.
A pleated filter structure 220 using the porous acidic polymer of the present invention is illustrated in FIG. 7. This is a pleated system open on both sides of a rectangular frame 228 with a length 222, width 224 and depth such that it can be used as a replacement filter in stack filter systems. The filter has a removal efficiency of over 99% at 1000 ppb.
FIG. 8 graphically illustrates the removal efficiency for three different filters. The graphs represent removal efficiency as a function of time at 20 ppm of NH3 concentration upstream from the filter. Filter size is ˜12″�12″�6″. Air flow is ˜100 cfm. Considering service life data only, it appears that filter #3 performed best. However, if additional data is considered, the conclusion is not so simple. Pressure drop of filter #1 was 0.2″ WC; for filter #2 was 0.3″ WC; and for filter #3 was 1.0″ WC. Filters #1 and #2 are very close to tool manufacturer's specifications, but #3 creates an excessive pressure drop that interferes with tool's proper ECU functioning. Excessive pressure drop is undesirable for multiple reasons. For example, it increases fan load and power consumption, reduces airflow through the tool and positive pressure inside the enclosure. Thus filter #1 made in accordance with the present invention provided a substantial improvement in service life while providing a pressure drop that is compatible with tool operation.
Another preferred embodiment of the invention involves the fabrication of high surface area filter elements using a three dimensional printing technique as described in U.S. Pat. Nos. 5,204,055, 5,340,656, and 5,387,380, the entire contents of these patents being incorporated herein by reference.
Such a method of fabrication of a filter element is illustrated in connection with FIG. 9. The process 200 includes forming a three dimensional model 202 of the filter element such that the dimensions are well defined. The first layer of the powder material used to form the filter is placed 204 the printer apparatus. A binder is then delivered 206 onto the powder material resulting in the binding of selected regions thereof. Steps 204 and 206 are repeated a number of times until the high surface area filter is formed. Finally, the excess material is removed 210. An illustrative example of a high surface area filter made in accordance with this method is shown in the example 240 of FIG. 10. The binder can be an acid polymerizable or acid cross linkable liquid.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Patent Citations
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Couple tied the knot on June 28.
Country On a Can
The Vietti Chili company is offering country acts the chance to appear on its labels.
The company produces at least 150,000 cans of chili per label design, which are shipped to stores in more than 30 states. The "Vietti Vinyl" campaign gives artists the chance to grace those labels and to offer downloads from the viettivinyl.com website. Acts featured in the past include Heartland, Restless Heart, The Warren Brothers and Chris Young. Interested artists are asked to call (615) 777-6995, extension 30, for information about being a part of the program.
More News
"Trisha Yearwood: The Song Remembers When" opens to the public July 3.
Song will also appear in commercials for Greater Texas Ford Dealerships during July.
Dierks Bentley, Luke Bryan, Brad Paisley and Others Bring Country to New York at FarmBorough Festival
Country music is alive and well in NYC.
Sharing life's joys and struggles with his fans is important to Jake.
Seventh annual concert series kicks off Sept. 30.


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How did three Danes end up being tortured in Lebanon?
Saving Afghanistan's archaeological sites
21 Feb 2011 03:30 GMT | Sport, Football
Claudio Ranieri resigned as coach of troubled Roma following their shock 4-3 loss at Genoa on Sunday in a match they had led 3-0.
"I have always thought about the good of Roma," he was quoted as saying by ANSA news service.
"After a game like that today, I think it is right to give a signal. At the final whistle I went into the dressing room to thank the team and I have decided to resign."
Cash-strapped Roma, who are in the process of being sold, lost 3-2 at home to Ukrainians Shakhtar Donetsk in the Champions league last-16 first leg on Wednesday.
Around 200 fans protested at Roma's training ground on Saturday, throwing flares and firecrackers at the gates before being dispersed by police.
Roma produced a stunning run to finish second in Serie A last term in Ranieri's first season in charge after taking over from Luciano Spalletti.
They now lie eighth and have not won in five games in all competitions.
Rome-born Ranieri has also had a difficult relationship with club captain Francesco Totti, who has played for Roma his whole career and is regarded by fans as the heartbeat of the club.
American consortium Di Benedetto is in talks to buy the club and reports had said they might look to replace the former Atletico Madrid, Chelsea, Valencia and Juventus coach in any case, with current Chelsea manager and Roma fan Carlo Ancelotti touted.
Retired former Roma striker Vincenzo Montella could take over in a caretaker role but it is unclear who would make the decision given the club's circumstances.
Rosella Sensi remains the president until the club is bought but creditor bank UniCredit has been in de facto control for months as it looks to recoup debts from a sale which has dragged on and stopped Ranieri buying players in January.
However, the club hierarchy were already pondering Ranieri's position before he resigned.
"We want to think about things calmy. We will make a decision with our head," director Gian Paolo Montali told reporters straight after the Genoa game.
Source: Reuters
Roma coach Claudio Ranieri stands firm despite fan protests over the team's recent performances.
Politics, Sport, Football
Two late goals snatch 2-1 win over Barcelona in the first leg of Champions League last-16 clash at Emirates Stadium.
Sport, Football
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Changing climate, unpredictable rains dry out the land, threaten the pastoral way of life in Somaliland.
Poverty & Development, Environment, Africa
Tensions rise as Greeks from both side of the bailout debate take to the streets to withdraw money and express angst.
Politics, Europe, Greece
The world's biggest producer and consumer of the metal sees a golden opportunity to expand its pricing power.
Business & Economy, Asia, China
Normalised Cuba-US relations could result in a hybrid economic model blending socialism and entrepreneurial spirit.
Business & Economy, Communism, Politics
Rival sides of Greece's debt debate rally days before voters are to decide on whether to reject creditors' conditions.
Politics, Business & Economy, Europe, Greece
Nigerian president under pressure to act as string of bloody attacks hit northern towns, killing more than 160 people.
War & Conflict, Humanitarian crises, Africa, Nigeria, Boko Haram
After decades of tension and hostility between the two nations, has change finally come to US-Cuba relations?
As the Baku games close, we examine the challenges facing journalists; plus, Angola, Portugal and 'reverse colonialism'.
Media, Europe, Azerbaijan
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The ICC chief prosecutor discusses Sudan's president escaping justice in South Africa and alleged war crimes in Gaza.
Politics, ICC, South Africa


text:
The touch of irony was there for all to see.
Mike D'Antoni embraced the "Showtime" concept when he took the Lakers coaching job two years ago, saying he would love to employ the fun-and-run style that made them champions five times in the 1980s.
But Byron Scott, an actual member of three of those teams, went a different way at his introductory news conference Tuesday.
"We can't play that way. We don't have a Magic Johnson," said the new Lakers coach.
He wasn't kidding.
Despite the reality check of an aging roster recently filled with two discards from other teams, Tuesday was a feel-good day for the Lakers.
Scott was blunt and to the point but also somehow refreshing, a touch with yesteryear the franchise needed, even if it lasted only a short time.
Not long after his news conference was hijacked by supportive and light-hearted comments from Magic Johnson, Kareem Abdul-Jabbar and Jamaal Wilkes, Scott added a bit of reverence.
"The only thing I regret is that Dr. [Jerry] Buss isn't here today," he said. "He's somebody that showed a lot of love and confidence in me back in the day, and a guy that you could call any time and you could talk to him about anything. Like basketball, money, anything."
Scott, 53, said he would try to make his former teammates proud, as well as the Buss family.
And he wanted very little to do with pushing the pace on offense, saying he would run a hybrid of schemes, which in the recent past included mostly high screen-and-rolls.
There will also be a reliance on defense, Scott promised.
"The first thing that Magic taught me when I got in this league is that we win championships by defending every single night," Scott said. "Offense is going to come and go. You're going to miss shots, you're going to make shots. But the one thing you control every single night is your effort on the defensive end. So we have to obviously get that back in the plans."
It's a noble concept, especially for a team that allowed 109.2 points a game, 29th out of 30 NBA teams, last season.
Scott even threatened those that don't defend.
"They don't do it, I'll take them out of the game," he said. "The only thing that you can really control with players is their minutes. That gets their attention."
Barely touching on a team that finished 22 games out of a playoff spot last season, Scott looked ahead to the first day of training camp in the coming months.
He also didn't want to see smiling faces and locker-room fun after a loss: "It should hurt," he said.
The coaching search took almost three months — Mike D'Antoni resigned April 30 and Scott officially was hired Monday.
He got the news of his hire while traveling in the Bahamas, a vacation he jokingly said he needed not because of an excruciatingly long wait but because of all the probing queries from fans.


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Tiwa Savage's BFF Elohor Aisien Confirms Pop Star Is Expecting A Boy!
Yesterday Tiwa Savage's baby shower went down on Femi Otedola's yacht in Victoria Island, Lagos and for the nautical themed event, the mummy to be and all her friends rocked white and blue sailor hats. [READ HERE IF YOU MISSED IT]
During the fun event, her BFF of 17 years, event planner Elohor Aisien made it known that Tiwa is expecting a boy. She shared a picture of herself with Tiwa and wrote in the caption,


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For those of us who didn't make 1600 on our SAT's the wordELEEMOSYNARY means: of, relating to, or supported by charity. The word choice is not only applicable but also particularly fitting. The Orange County elites would consider it "charitable" to inform the lesser voting public about the high minded desires behind the tax increase. It is ironic, though, that the "alms" will be taken rather than given.
I hope they have the good sense not to replicate Chapel Hill's banana-republic crimes against democracy, but rather put some teeth into the current laws banning the use of public funds for political campaigns. There needs to be a quick and easy process by which citizens may request an immediate injunction against this garbage, with severe penalties levied against officials who defy the injunctions.


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Ask Better Homes & Gardens
Experts and BHG readers answer.
Expertssee all experts
rabbit and squirrel pests
What can I do to keep away these cute pests out of my garden? They even dig under my fences to get at the garden. I grow organic. I am thinking about making box beds. Any other ideas?
To keep rabbits from digging under the fence, you should bury a portion of the fence 6 inches under ground with a section extending outward 6 to 12 inches. The upright portion of the fence needs to extend at least 18 inches aboveground. And the mesh in the fence should be no larger than 1 inch in diameter.
Squirrels, of course, can climb over a fence, so they are more difficult to control. You might be able to thwart them by covering your plantings with floating row cover anchored on the edges until plants become established.
There are some organic rabbit and squirrel repellents available, such as garlic, hot pepper, and cinnamon.
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Stone Roses' Second Coming
Channelling artistic inspiration is, for many great musicians, not something that can be switched on and off. However waiting five and a half years to record the follow-up to your groundbreaking, culturally significant debut album is akin to commercial suicide - especially when said album dismantles the perfect pop formula you had cultivated in favour of extended guitar breaks and 'funky' rhythms. The Second Coming got a somewhat inevitable 'mixed reception' and before long the once indestructible Stone Roses were disintegrating. Key members left the band, concert dates were cancelled, with events coming to a head as fans booed and threw objects onstage during a disastrous performance at the Reading Festival in 1996. The Stone Roses split two months later.


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Would you be willing to answer a few brief questions about PlayStation Forums?
Batman: Arkham Knight — Tips and Tricks
[RESOLVED] [6/19/2015] PlayStation Store Connectivity Issues
DEV POST: Servers are back up folks!
Should I Buy These Games? Any Alternatives I Should Pick?Icaraeus
Arkham Knight: I collected all Riddler trophies and did every riddle?Cyclone_Dash
Batgirl: A Matter Of Family DLC Release DateItsJustEmman


text: We're sorry, Big Sister Matchbox Mouse is no longer available Why not try one of these instead? Miniature Wooden Noah's Ark Gift Set by The Chic Country Home £28$58.60€40.68$45.56 Magical Fairy Door by Not Before Tea £19.95$41.75€28.98$32.46 My Pink Fairy Door by cheeky elephant £23$48.14€33.42$37.43 20% OFF Dotty Tea Set by birdyhome £22$46.05€31.96$35.80 £17.60$36.84€25.57$28.64 can be personalised Big Sister Matchbox Mouse by The Chic Country Home £22.95$48.03€33.34$37.34 7 customer reviews(7) This item is no longer available free gift wrap This item is not available for delivery to United States. we're sorry we're sorry, This item is no longer available buy a gift voucher related categories baby & child > toys & games > pretend play & dressing up > play scenes baby & child > toys & games > soft toys & dolls baby & child > woodland trend by The Chic Country Home Location: Notts, GB read seller's profile see seller's complete range more items from this seller Baby Girl Or Boy Matchbox Mouse £13.95$29.20€20.27$22.70 Little Vintage Floral Suitcase Set £25$52.33€36.32$40.68 Little Sister Mouse In A Matchbox £18.95$39.66€27.53$30.83 20% OFF Heart Wreath Jewellery Or Trinket Box £25$52.33€36.32$40.68 £20$41.86€29.06$32.54 Miniature Wooden Noah's Ark Gift Set £28$58.60€40.68$45.56 Christening Baby Rabbit £21$43.95€30.51$34.17 view all you may also like PRODUCT DETAILS CUSTOMER REVIEWS DELIVERY RETURNS free gift wrap ask seller a question save for later A wonderful addition to our ever popular matchbox mice collection. New Design Available... Description and images to be updated 14.03.2015 A wonderful big sister mouse who looks so gorgeous dressed in her pretty pink polka dot skirt. She comes in her own little matchbox bed, which even has her image on the front. The matchbox bed comes complete with a cotton mattress, floral pillow and pink knitted blanket. A truly wonderful gift for children or adults. Skirt can be removed. Set includes: one big sister mouse wearing a skirt, matchbox bed, mattress, pillow and blanket. made from: The mouse is made from cotton. Cream sturdy card matchbox. dimensions: Size: Mouse: Height: 14cm from the tops of their ears to the tips of their cute little toes. Matchbox Bed: Height: 5cm, Length: 14cm, Width: 8cm product code: 162874 7 customer reviews Thu 27 Feb 2014 Excellent service Thu 09 Jan 2014 Cute, perfect for young children Mon 06 Jan 2014 Absolutely gorgeous, my daughter loves hers! Sat 04 Jan 2014 Very popular present Sat 19 Oct 2013 Lovely present,very good quality a very special gift. Fri 19 Jul 2013 Excellent quality and well-loved. Tue 04 Dec 2012 Gorgeous product, beautifully made with such attention to detail. Worth every penny. see all customer reviews hide some customer reviews read about our product rating system ratings guide trusted independent customer feedbackforum excellent bad good poor This product is dispatched to you by The Chic Country Home. MAINLAND UK order now and receive this item on or before price Standard Delivery Monday 13 July £2.75$5.75€3.99$4.47 Express Next Day 1pm Tuesday 7 July £9.70$20.30€14.09$15.78 NON-MAINLAND UK estimated delivery price Northern Ireland 2-5 working daysfrom dispatch £2.75$5.75€3.99$4.47 Other UK Islands 2-5 working daysfrom dispatch £4.95$10.36€7.19$8.05 INTERNATIONAL DELIVERY estimated delivery price Not currently available for this region You have 28 days, from receipt of cancellable goods, to notify the seller if you wish to cancel your order or exchange an item. Please note: goods that are personalised, bespoke or made-to-order to your specific requirements, perishable products and personal items sold with a hygiene seal (cosmetics, underwear) in instances where the seal is broken are non-refundable, unless faulty. Read more about our returns policy.Should you choose to return or exchange your order you will need to deliver the item(s) to the UK, where this seller is based. The Chic Country Home's return policy


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2003 Dodge Ram 1500 Q&A
2003 Dodge Ram 1500 Question: What would cause my Dodge Ram to lock up and not be able to start?
4.7 L V8, recently had factory battery replaced, oil changed, and state inspection done. Only driving since service work was moving it out of the driveway to the curb. Truck has 110K miles, and has had no serious issues or accidents. When you try to start it, truck powers up, radio works, but when you try to start it up, it has a loud clunk and never turns over. Viewing it from under the hood you can see it try, but never turns over. Any help would be greatly appreciated. - Crazy Cajun
2 Answers
Answer 1
There are several possibilities. 1. The engine is locked up - try to turn the engine over by hand on the crankshaft bolt 2. The starter is bad 3. An accessory is locked up - alternator, PS pump, A/C compressor remove belt and check all accessories turn freely - Chevy Power
Answer 2
Did you personally check the oil level since the service? Make sure it has oil , a drain plug (not leaking or missing)and a filter properly installed and not puking oil.How far away was the shop that did the oil change etc.? Any strange noises or rough running before the no crank issue? - ziptie12
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Real, honest-to-goodness holograms are a thing now
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