Note: Descriptions are shown in the official language in which they were submitted.
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TELESCOPING BOXES, BLANKS, AND SYSTEMS FOR POUR-STYLE BAG-IN-BOX
DISPENSED PRODUCTS
BACKGROUND
[0001] Bag-in-box dispensers provide a user access to dispense liquid
product (e.g., soap, oil,
cleaner, wine, etc.) from a bag that is held within a box. In some cases, a
user accesses a
dispensing valve (e.g., opening, nozzle, tap, etc.) on the bag (often
extending through a hole in
the box) to dispense liquid from the bag, while the majority of the bag is
stored within the box.
Conventional box designs for bag-in-box dispensers include a corrugated box
that is designed to
be shipped on a pallet in an upright orientation (e.g., with other like
boxes/product). Then, each
bag-in-box product is taken off the pallet for use and/or stocking on a shelf
for sale. Notably,
shipping and handling under such circumstances puts predictable and largely
unidirectional
stress on the box such that box designs can afford to be limited while still
maintaining the box
and bag stored inside in working order through distribution to the final
destination. For example,
the strength characteristics for the box can be designed with the knowledge
that the box will only
be shipped in the upright orientation.
BRIEF SUMMARY
[0002] Embodiments of the present invention are directed to corrugated box
designs that are
designed to withstand the individual e-commerce shipping environment, which
includes the same
shipping and handling that occurs for other types of boxes in this environment
(e.g., throwing the
boxes, dropping the boxes in all orientations, vibration within a transport
vehicle with weight
stacked on top). Importantly, in the individual e-commerce shipping
environment, there is no
predictable orientation for the box design, and all of the above (and other)
circumstances occur in
all orientations. Thus, while prior box designs for bag-in-box dispensers
could predict their
orientation (e.g., upright) and had the benefit of relatively
safe/professional handling and
transfer, the present invention takes into account all of those uncertainties
and likely occurrences
to still deliver an intact box to the final destination.
[0003] For bag-in-box products, it is very important to keep the box (and
any perforations)
intact during shipping because otherwise the liquid product in the bag may
spill out if the bag
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breaks, rips, or tears, as the bag is more susceptible to breaking and/or
leaking if the box is
compromised/weakened. That situation is of extra concern because spilled
liquid can cause
significant damage to other boxes or transportation equipment (e.g., trucks,
conveyors,
warehouse flooring, etc.) during shipping and is difficult to clean (e.g., in
comparison to non-
liquid products being shipped). In this regard, the box designs of the present
invention are
engineered to withstand and pass various standardized distribution sequences
that are specifically
designed to replicate harsh conditions that a box goes through during
individual e-commerce
shipping (e.g., through various known consumer-based shipping services). Such
example safety
test standards include the International Safe Transit Association (ISTA) test
standards, including
the Ship In Own Container (SIOC) test protocols. In such a regard, the
resulting box designs of
the present invention are the product of significant testing, as many other
designs were
disregarded after failing such tests.
[0004]
Embodiments of the present invention provide example box designs for safely
and
successfully transporting a bag of liquid and still enabling conversion into a
bag-in-box
dispenser, where the bag-in-box dispenser is designed to enable pouring of the
liquid product
therefrom. For example, a user may be able to hold the box (now converted into
the bag-in-box
dispenser), tip it, and pour the liquid out from a dispensing valve that
extends through a front
wall of the box. Such example liquid includes floor cleaner, wine, juice,
coffee, among other
liquids that can be poured. Notably, the various box designs described herein
are designed to
hold a bag of liquid with volume ranging from 2 liters to 10 liters (though
other ranges are
contemplated) and/or a weight ranging from approximately 5 lbs. to 25 lbs.
(though other ranges
are contemplated). In some embodiments, such box designs may utilize
telescoping half-slotted
containers (HSCs), although embodiments of the present invention are not meant
to be limited to
such a box design. In this regard, notably, embodiments of the present
invention provide a box
design with various features that are designed to aid in safe transport of the
stored bag, while still
providing for the conversion into a useful bag-in-box dispenser at the point
of intended product
usage.
[0005] To
achieve such a goal, some embodiments of the present invention provide a box
design with a top portion and a bottom portion. The top portion includes a
perforation feature
defined on the front wall, wherein the perforation feature is defined by a
series of perforations
and is removable from a remainder of the front wall. The perforation feature
is configured to
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enable a dispensing valve of the bag to extend past or through the front wall
of the top portion
when the box is converted into the bag-in-box dispenser. The bottom portion
includes a cut-out
feature in the front wall that aligns with the perforation feature. The cut-
out feature may be
shaped to hold a dispensing valve (e.g., opening) of the bag once the bag-in-
box dispenser is
converted. In this regard, upon arrival at the final destination, a user may
remove the perforation
feature, lift up the top portion (e.g., slightly) from the bottom portion and
arrange the dispensing
valve into the cut-out feature, and then reposition the top portion over the
bottom portion so as to
convert the box into the bag-in-box dispenser with the dispensing valve
available for use (e.g.,
for pouring out liquid from the bag). Various additional features, such as a
second perforation
feature and corresponding handle on the back wall, finger access portions,
positioning of a side
flange, among others described herein, are contemplated for some embodiments,
and may aid in
providing safe transport of the stored bag, while still providing for easy
conversion into a useful
bag-in-box dispenser upon arrival at the final destination.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0006] Having thus described the invention in general terms, reference will
now be made to
the accompanying drawings, which are not necessarily drawn to scale, and
wherein:
[0007] FIG. 1 shows a front, top perspective view of an example corrugated
box, in
accordance with some embodiments discussed herein;
[0008] FIG. 2 shows a rear, top perspective view of the example corrugated
box shown in
FIG. 1, in accordance with some embodiments discussed herein;
[0009] FIG. 3 shows a front, top perspective view of a bottom portion of
the example
corrugated box shown in FIG. 1, in accordance with some embodiments discussed
herein;
[0010] FIG. 4 shows a rear, top perspective view of the bottom portion of
the example
corrugated box shown in FIG. 1, in accordance with some embodiments discussed
herein;
[0011] FIG. 5 illustrates a layout of a box blank for the example
corrugated box shown in
FIG. 1, in accordance with some embodiments discussed herein;
[0012] FIG. 6 illustrates an example method of converting an example
corrugated box into a
bag-in-box dispenser, in accordance with some embodiments discussed herein;
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[0013] FIG. 7 shows a front, top perspective view of the example corrugated
box shown in
FIG. 1, wherein a first perforation feature has been removed, in accordance
with some
embodiments discussed herein;
[0014] FIG. 8 shows a rear, top perspective view of the example corrugated
box shown in
FIG. 1, wherein a second perforation feature has been removed, in accordance
with some
embodiments discussed herein;
[0015] FIG. 9 shows an example top portion of a corrugated box displaced
above an example
bottom portion of the corrugated box, wherein the first and second perforation
features have been
removed, in accordance with some embodiments discussed herein;
[0016] FIG. 10 shows a front, top perspective view of the example
corrugated box shown in
FIG. 7, wherein the top portion has been lifted up from the bottom portion and
a dispensing
valve of a bag stored within the box is accessible for positioning in a cut-
out feature of the
bottom portion, in accordance with some embodiments discussed herein;
[0017] FIG. 11 shows a front, top perspective view of the example
corrugated box shown in
FIG. 10, wherein the dispensing valve has been positioned into a dispensing
position and the top
portion has been slid back over the bottom portion to convert the box into the
bag-in-box
dispenser, in accordance with some embodiments discussed herein;
[0018] FIG. 12 shows a rear, top perspective view of the example corrugated
box shown in
FIG. 11, wherein the box has been converted into the bag-in-box dispenser with
an available
handle feature for use, in accordance with some embodiments discussed herein;
and
[0019] FIG. 13 illustrates a flowchart of an example method of forming a
box, shipping the
box with a bag stored therein, and converting the box into the bag-in-box
dispenser, in
accordance with some embodiments discussed herein.
DETAILED DESCRIPTION
[0020] Some example embodiments now will be described more fully
hereinafter with
reference to the accompanying drawings, in which some, but not all example
embodiments are
shown. Indeed, the examples described and pictured herein should not be
construed as being
limiting as to the scope, applicability or configuration of the present
disclosure. Rather, these
example embodiments are provided so that this disclosure will satisfy
applicable legal
requirements. Like reference numerals refer to like elements throughout.
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[0021] Notably, while some embodiments describe various positional
qualifiers for various
features, such as "top", "bottom", "front", "back", "side", etc. embodiments
described herein are
not meant to be limited to such qualifiers unless otherwise stated. Along
these lines, and as an
example, the "top" portion is also contemplated to be a "bottom" portion
depending on the box
design/orientation or a "front" wall may be a "side" wall depending on the box
design/orientation. The directional qualifiers herein are generally used to
aid in describing the
invention in the context of the drawings and/or description but are not
otherwise intended to be
limiting.
[0022] While some embodiments describe a "user", use of such a term herein
is not meant to
be limited to a person or a single person, as the "user" may be an end user, a
consumer, a
manufacturer, among other types of users along a supply chain in relation to
the box design.
Further, when utilizing the word "user", the actor(s) may be operating one or
more
machines/system that cause the intended function (e.g., forming the box or
converting the box to
a bag-in-box dispenser).
[0023] Various example embodiments of the present invention provide example
box designs
for safely shipping a bag of liquid and still enabling conversion into a bag-
in-box dispenser from
the shipped box, where the bag-in-box dispenser is designed to enable pouring
of the liquid
product therefrom. For example, various box designs described herein are
designed to hold a
bag of liquid with volume ranging from 2 liters to 10 liters (though other
ranges are
contemplated) and/or a weight ranging from approximately 5 lbs. to 25 lbs.
(though other ranges
are contemplated). Some examples of possible liquids that may be shipped in
such quantity
include various cleaners and washing liquids, such as may be poured onto a
surface or into bin or
other receptacle from the bag-in-box dispenser. However, other example liquids
include wine,
juice, or any type of liquid that would benefit from being poured from the bag-
in-box dispenser.
Along these lines the term "liquid" used herein may refer to any type of
substance in liquid state
(e.g., fluid, creams, lotions, gels, water, etc.).
[0024] In some embodiments, such box designs may utilize a version of a box
design called a
telescoping half-slotted container (HSC), although embodiments of the present
invention are not
meant to be limited to such a box design. Other example box designs include
regular slotted
containers, wraparounds, overlapping slotted containers, die-cut containers,
among others.
Various embodiments described herein provide one or more features that alone
or in combination
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with each other provide a suitable box design for providing safe transport of
the stored bag,
while still providing for easy conversion of a useful bag-in-box dispenser
upon arrival at the final
destination.
[0025]
Notably, example box designs of the present invention are designed to
withstand and
pass various laboratory distribution tests that are specifically designed to
replicate harsh
conditions a box goes through during individual e-commerce shipping (e.g.,
through various
known shipping services). Such example safety test standards include the
International Safe
Transit Association (ISTA) test standards which includes Ship In Own Container
(SIOC) test
standards, such as the ISTA Series 6-Amazon.com-SIOC test protocol (i.e., the
ISTA Series 6-
Amazon.com-SIOC test for 2018, with a version date with a last technical
change in March 2018
and a last editorial change in March 2018 ¨ where further details are
available at ista. orL).
Based on the packaging weight and/or girth, the box may need to undergo an
appropriate Type
test (e.g., Type A for under 50 lbs. or Type B for over 50 lbs.). For example,
the test standards
require that the box be packaged as planned to be shipped and be put through a
testing protocol
that includes numerous drops from various heights with the box falling on
different sides (e.g.,
walls, faces) and edges. This simulates possible drops that may occur during
handling by
shipping personnel. Next, the same box undergoes vibration testing that
includes prolonged
vibration (e.g., for 2.5 hours, although other durations are contemplated)
with weight placed on
top of the box ¨ again at specified orientations (often required to be on the
"weakest" face, e.g.,
an orientation which the corrugated flutes are not vertically oriented
relative to the applied
compression forces). This simulates travel within a transport vehicle (e.g.,
an airplane, train,
truck, van, etc.) with other boxes being stacked on top of it. Finally, the
same box then goes
through more drops of varying height and on varying sides, corners, or edges,
with one of the last
drops being at a greater height and on the "weakest" side or edge. This once
again simulates
possible drops that may occur during handling by shipping personnel. Depending
on the desired
outcome, the box may need to pass certain test criteria in order to pass the
tests. Notably, the
ISTA Series 6-Amazon.com-SIOC test protocol acceptance criteria includes (i)
the product is
fully functional in its intended use, (ii) there are no leaks, (iii) any
tamper evidence application is
not compromised (e.g., seal integrity is intact), and (iv) any secondary
packaging that is
considered part of the product is free from serious
damage/indentations/scratching.
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[0026] The box may be designed to pass the ISTA Series 6-Amazon.com-SIOC
test protocol
or other shipping test protocol (e.g., to be able to ship using individual
shipping options ¨ such as
the mail, truck delivery, etc.), and also maintain certain form standards that
enable it to be
converted into the bag-in-box dispenser upon reaching its final destination.
In this regard, the
box should survive (e.g., withstand) the entire test process while maintaining
a desired form such
that the flaps and any perforation features are intact, and with the bag
maintained within the box
without liquid spilling/leaking therefrom, such that the box may be converted
into a functioning
bag-in-box dispenser as intended. In some embodiments, the box may be
considered to maintain
a desired form even with some flexing, but without an undesirable degree of
bulging, such as
may include significant changes in the shape of the box to limit its function
(e.g., cause
perforations to tear or release prematurely, cause flaps to tear or open,
cause adhesive joints to
fail or open prematurely, cause the box to no longer fit in a designated spot
at the final
destination (e.g., in a storage rack or storage position) or be suitable for
stacking or supporting
additional loads (e.g., on top of the box), prevent full evacuation of the
liquid in the bag, cause
decreased overall rigidity or integrity of the box to hinder transportation or
manipulation of the
box). In such a regard, the resulting box designs of the present invention are
the product of
significant testing, as many other designs were disregarded after failing such
tests.
[0027] An example corrugated box 10 that accomplishes such advantages,
including passing
the above noted test standards, is shown in FIG. 1. With reference to FIGs. 1-
4, the corrugated
box 10 is formed of a top portion 20 and a bottom portion 30 (an example top
portion 20 and
bottom portion 30 are further shown displaced relative to each other in FIG.
9).
[0028] The top portion 20 comprises four walls (e.g., faces): a front wall
22, a back wall 24,
and two opposing side walls 26, 28. Corresponding panels (e.g., a front panel
22', back panel
24', a first side panel 26', and a second side panel 28') can be seen in the
box blank form of the
top portion 20' shown in FIG. 5. In this regard, the term "panels" may be used
when in box
blank form and the term "walls" may be used when in the erected/formed box
form. As shown,
the top portion 20 also includes a side flap 25 (notably, the side flap 25 may
be attached to any
suitable wall/panel depending on the desired box design). To form the box top
portion 20 shown
in FIG. 1, the side flap 25 may be attached, such as using adhesive (although
additional or
alternative attachment means can be utilized, such as tape, staples, etc.), to
the back wall 24
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(although other walls can be used depending on the arrangement of the box
blank). When
formed, the top portion defines an opening 42 (shown in FIG. 9).
[0029] With further reference to FIG. 5, the top portion 20 also includes
top flaps 27a, 27b,
29a, 29b that each extend from corresponding panels 22', 24', 26', 28'. In
particular, a top front
flap 27a extends upwardly from the front panel 22'; a top back flap 27b
extends upwardly from
the back panel 24'; a top first side flap 29a extends upwardly from the first
side panel 26'; and a
top second side flap 29b extends upwardly from the second side panel 28'.
Returning to FIG. 1,
the top flaps of the top portion 20 fold from their walls to form a top 87. In
this regard, the top
first side flap 29a and the top second side flap 29b may fold underneath the
top front flap 27a
and the top back flap 27b, and the edges of the top front flap 27a and the top
back flap 27b may
meet together or close together, forming a flap gap 82. Although shown at a
mid-point along a
width of the top 87, the flap gap 82 may be positioned anywhere along a width
of the top 87
(e.g., closer to one side or the other). Likewise, the box design may be
formed to include
overlapping top or bottom flaps. One or more pieces of tape 80 may extend
across the flap gap
82 to form the top 87 (although additional or alternative attachment means can
be utilized, such
as adhesive, staples, etc.).
[0030] The bottom portion 30 comprises four walls (e.g., faces): a front
wall 32, a back wall
34, and two opposing side walls 36, 38. Corresponding panels (e.g., a front
panel 32', a back
panel 34', a first side panel 36', and a second side panel 38') can be seen in
the box blank form
of the bottom portion 30' shown in FIG. 5. As shown, the bottom portion 30
also includes a side
flap 35 (notably, the side flap 35 may be attached to any of the walls/panels
depending on the
desired box design). To form the box bottom portion 30 shown in FIGs. 3-4, the
side flap 35
may be attached, such as using adhesive (although additional or alternative
attachment means
can be utilized, such as tape, staples, etc.), to the outside of the back wall
34. When formed, the
bottom portion defines an opening 43 (shown in FIG. 3) that is sized to
receive and store a bag,
such as a bag of liquid of volume ranges from 2 liters to 10 liters. Notably,
by attaching the side
flap 35 to an outside surface of one of the walls, the side flap (which
contains a rough corrugated
edge) is separated from the stored bag held within the opening 43 of the
bottom portion 30 so as
to avoid damage to the stored bag during shipping. Of further note, the bottom
portion 30 is
sized to be received by and fit within the opening 42 of the top portion 20.
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[0031] With further reference to FIG. 5, the bottom portion 30 also
includes bottom flaps
37a, 37b, 39a, 39b that each extend from corresponding panels 32', 34', 36',
38'. In particular, a
bottom front flap 37a extends downwardly from the front panel 32'; a bottom
back flap 37b
extends downwardly from the back panel 34'; a bottom first side flap 39a
extends downwardly
from the first side panel 36'; and a bottom second side flap 39b extends
downwardly from the
second side panel 38'. The bottom flaps of the bottom portion 30 fold from
their respective
walls to form a bottom. In this regard, the bottom first side flap 39a and the
bottom second side
flap 39b may fold underneath the bottom front flap 37a and the bottom back
flap 37b, and the
edges of the bottom front flap 37a and the bottom back flap 37b may meet
together or close
together along a flap gap that may be covered by one or more pieces of tape
(although additional
or alternative attachment means can be utilized, such as adhesive, staples,
etc.).
[0032] With reference back to FIG. 1, the top portion 20 of the corrugated
box 10 is designed
with a first perforation feature 50. The first perforation feature 50 is
defined by a series of
perforations 55a (e.g., weak points) that help a user with removal thereof,
such that the first
perforation feature 50 is removable from a remainder of the front wall 22 of
the top portion 20.
[0033] As detailed further herein, the first perforation feature 50 is
removable to help convert
the box 10 into a bag-in-box dispenser, such as shown in FIG. 11. In this
regard, a benefit of the
first perforation feature 50 is that it facilitates removal of a portion of
the box 10 to allow a user
to access a dispensing valve 92 (e.g., opening, nozzle, tap, etc.) on the bag
90 that is held within
the box 10 and enable repositioning of the dispensing valve 92 to a dispensing
position, such as
at least partially extending outside of the box 10 (and, thus, accessible by a
user for dispensing
the liquid from the bag).
[0034] In some embodiments, the first perforation feature 50 is aligned
with a cut-out feature
51 of the bottom portion 30 (described below) and forms an elongated shape
that enables a user
to at least slightly lift the top portion 20 from the bottom portion 30 and
access and reposition the
dispensing valve 92. Further, as noted herein, the elongated shape of the
first perforation feature
50 enables sliding of the top portion 20 over the bottom portion 30 even while
the dispensing
valve 92 is in the dispensing position (e.g., shown between FIGs. 10-11).
[0035] In some embodiments, the first perforation feature 50 forms an
elongated shape 54
that extends along a portion of the length of the front wall 22 (e.g., shown
as length LFw). For
example, the first perforation feature 50 may have an elongated shape 54 with
a first perforation
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feature length (LpF) that extends from a position at or above a center
position (e.g., a line
indicating the approximate center of the length of the front wall is shown as
line C) along the
length of the front wall (LFw) toward the bottom edge 23a of the front wall
22. In some
embodiments, the first perforation feature length is greater than a
corresponding length
characteristic of the dispensing valve (e.g., the length of the first
perforation feature may be
greater than the diameter of a nozzle 91 of the dispensing valve 92 ¨so as,
for example, to
enable the nozzle 91 to be pulled through the opening (e.g., hole) in the
front wall 22
corresponding to the removed first perforation feature 50). In such a regard,
the length of the
first perforation feature 50 may be great enough to enable the top portion 20
to be lifted
upwardly from the bottom portion 30 so that a user can pull the dispensing
valve 92 through an
opening formed in the front wall 22 (e.g., by removal of the first perforation
feature 50). As an
example, the first perforation feature 50 may form an elongated slot type
shape. In this regard,
such as with reference to FIG. 10, a user can slightly lift the top portion
20, access and reposition
the dispensing valve 92 and slightly lower the top portion 20 back onto the
bottom portion 30
with the dispensing valve 92 being maintained within the opening formed by the
removed first
perforation feature 50. In such a regard, the first perforation feature 50
does not need to extend
all the way to the bottom edge 23a of the front wall 22 in order to enable
conversion to the bag-
in-box dispenser.
[0036] However, in the illustrated embodiment, the first perforation
feature 50 extends from
a position 50a on the front wall 22 down to the bottom edge 23a of the front
wall 22. In such
example embodiments, an added benefit is that the top portion 20 can be
completely removed
from the bottom portion 30 for easy repositioning of the dispensing valve 92
into the dispensing
position and is still able to be slid back over the installed dispensing valve
92 that is sticking out
past the front wall 22. In some embodiments, the first perforation feature 50
defines an
elongated shape 54 that may increase in width in a direction leading to the
bottom edge 23a of
the front wall 22 of the top portion 20 to further aid in ease of sliding the
top portion 20 back
over the bottom portion 30 while the dispensing valve 92 is in the dispensing
position.
[0037] In some embodiments, the width of the first perforation feature 50
proximate the
bottom edge 23a of the first wall 22 of the top portion 20 may be sized to
receive one or more
pieces of tape (e.g., see tape 84 shown within the width Pwi of the first
perforation feature 50).
Notably, in some embodiments, the tape may extend underneath the box 10 (e.g.,
along the
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bottom portion 30) and be used to secure the top portion 20 to the bottom
portion 30. In some
embodiments, a second perforation feature 56 (such as described herein) may be
on the back wall
24 of the top portion 20 and have a width Pw2 configured to receive the tape
84. In such
embodiments, a user or machine may remove the first and second perforation
features 50, 56 and
the tape 84. In some embodiments, a user or machine may remove the first
and/or second
perforation features 50, 56 which may result in removal of the one or more
pieces of tape. In
some such embodiments, such removal may enable separation of the top portion
20 from the
bottom portion 30.
[0038] In some embodiments, the first perforation feature 50 may be spaced
apart from a top
edge 22a of the front wall 22 to maintain a desired rigidity, such that may
otherwise be
compromised if one or more perforations (e.g., weak points) were positioned at
or too near the
top edge 22a. For example, a top edge 50a of the first perforation feature 50
may be spaced a
distance of at least 1 inch from the top edge 22a of the front wall (although
other distance ranges
are contemplated (e.g., for boxes with different dimensions), such as at least
2 inches, 3 inches,
etc.).
[0039] Returning to FIG. 1, the top portion 20 may further define a first
finger access feature
52 (further shown in FIG. 6) positioned adjacent to the first perforation
feature 50. The first
finger access feature 52 may be at least partially defined by a series of
perforations 55b (e.g., a
separate series of perforations than the first perforation feature) and may be
removable separately
from the first perforation feature 50 to enable easier access for a user to
remove the first
perforation feature 50. Though the first finger access feature 52 is shown
defined on the front
wall 22, in various embodiments, the first finger access feature 52 may be
formed on one or
more walls or top flaps. Along similar lines, though the first finger access
feature 52 is shown as
a semi-circle, any suitable shape may be used. With reference to FIG. 7, like
with the first
perforation feature 50, a top 79a of the first finger access feature 52 may be
spaced apart from a
top edge 22a of the front wall 22, such as shown by DFAl.
[0040] In some embodiments, the bottom portion 30 of the box 10 may define
a cut-out
feature 51 that further aids in conversion into the bag-in-box dispenser. For
example, with
reference to FIGs. 3 and 5, the bottom portion 30 comprises a cut-out feature
51 that defines an
absent (e.g., pre-removed) portion of the front wall 32 of the bottom portion
30. In this regard,
the cut-out feature 51 may be an area cut-out from the normal rectangular
footprint of the front
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wall 32 of the bottom portion 30 (e.g., in some embodiments the front wall 32
may define a
corresponding modified shape (e.g., modified from a normal footprint of the
wall, such as the
opposing back wall 34) - for example, in such a regard, there need not be a
cut-out that occurs as
the front wall 32 could simply be formed with the modified shape). In the
illustrated
embodiment, the cut-out feature 51 is defined along a top edge 33a of the
front wall 32 of the
bottom portion 30. The cut-out feature 51 is positioned on the front wall 32
of the bottom
portion 30 to align with the first perforation feature 50 of the top portion
20 when the bottom
portion 30 is received within the top portion 20 (e.g., shown upon removal of
the first perforation
feature 50, such as shown in FIGs. 7 and 10). In some embodiments, the cut-out
feature 51 is
configured to enable the dispensing valve 92 to extend past or through the
front wall 32 of the
bottom portion 30 when the box 10 is converted into the bag-in-box dispenser.
Along these
lines, with reference to FIGs. 10-11, in some embodiments, the cut-out feature
51 (or a portion
thereof) defines a shape (e.g., a semi-circle, although other shapes are
contemplated) that
corresponds to a portion 91 of the dispensing valve 92 such that the cut-out
feature 51 at least
partially holds the dispensing valve 92 in position when the box 10 is
converted into the bag-in-
box dispenser. Although shown and described as being pre-removed, in some
embodiments, the
cut-out feature 51 may be removable such as by using a series of perforations
¨ such as may be
similar to the first perforation feature 50 described herein.
[0041] With reference back to FIG. 2, the top portion 20 of the corrugated
box 10 may also
be designed with a second perforation feature 56. The second perforation
feature 56 is defined
by a series of perforations 56a (e.g., weak points) that help a user with
removal thereof, such that
the second perforation feature 56 is removable from a remainder of the back
wall 24 of the top
portion 20.
[0042] As detailed further herein, the second perforation feature 56 may be
removable to
provide a user access to a handle feature 70 when the box 10 is converted into
a bag-in-box
dispenser, such as shown in FIG. 12. Additionally, however, in some
embodiments, the second
perforation feature 56 may be shaped similarly as the first perforation
feature 50 (e.g., form an
elongated shape 55) and, thus, may enable the top portion 20 to be
positioned/slid back onto the
bottom portion 30 with either the front wall 22 or the back wall 24 facing the
same direction as
the front wall 32 of the bottom portion 30 (with the dispensing valve 92
installed in the
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dispensing position). In such a regard, the second perforation feature 56 may
(like the first
perforation feature) extend to a bottom edge 23c of the back wall 24 of the
top portion 20.
[0043] In some embodiments, the second perforation feature 56 is aligned
with a handle
feature 70 of the bottom portion 30 and forms a shape 55 that enables a user
to access the handle
feature 70 when the top portion 20 is positioned over the bottom portion 30
(e.g., shown in FIG.
12). In this regard, the handle feature 70 (which is shown in FIG. 4), is
defined on the back wall
34 of the bottom portion 30. The handle feature 70 is defined by one or more
perforations on the
back wall 24 and is either already formed into or capable of being formed into
a handle for
receiving a user's hand or fingers such as for use during pouring liquid from
the bag stored in the
box after the box has been converted into the bag-in-box dispenser (e.g.,
shown in FIG. 12). In
the illustrated embodiment of FIG. 4, the handle feature 70 defines a first
portion 72a and an
adjacent second portion 72b that can be removed or pushed into the bottom
portion 30 to enable
insertion of a user's hand or fingers ¨ thereby forming a handle (although
other designs are
contemplated to form a handle). In some embodiments, one or more portions of
the handle
feature 70 may be solid cut (e.g., opposed to a series of perforations). For
example, a center line
70a (shown in FIG. 5) may be solid cut, such as may aid in a user's or
machine's formation of
the handle feature 7- thereafter.
[0044] Like the first perforation feature 50, in some embodiments, the
second perforation
feature 56 may be spaced apart from a top edge 24a of the front wall 24 to
maintain a desired
rigidity, such that may otherwise be compromised if one or more perforations
(e.g., weak points)
were positioned at or too near the top edge 24a of the back wall 24 of the top
portion 20.
[0045] Returning to FIG. 2, the top portion 20 may further define a second
finger access
feature 58 (further shown in FIG. 8) positioned adjacent to the second
perforation feature 56.
The second finger access feature 58 may be at least partially defined by a
series of perforations
56b (e.g., a separate line of perforations than the second perforation
feature) and may be
removable separately from the second perforation feature 56 to enable easier
access for a user to
remove the second perforation feature 56. Though the second finger access
feature 58 is shown
defined on the back wall 24, in various embodiments, the second finger access
feature 58 may be
formed on one or more walls or top flaps. Along similar lines, though the
second finger access
feature 58 is shown as a semi-circle, any suitable shape may be used. With
reference to FIG. 8,
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like with the second perforation feature 56, a top 79b of the second finger
access feature 58 may
be spaced apart from a top edge 24a of the back wall 24, such as shown by
DFA2.
[0046] In some embodiments, the box 10 (or portions thereof) may be formed
of single-
walled corrugate. However, in other embodiments, the box 10 (or portions
thereof) may be
formed of double-walled corrugate to add strength to the box 10, such as may
be beneficial for
individual box shipping and/or passing the test standards noted herein. In
some embodiments,
both the top portion 20 and the bottom portion 30 are formed of double-walled
corrugate. In
some embodiments, the box 10 (or portions thereof) may be formed of additional
layers of
corrugate (e.g., triple-walled corrugate, or more), such as may be beneficial
for further increased
strength. In some embodiments, the box 10 (or portions thereof) may be formed
of other types
of material, such as cartonboard, microflute corrugate, etc.
[0047] FIG. 6 illustrates an example process an end user goes through to
convert the now
shipped box 10 into a bag-in-box dispenser. First, a user removes the first
perforation feature 50
(e.g., by using the first finger access portion 58 ¨ although in some
embodiments there may not
be a finger access portion). In embodiments, with a finger access portion 58
the user may insert
their finger into the first finger access portion 58 and pull the first finger
access portion 58 up
and/or off and the first perforation feature 50 upwardly (e.g., step 110).
With reference to FIG.
7, removal of the first perforation feature 50 reveals, at least partially,
the cut-out feature 51 of
the bottom portion 30. Notably, while not shown in FIG. 6, the same process
can be repeated to
remove the second perforation feature 56, such as by using the second finger
access portion 58
(e.g., shown in completed form in FIG. 8). Returning to FIG. 6, according to
step 120, a user can
now lift (e.g., raise) the top portion 20 from the bottom portion 30 (e.g.,
shown also in FIG. 9).
With reference to FIG. 10, removal of the first perforation feature 50 reveals
the dispensing
valve 92 and the cut-out feature 51 of the bottom portion 30. With the top
portion 20 raised, a
user can reach in and pull the dispensing valve 92 out and position it within
the cut-out feature
51 and in to the dispensing position. Then, the user can simply lower the top
portion 20 over the
installed dispensing valve 92, such as shown in FIG. 11, to convert it into
the bag-in-box
dispenser that can now be utilized for pouring liquid from the stored bag 90
(e.g., step 130). As
noted herein, the user can also form the handle by pushing in portions 72a and
72b of the handle
feature 70 and thereafter utilize the handle to aid in pouring and/or full
evacuation of the liquid
(e.g., reference FIG. 12). In some embodiments, the converted bag-in-box
dispenser may define
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an internal gap within the openings of the top and bottom portions 20, 30.
Said differently, and
with reference to FIG. 11, after the top portion 20 is slid back down onto the
bottom portion 30,
there may be extra space which is illustrated by the distance between the
bottom edge 23a of the
front wall 22 of the top portion 20 and the bottom edge 32a of the front wall
32 of the bottom
portion 30.
[0048] Notably, a benefit for positioning the dispensing valve 92 closer to
the top edge of the
front wall 22 is that a user can visually confirm pouring accuracy when
holding the box 10. A
further benefit of sliding the top portion 20 back over the installed
dispensing valve 92 is that the
top portion 20 may aid in pour control as it may help keep the dispensing
valve 92 positioned
within the cut-out feature 51, such as via an interference fit ¨ as shown in
FIG. 11. Notably,
however, some users may desire not to reposition/slide the top portion 20 back
over the bottom
portion 30, and just use the bottom portion 30 as the bag-in-box dispenser
and, thus, some
embodiments provide increased versatility.
Example Flowchart(s)
[0049] Embodiments of the present invention provide methods and systems for
forming a
box, shipping the box with a bag stored therein, and converting the box into
the bag-in-box
dispenser, according to various embodiments described herein. In this regard,
associated
systems and methods for manufacturing, shipping, and forming example box
designs and
converting into corresponding bag-in-box dispensers described herein are
contemplated by some
embodiments of the present invention. Such systems and methods may include
various machines
and devices, including for example box forming devices (e.g., for folding,
gluing, and/or taping
boxes, among other things) and/or corrugators. In this regard, known
corrugators utilize web
product (e.g., liner) and flute medium to form corrugated web product (which
may be formed
into any number of layered corrugate, such as conventional corrugate (liner,
flute medium, liner)
or double-walled corrugate (liner, flute medium, liner, flute medium, and
liner)). The formed
corrugated web product may then be cut (e.g., scored, sliced, perforated,
etc.) as needed to form
a box blank of the desired box (e.g., any of the box designs described
herein). An example
corrugator is further described in U.S. Publication No. 2019/0016081, which
was filed July 12,
2018, and entitled "Controls for Paper, Sheet, and Box Manufacturing Systems",
the contents of
which is incorporated by reference herein in its entirety.
CA 03146503 2022-01-07
WO 2021/028735 PCT/IB2020/055818
[0050] Various examples of the operations performed in accordance with some
embodiments
of the present invention will now be provided with reference to FIG. 13. In
this regard, FIG. 13
illustrates a flowchart according to an example method for forming a box,
shipping the box with
a bag stored therein, and converting the box into the bag-in-box dispenser
according to an
example embodiment 200. The operations illustrated in and described with
respect to FIG. 13
may, for example, be performed by, with the assistance of, and/or under the
control of one or
more of a user or a machine for performing the operation (e.g., a corrugator
for forming the
corrugated box blanks, a box-forming machine for forming the box or portions
thereof, a bag
loading machine for loading the bag into the box, etc.).
[0051] Operation 202 may comprise forming the corrugated web product, and
operation 204
may comprise forming the box blank, such as may include both the top portion
20 and the
bottom portion 30. As noted above, such operations may be performed by various
known
machines/devices, such as a corrugator.
[0052] Operation 206 may comprise erecting (e.g., forming) the top portion,
which may
occur using a box forming machine and/or via a user. Similarly, operation 208
may comprise
erecting (e.g., forming) the bottom portion, which may also occur using a box
forming machine
and/or manually via a user. Operation 210 may include inserting the bag of
liquid into the
bottom portion and forming the completed box with stored bag therein by
positioning the top
portion thereover. In some embodiments, the operation 210 may include securing
the top portion
to the bottom portion, such as via tape, adhesive, etc. This may be completed
by a
machine/device and/or via a user.
[0053] Operation 212 may comprise shipping the box with stored bag therein,
such as using
individual box shipping means described herein. Then, such as upon arrival at
the final
destination, operation 214 may comprise converting the box into the bag-in-box
dispenser, such
as described further herein. This may be performed using a machine/device
and/or via a user.
Conclusion
[0054] Many modifications and other embodiments of the inventions set forth
herein may
come to mind to one skilled in the art to which these inventions pertain
having the benefit of the
teachings presented in the foregoing descriptions and the associated drawings.
Therefore, it is to
be understood that the embodiments of the invention are not to be limited to
the specific
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embodiments disclosed and that modifications and other embodiments are
intended to be
included within the scope of the invention. Moreover, although the foregoing
descriptions and
the associated drawings describe example embodiments in the context of certain
example
combinations of elements and/or functions, it should be appreciated that
different combinations
of elements and/or functions may be provided by alternative embodiments
without departing
from the scope of the invention. In this regard, for example, different
combinations of elements
and/or functions than those explicitly described above are also contemplated
within the scope of
the invention. Although specific terms are employed herein, they are used in a
generic and
descriptive sense only and not for purposes of limitation.
17
