This invention relates generally to bag-in-box containers for fluent materials and, more particularly, to a bag-in-box container that is configured for use as a ships in own container (SIOC) package.
It is common practice to contain fluent products, e.g. liquid detergents, in a so-called bag-in-box package rather than, for example, conventional plastic bottles. Such bag-in-box packages can provide particular advantages for shipping bulk quantities of fluent products. Previously identified advantages of bag-in-box packages include more efficient usage of volume, cost reductions over alternative packaging materials, and easier disposal. Further, the shape of bag-in-box packages matches that of conventional shipping containers, such as boxes forming overpacking, such that one or more bag-in-box packages can be efficiently protected within the overpacking. Alternatively, a quantity of bag-in-box packages may be shipped on a pallet. While prior systems for shipping bag-in-box packages have provided an efficient means for shipping bulk supplies of fluent products, shipping of smaller quantities of fluent materials, such as in quantities that may be purchased and used by individual consumers, can be less cost efficient due to redundancy in packaging requirements to ensure that the bag-in-box packaging is protected against damage so as to avoid leakage of the fluent product.
A particular example of challenges associated with shipping products with minimum packaging while maintaining the integrity of the shipping package can be found in c-commerce, where consumer expectations and shipping cost often require that packaging materials and/or packaging size be minimized. Although a typical box of the bag-in-box package can contain and protect the bag during normal consumer handling of the package, such bag-in-box packages generally cannot be shipped under standard package shipping and handling conditions without additional protective wrapping or packaging over the box. For example, known bag-in-box packages often include at least one feature defining a weakened access area on the box to provide easy consumer access to a dispensing device connected to a product bag within the box. Without additional protective wrapping or packaging over the box, the weakened access feature in such known bag-in-box packages may break and compromise the package integrity during standard shipping and handling, that may include impacts, or other forces applied to the package, that can occur as the bag-in-box package moves through e-commerce shipping channels.
In accordance with an aspect of the invention, a bag-in-box shipping container is provided including an outer rigid container and an inner flexible container including a dispensing device. The shipping container comprises a plurality of panels defining sides of the rigid container, including an outer front panel, a first side panel, a back panel, a second side panel, and an inner front panel connected in series along a longitudinal direction at respective first, second, third, and fourth fold lines. A plurality of top flaps are foldably joined to upper edges of the panels to define a top side of the rigid container. A plurality of bottom flaps are foldably joined to lower edges of the panels to define a bottom side of the rigid container. Outer and inner portal covers are formed in the respective outer and inner front panels, and a tear tab is defined by perforated lines adjacent the upper edge of the outer front panel, longitudinally aligned with the outer portal cover.
The outer front panel may extend over the inner front panel, and portions of the outer front panel adjacent to opposing longitudinal edges of the outer front panel may be adhered to adjacent portions of the inner front panel.
At least a portion of the outer front panel may not be attached to the inner front panel extending from the tear tab to the outer portal cover.
The shipping container may further include a glue tab connected to the outer front panel at a tab fold line opposite from the first fold line, and the glue tab can be adhered to the second side panel.
A tear strip may be provided extending along an inner side of the outer front panel from the tear tab to the outer portal cover.
The outer and inner portal covers may be defined by perforations in the respective outer and inner front panels.
The outer portal cover may be separated from the lower edge of the outer front panel by a continuous section of the outer front panel.
A portion of the outer portal cover may be adhered to an adjacent portion of the inner portal cover.
The adhered portions of the outer and inner portal covers may be detachable from the outer and inner front panels to define an opening for receiving the dispensing device of the inner flexible container.
The top and bottom flaps may comprise major flaps attached the first and second side panels, and minor flaps attached to the back panel and one of the front panels, wherein the minor flaps may be located between respective major flaps at the top and bottom sides of the container.
In accordance with another aspect of the invention, a bag-in-box shipping container is provided including an outer rigid container and an inner flexible container including a dispensing device. The shipping container comprises a plurality of panels defining sides of the rigid container, including an outer front panel, a first side panel, a back panel, a second side panel, and an inner front panel connected in series along a longitudinal direction at respective first, second, third, and fourth fold lines. A plurality of top flaps are foldably joined to upper edges of the panels to define a top side of the rigid container. A plurality of bottom flaps are foldably joined to lower edges of the panels to define a bottom side of the rigid container. Outer and inner portal covers are defined by perforations in the respective outer and inner front panels. A tear tab is defined by perforated lines adjacent the upper edge of the outer front panel, longitudinally aligned with the outer portal cover, and a tear strip defined by a strip of tape extends along an inner side of the outer front panel from the tear tab to the outer portal cover.
A portion of the outer portal cover may be adhered to an adjacent portion of the inner portal cover.
The tear tab and tear strip may be movable to slit the outer front panel from the tear tab to the outer portal cover and to detach the adhered portions of the outer and inner portal covers from the outer and inner front panels to define an opening for receiving the dispensing device of the inner flexible container.
The opening for receiving the dispensing device of the inner flexible container may be separated from the lower edges of the outer and inner front panels by continuous sections of the respective outer and inner front panels.
In accordance with a further aspect of the invention, a one-piece blank of sheet material for forming a bag-in-box shipping container is provided. The blank comprises an outer front panel, a first side panel, a back panel, a second side panel, and an inner front panel connected in series along a longitudinal direction at respective first, second, third, and fourth fold lines. One or more top flaps are foldably joined to an upper edge of one or more of the panels. One or more bottom flaps are foldably joined to a lower edge of one or more of the panels. Outer and inner portal covers are formed in the respective outer and inner front panels, and a tear tab is formed adjacent the upper edge of the outer front panel, longitudinally aligned with the outer portal cover.
A glue tab may be provided connected to the outer front panel at a tab fold line opposite from the first fold line.
A tear strip may be provided extending along an inner side of the outer front panel from the tear tab to the outer portal cover.
The tear tab may be defined by a pair of perforated lines extending into the outer front panel from the upper edge of the outer front panel.
The outer and inner portal covers may be defined by perforations in the respective outer and inner front panels.
The outer portal cover may be separated from the lower edge of the outer front panel by a continuous section of the outer front panel.
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein:
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, and not by way of limitation, specific preferred embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention.
The present description is directed to a container construction commonly known as a bag-in-box container. The container described herein can facilitate compact shipping and storage of the container prior to use, by providing a collapsed configuration until the container is needed for containment and shipping of a fluent product. The described container can comprise an outer rigid container surrounding an inner flexible container including a dispensing device. The outer rigid container can be formed from a blank processed either with equipment designed for this purpose or by hand. For example, the blank may be folded using equipment similar to currently available case forming machines, or the container can be formed through manually implemented steps, or through a combination of machine implemented and manual steps. Further, the outer rigid container is provided with a configuration that can meet standards for shipping without requiring overpacking, including aspects that facilitate container strength, as may be understood further from the following detailed description.
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A blank 10 can further include a glue tab 42 connected to the outer front panel 24 at a tab fold line 44 opposite from the first fold line 34. A longitudinal edge of the glue tab 42 opposite from the tab fold line 44 can define the first longitudinal edge 16 of the blank 10. It may be understood that the glue tab 42 can define an additional or sixth panel, i.e., in addition to the outer front panel 24, first side panel 26, back panel 28, second side panel 30, and inner front panel 32, such that the blank 10 can be used to form a six panel box or container, as described in the container forming steps below.
First and second major top flaps 46, 48 are foldably joined to upper edges of the respective first and second side panels 26, 30 along respective upper score lines 541, 543. First and second minor top flaps 50, 52 are foldably joined to upper edges of the back panel 28 and inner front panel 32 along respective upper score lines 542, 544. It may be noted that the upper score lines 541, 542, 543, 544 may be located at slightly different levels to accommodate positioning of the top flaps 46, 48, 50, 52 during a folding operation.
First and second major bottom flaps 56, 58 are foldably joined to lower edges of the respective first and second side panels 26, 30 along respective lower score lines 641, 643. First and second minor bottom flaps 60, 62 are foldably joined to lower edges of the back panel 28 and inner front panel 32 along respective lower score lines 642, 644. It may be noted that the lower score lines 641, 642, 643, 644 may be located at slightly different levels to accommodate positioning of the bottom flaps 56, 58, 60, 62 during a folding operation.
An outer portal cover 66a is formed in the longitudinal center of the outer front panel 24, as defined by perforations, e.g., through perforations in the outer front panel 24. Referring to
It should be noted that “perforation,” as used herein, can include intermittent or continuous cuts extending fully or partially through the material described as containing the perforation. Further, it should be understood that the upper edge 68a is preferably an imaginary line that connects the upper ends of the sloped lines 72a, 74a, and comprises a line extending across a solid (non-perforated) section of the outer front panel 24.
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As used herein “continuous” refers to material of the panels that does not include features that form a break or separation in the material, such as may typically be formed by perforations, holes, cut outs, or similar features. In accordance with particular aspects of the present description, the portal covers 66a, 66b are each surrounded with continuous material such that no perforations, holes or cut outs extend from the edges of the outer and inner front panels 24, 32 to the portal covers 66a, 66b.
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In accordance with the embodiment described herein, the two adhesive strips A1 are located laterally outward from the portal covers 66a, 66b, wherein the remaining area of the outer front panel 24 between the two adhesive strips A1, and extending from the tear tab 90 to the outer portal cover 66a, does not include adhesive so as to avoid adhesive joints that could interfere with user implemented steps for opening the rigid container 8a, as will be described further below. It should be understood that the glue tab 42 attached to the second side panel 30, and the associated 90 degree junction formed at the tab fold line 44, provides increased rigidity to the front wall 25. That is, although the outer and inner front panels 24, 32 are not adhered to each other across the full face of the panels 24, 32, additional panel strength to resist distortion, such as buckling, of the front wall 25 is provided via the glue tab 42.
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Following placement of the flexible container 8b into the rigid container 8a, the top flaps 46, 48, 50, 52 can be folded in the same sequence of steps as described above for the bottom flaps 56, 58, 60, 62. Specifically, referring to
It should be understood that the folding steps for forming the rigid container 8a may be performed in an order that is different from the folding steps described above. Further, placement of the flexible container 8b into the rigid container may be performed by inserting the flexible container 8b into an open bottom end of the rigid container 8a subsequent to folding of the top flaps 46, 48, 50, 52, followed by folding of the bottom flaps 56, 58, 60, 62 to fully enclose the flexible container 8b within the rigid container 8a.
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After the outer portal cover 66a is separated from the outer front wall 24, the remaining upper portion 87b of the inner portal cover 66b is pivoted outwardly about the upper edge 68b to separate the perforated lines 72b, 74b, 76a, 78b, 80b, 82b from the inner front panel 32 and define an enlarged spout access portal or opening 106, see
From the above description, it may be understood that the rigid container 8a does not include any holes or cutouts to form the spout access opening 106. Further, a tear strip 96 is provided to form the spout opening 104 by displacing the outer portal cover 66a and removable portal cover segment 86b, wherein the spout opening 104 provides a hole that facilitates gripping and pivoting the inner portal cover 66b outwardly for formation of the spout access opening 106. Hence, a continuous solid layer of material, i.e., without perforations, holes or cutouts, surrounds each of the outer and inner portal covers 66a, 66b and forms a solid double thickness front wall 25 for structural strength during shipping, and the tear strip 96 provides ready access to form the spout opening 104 at the point of use. The structural strength of the front wall 25 is further enhanced by the glue tab 42 folded perpendicular to the front wall 25 and affixed to the second side wall 30 to resist distortion of the front wall 25, such as may result from forces applied to the container 8, e.g., forces resulting from dropping the container 8 during shipping.
It should also be noted that the container 8 described herein may be relatively small, e.g., a container sized to hold approximately 140 oz. of a fluent product such as laundry detergent or softener, that can be shipped directly to an individual consumer as an end user. However, the container 8 is not limited to a particular size and the container 8 may be smaller or larger than the container described herein.
By providing the above-described bag-in-box container 8 with aspects facilitating the strength and/or durability of the outer rigid container 8a, the present bag-in-box container 8 is serviceable as a ships in own container (SIOC) bag-in-box package. That is, the container 8 provides a continuous solid surface around the portal covers 66a, 66b in the front wall 25 and provides a strengthening glue tab 42 adjacent to the front wall 25 to resist distortion of the front wall 25. Accordingly, the perforated features 66a, 66b, forming part of the system for providing convenient consumer access to the dispensing device 102, will remain intact during impacts, or other rough handling, that could occur during shipping of the container 8, e.g., during transport though typical e-commerce shipping channels.
Further, the rigid container 8a and flexible container 8b can facilitate compact shipping and storage of the container components prior to use, by providing a collapsed configuration until the container 8 is needed for containment and shipping of a fluent product. Hence, a system is described for providing a container 8 for fluent product that can reduce the volume or space requirement for storing the container components prior to filling with the fluent product, and that can reduce shipping costs, e.g., via reduced material cost and smaller package size, as a result of not requiring overpacking for shipping the filled container 8.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.