TELESCOPING BOXES, BLANKS, AND SYSTEMS FOR POUR-STYLE BAG-IN-BOX DISPENSED PRODUCTS

Abstract

Corrugated boxes, box blanks, and systems for individually shipping a bag of liquid stored therein and converting into a bag-in-box dispenser are provided. An example box comprises a top portion with a removable perforation feature defined on a front wall. A bottom portion is sized to fit within an opening of the top portion and includes a cut-out feature in a front wall that aligns with the perforation feature of the top portion when the box is formed. The removed perforation feature and the cut-out feature enable a dispensing valve of a stored bag to extend past/through both front walls when the box is converted into the bag-in-box dispenser. The box is configured to store a bag of liquid ranging from 2 to 10 liters and is designed to pass individual box shipping test standards, such as ISTA and SIOC test standards. Methods of forming the box are also provided.

Description

BACKGROUND

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

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.

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 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.

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.

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 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)

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:

FIG. 1 shows a front, top perspective view of an example corrugated box, in accordance with some embodiments discussed herein;

FIG. 2 shows a rear, top perspective view of the example corrugated box shown in FIG. 1, in accordance with some embodiments discussed herein;

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;

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;

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;

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;

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;

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;

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;

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;

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;

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

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

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.

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.

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).

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.).

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 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.

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 www.ista.org). 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.

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.

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).

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 (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).

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.).

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.

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.).

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.

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).

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).

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 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.

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.

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 P_W1 of the first perforation feature 50). Notably, in some embodiments, the tape may extend underneath the box 10 (e.g., along the 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 P_W2 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.

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.).

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 D_FA1.

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 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.

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.

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 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.

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.

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.

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, 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 D_FA2.

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.

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 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.

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)

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 Jul. 12, 2018, and entitled “Controls for Paper, Sheet, and Box Manufacturing Systems”, the contents of which is incorporated by reference herein in its entirety.

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.).

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.

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.

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

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 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.

Claims

1. A corrugated box for shipping a bag of liquid stored therein and converting into a bag-in-box dispenser, the box comprising: a top portion comprising a plurality of walls, wherein the top portion defines an opening, wherein the top portion includes: a perforation feature defined on a first wall of the plurality of walls, wherein the perforation feature is defined by a series of perforations and is removable from a remainder of the first wall, wherein the perforation feature is configured to enable a dispensing valve of the bag to extend past or through the first wall of the top portion when the box is converted into the bag-in-box dispenser and the perforation feature is removed; anda bottom portion comprising a plurality of walls, wherein the bottom portion defines an opening configured to receive the bag of liquid, wherein the bottom portion is sized to fit within the opening of the top portion, wherein the bottom portion defines: a cut-out feature that defines a portion of a first wall of the plurality of walls of the bottom portion that is at least one of pre-removed or capable of being removed from a remainder of the first wall of the bottom portion, wherein the cut-out feature is positioned on the first wall of the bottom portion to align with the perforation feature of the top portion when the bottom portion is received within the top portion, wherein the cut-out feature is configured to enable the dispensing valve to extend past or through the first wall of the bottom portion when the box is converted into the bag-in-box dispenser.

2. The box of claim 1, wherein the first wall of the top portion defines a top edge, a bottom edge and a length therebetween, and wherein the perforation feature extends from a position at or above a center position along the length to the bottom edge.

3. The box of claim 2, wherein the perforation feature defines an elongated shape that increases in width in a direction leading to the bottom edge of the first wall of the top portion.

4. The box of claim 2, wherein a width of the perforation feature proximate the bottom edge of the first wall of the top portion is sized to receive one or more pieces of tape, wherein the tape is used to secure the top portion to the bottom portion.

5. The box of claim 4, wherein removal of the perforation feature results in the removal of the one or more pieces of tape to enable movement of the top portion relative to the bottom portion.

6. The box of claim 1, wherein the first wall of the top portion has a top edge, a bottom edge and a length therebetween, and wherein the perforation feature defines an elongated shape with a perforation feature length that extends from a position at or above a center position along the length toward the bottom edge, wherein the perforation feature length is greater than a corresponding length characteristic of the dispensing valve such that the top portion may be lifted upwardly from the bottom portion and a user can pull the dispensing valve through an opening formed in the first wall of the top portion by removal of the perforation feature.

7. The box of claim 1, wherein the first wall of the top portion has a top edge, wherein the perforation feature is positioned on the first wall of the top portion such that it is spaced apart from the top edge.

8. The box of claim 1, wherein the cut-out feature defines a shape that corresponds to a portion of the dispensing valve such that the cut-out feature holds the dispensing valve in position when the box is converted into the bag-in-box dispenser.

9. The box of claim 8, wherein the cut-out feature is defined along a top edge of the first wall of the bottom portion.

10. The box of claim 1, wherein the top portion further defines a finger access feature positioned adjacent to the perforation feature.

11. The box of claim 1, wherein the perforation feature is a first perforation feature, wherein the top portion further includes a second perforation feature defined on a second wall of the plurality of walls of the top portion, wherein the second wall of the top portion is opposite the first wall of the top portion, wherein the second perforation feature is defined by a series of perforations and is removable from a remainder of the second wall, and wherein the bottom portion further comprises a handle feature that is defined on a second wall of the plurality of walls of the bottom portion, wherein the second wall of the bottom portion is opposite the first wall of the bottom portion, wherein the handle feature is defined by one or more perforations on the second wall of the bottom portion, wherein the handle feature is positioned on the second wall of the bottom portion to align with the second perforation feature of the top portion when the bottom portion is received within the top portion.

12. The box of claim 11, wherein the second wall of the top portion has a top edge, a bottom edge and a length therebetween, and wherein the second perforation feature extends from a position at or above a center position along the length to the bottom edge.

13. The box of claim 1, wherein the bottom portion defines a side flap that is attached to an outside surface of one of the plurality of walls so to form the opening of the bottom portion, wherein the side flap is attached to the outside surface so as to be separated from the stored bag within the box to avoid damage to the stored bag during shipping.

14. The box of claim 1, wherein the box is configured to store the bag of liquid with volume ranging from 2 liters to 10 liters and keep the bag from damage or leaking during individual box shipping.

15. The box of claim 14, wherein the box is designed to store the bag and pass individual box shipping test standards, including at least the 2018 International Safe Transit Association (ISTA) Series 6-Amazon.com-Ship In Own Container (SIOC) test protocol for Type A.

16. The box of claim 1, wherein the box is designed to survive individual box shipping such that the perforation feature is intact and the bag is free of damage or leaking so as to enable conversion of the box into the bag-in-box dispenser thereafter.

17. A system including the box of claim 1, wherein the system further includes the bag of liquid including the dispensing valve, wherein the bag is stored within the opening of the bottom portion of the box.

18. A box blank for a corrugated box for shipping a bag of liquid stored therein and converting the box into a bag-in-box dispenser, wherein the box blank is formed of corrugate and comprises: a top portion comprising a plurality of panels, wherein the top portion, when formed into a box top portion, defines an opening, wherein the top portion defines: a perforation feature defined on a first panel of the plurality of panels, wherein the perforation feature is defined by a series of perforations and is removable from a remainder of the first panel, wherein the perforation feature is configured to enable a dispensing valve of the bag to extend past or through the first panel when the box is converted into the bag-in-box dispenser and the perforation feature is removed; anda bottom portion comprising a plurality of panels, wherein, when formed into a box bottom portion, the bottom portion defines an opening configured to receive the bag of liquid and the bottom portion is sized to fit within the opening of the top portion, wherein the bottom portion defines: a cut-out feature that defines a portion of a first panel of the plurality of panels of the bottom portion that is at least one of pre-removed or capable of being removed from a remainder of the first panel of the bottom portion, wherein the cut-out feature is positioned on the first panel of the bottom portion to align with the perforation feature of the top portion when the bottom portion is received within the top portion, wherein the cut-out feature is configured to enable the dispensing valve to extend past or through the first panel of the bottom portion when the box is converted into the bag-in-box dispenser.

19. The box blank of claim 18, wherein the first panel of the top portion defines a top edge, a bottom edge and a length therebetween, and wherein the perforation feature extends from a position at or above a center position along the length to the bottom edge.

20. The box blank of claim 19, wherein the perforation feature defines an elongated shape that increases in width in a direction leading to the bottom edge of the first panel of the top portion.

21. The box blank of claim 18, wherein the first panel of the top portion defines a top edge, a bottom edge and a length therebetween, and wherein the perforation feature defines an elongated shape with a perforation feature length that extends from a position at or above a center position along the length toward the bottom edge, wherein the perforation feature length is greater than a corresponding length characteristic of the dispensing valve such that the formed box top portion may be lifted upwardly from the formed box bottom portion and a user can pull the dispensing valve through an opening formed in the first panel of the formed box top portion by removal of the perforation feature.

22. The box blank of claim 18, wherein the first panel of the top portion defines a top edge, wherein the perforation feature is positioned on the first panel such that it is spaced apart from the top edge.

23. The box blank of claim 18, wherein the cut-out feature defines a shape that corresponds to a portion of the dispensing valve such that the cut-out feature is configured to hold the dispensing valve in position when the box is converted into the bag-in-box dispenser.

24. The box blank of claim 18, wherein the perforation feature is a first perforation feature, wherein the top portion further includes a second perforation feature defined on a second panel of the plurality of panels of the top portion, wherein the second panel of the top portion is opposite the first panel of the top portion, wherein the second perforation feature is defined by a series of perforations and is removable from a remainder of the second panel, and wherein the bottom portion further comprises a handle feature that is defined on a second panel of the plurality of panels of the bottom portion, wherein the second panel of the bottom portion is opposite the first panel of the bottom portion, wherein the handle feature is defined by one or more perforations on the second panel of the bottom portion, wherein the handle feature is positioned on the second panel of the bottom portion to align with the second perforation feature of the top portion when the box bottom portion is received within the box top portion.

25. The box blank of claim 18, wherein the box, when formed, is configured to store the bag of liquid with volume ranging from 2 liters to 10 liters and keep the bag from damage or leaking during individual box shipping.

26. The box blank of claim 25, wherein the box, when formed, is designed to store the bag and pass individual box shipping test standards, including at least the 2018 International Safe Transit Association (ISTA) Series 6-Amazon.com-Ship In Own Container (SIOC) test protocol for Type A.

27. The box blank of claim 18, wherein the box, when formed, is designed to survive individual box shipping such that the perforation feature is intact and the bag is free of damage or leaking so as to enable conversion of the box into the bag-in-box dispenser thereafter.

28. A method of manufacturing a box blank for a corrugated box for shipping a bag of liquid stored therein and converting into a bag-in-box dispenser, the method comprising: forming corrugated web product;cutting out a top portion of the box blank from the corrugated web product, wherein the top portion comprises a plurality of panels, wherein the top portion, when formed into a box top portion, defines an opening, wherein the top portion defines: a perforation feature defined on a first panel of the plurality of panels, wherein the perforation feature is defined by a series of perforations and is removable from a remainder of the first panel, wherein the perforation feature is configured to enable a dispensing valve of the bag to extend past or through the first panel when the box is converted into the bag-in-box dispenser and the perforation feature is removed; andcutting out a bottom portion of the box blank from the corrugated web product, wherein the bottom portion comprises a plurality of panels, wherein, when formed into a box bottom portion, the bottom portion defines an opening configured to receive the bag of liquid and the bottom portion is sized to fit within the opening of the top portion, wherein the bottom portion defines: a cut-out feature that defines a portion of a first panel of the plurality of panels of the bottom portion that is at least one of pre-removed or capable of being removed from a remainder of the first panel of the bottom portion, wherein the cut-out feature is positioned on the first panel of the bottom portion to align with the perforation feature of the top portion when the bottom portion is received within the top portion, wherein the cut-out feature is configured to enable the dispensing valve to extend past or through the first panel of the bottom portion when the box is converted into the bag-in-box dispenser.

29. The method of claim 28 further comprising: erecting the box top portion; anderecting the box bottom portion.

30. The method of claim 29 further comprising: inserting the bag of liquid into the opening of the box bottom portion; andsliding the box top portion over the box bottom portion with the bag stored therein.