Collapsible bulk cage liner

A liner cassette for use with an existing intermediate bulk container includes a box and a liner. The box is configured to unfold within the intermediate bulk container and the liner is configured to fit within the box. The liner cassette includes two configurations. In a first configuration, the box and liner may be folded substantially flat to facilitate transportation. In a second configuration, the box and liner are configured to provide a liquid containment system for the existing intermediate bulk container.

FIELD OF THE INVENTION

The present invention generally relates to intermediate bulk containers. More particularly, the present invention pertains to a liner for use with an intermediate bulk container and a method of installing the liner in the intermediate bulk container.

BACKGROUND OF THE INVENTION

Intermediate bulk containers (“IBC”) are widely utilized to transport, store and dispense goods. In particular, IBCs are utilized to contain liquid goods. IBCs generally include a cage or other such rigid walls and, to contain liquid goods, IBCs typically include a rigid plastic bottle that is placed within the cage. These bottles may be replaced when they become soiled or leaky.

Unfortunately, conventional IBC bottles are relatively bulky to ship. Other disadvantages associated with conventional IBC bottles are their weight and expense. Accordingly, it is desirable to provide an IBC cage liner that is capable of overcoming the disadvantages described herein at least to some extent.

SUMMARY OF THE INVENTION

The foregoing needs are met, to a great extent, by the present invention, wherein in some embodiments an intermediate bulk container (“IBC”) packaging system is provided.

An embodiment of the present invention relates to a liner cassette to line a cage of an intermediate bulk container. The liner cassette includes a liner and a box. The liner includes an envelope and a spout. The envelope is configured to contain a product. The spout is configured to provide access to the envelope. The box includes a set of sheet stock panels. The set of sheet stock panels include a bottom panel, a plurality of side panels, a plurality of fold zones, and a spout access. The plurality of fold zones is configured to conform to a radiused edge disposed between two side panels of the plurality of side panels. The spout access is disposed in a panel of the plurality of side panels. The liner cassette includes a first conformation and a second conformation. The first conformation is substantially flat with the set of sheet stock panels folded one upon the other and the liner is disposed between the folded set of sheet stock panels. The second conformation is substantially conformal to an interior of the cage.

Another embodiment of the present invention pertains to a packaging system. The packaging system includes an intermediate bulk container and a liner cassette. The intermediate bulk container includes a cage having a set of walls and a floor. The liner cassette is configured to line the cage. The liner cassette includes a liner and a box. The liner includes an envelope and a spout. The envelope is configured to contain a product. The spout is configured to provide access to the envelope. The box includes a set of sheet stock panels. The set of sheet stock panels include a bottom panel, a plurality of side panels, a plurality of fold zones, and a spout access. The plurality of fold zones is configured to conform to a radiused edge disposed between two side panels of the plurality of side panels. The spout access is disposed in a panel of the plurality of side panels. The liner cassette includes a first conformation and a second conformation. The first conformation is substantially flat with the set of sheet stock panels folded one upon the other and the liner is disposed between the folded set of sheet stock panels. The second conformation is substantially conformal to an interior of the cage.

Yet another embodiment of the present invention relates to a method of replacing a liner cassette in a cage of an intermediate bulk container. In this method, a flat-packed liner cassette is disposed in the cage and the flat-packed liner cassette is unfolded to substantially conform to the interior of the cage. The liner cassette includes a liner and a box. The liner includes an envelope and a spout. The envelope is configured to contain a product. The spout is configured to provide access to the envelope. The box includes a set of sheet stock panels. The set of sheet stock panels include a bottom panel, a plurality of side panels, a plurality of fold zones, and a spout access. The plurality of fold zones is configured to conform to a radiused edge disposed between two side panels of the plurality of side panels. The spout access is disposed in a panel of the plurality of side panels. The liner cassette includes a first conformation and a second conformation. The first conformation is substantially flat with the set of sheet stock panels folded one upon the other and the liner is disposed between the folded set of sheet stock panels. The second conformation is substantially conformal to an interior of the cage.

DETAILED DESCRIPTION

The present invention provides, in some embodiments, an intermediate bulk container (“IBC”) liner packaging system, a method of generating a replacement liner cassette for the packaging system, and a method of installing the liner cassette in the packaging system. For the purpose of this disclosure, a box or container is defined as a receptacle or cover to enclose or partially enclose an item. Also for the purpose of this disclosure, a liner is defined as a membrane, envelope, or bag for retaining liquid contents. In an embodiment, the invention provides a liner cassette that includes a box and liner for use in an existing IBC cage. The liner cassette may be folded or collapsed to facilitate transport The box may include any suitable sheet stock such as, for example, fiberboard, corrugated fiberboard, corrugated plastic or plastic composite, metals, fabrics, composites, and the like. For the purpose of this disclosure, the term, “fiberboard” is defined as at least including, for example, paper, paperboard, cardboard, corrugated cardboard, cellulosic, fiberglass, carbon fiber, spun ceramic fibers such as silica-alumina ceramic, and/or resinous material which is similar in character to fiberboard, and which is manipulated in the same or similar manner as fiberboard. This includes any suitable material capable of being folded from a blank. In this regard, the term “blank” refers to at least a piece or unit of fiberboard that is cut or scored and/or suitable for folding into a particular conformation such as a box, lid, or tube.

In another embodiment, the invention provides for a method of generating a replacement liner cassette for the packaging system. In this method, the various components of the liner cassette may be assembled and packaged or “flat-packed” for transport.

In yet another embodiment, the invention provides for a method of installing the liner cassette in the packaging system. In this method, the flat-packed liner cassette may be placed in an existing IBC and unfolded or assembled.

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. As shown inFIG. 1, a intermediate bulk container (“IBC”) liner packaging system10includes a liner cassette12for use in an existing IBC14. The liner cassette12includes a liner16, box18, and one or more fittings20A and20B. The IBC14includes a cage22and a pallet or base24.

The liner16includes any suitable material such as, for example, polyethylene, polypropylene, plastic, rubber, and the like. In various forms, the liner16may be flexible and/or may be folded substantially flat to reduce a volume of air contained therein. In a particular example, the liner16may include a Food and Drug Administration (“FDA”) approved material for use with food. In another particular example, the liner16may be suitable to store and/or transport hazardous and/or Department of Transportation (DOT) regulated liquids.

The box18may include any suitable material or combination of materials. In general, suitable materials include various sheet stock or the like. Particular examples of suitable materials include corrugated cardboard (coated and uncoated) and corrugated plastic panels. The box18may include a floor, sidewalls, and a lid. In a particular example, the liner16may be attached to the floor. For storage and transport of the liner cassette12, the sidewalls and lid may be folded down or stacked upon the floor and line16to generate a de-bulked configuration or “flat pack.” In this flat pack form, the liner cassette12may be relative easily transported and/or stored. For example, about 800 liner cassettes12may be transported in a standard tractor trailer.

Optionally, the liner cassette12may include the fittings20aand20b. In various forms the fittings20aand20binclude any suitable fitting such as, for example, caps, adapters, valves, and the like. If included, the fittings20aand20bmay facilitate filling and/or dispensing contents into and/or out of the packaging system10.

FIG. 2is a plan view of components suitable for use in the liner cassette12according toFIG. 1. As shown inFIG. 2, the liner cassette12includes the liner16and a plurality of pre-cut and pre-scored blanks suitable for assembling the box18. The liner16includes a spout30A and/or a spout30B configured to mate with the fittings20A and20B. The liner16may be folded during assembly of the liner cassette12. For example, the liner16may be along fold lines32A to32D. In other examples the liner16may have more or fewer spouts and may be folded in any suitable manner for storage, packaging and/or distribution.

The pre-cut and pre-scored blanks suitable for assembling the box18may include, for example a cover34, one or more side units36, and bottom unit38. The cover34is optionally included to cover or otherwise protect the liner16and/or the packaging system10. If included, the cover34optionally includes a spout access40. The spout access40may include a “knock out” section disposed to align with the spout30A in the assembled packaging system10. For example, the spout access40may be partially perforated to facilitate removal. The cover34further includes a set of tabs42A to42H that may be folded along a corresponding set of fold lines44A to44H. The fold lines44A to44H may be scored, pre-stressed, and/or pre-folded to facilitate folding the tabs42A to42H relative to the cover34. In an embodiment, the tabs42A to42H are folded at about 90° to the cover34and inserted between the cage22and the box18or liner16. In this manner, the cover34may be secured to the packaging system10.

The one or more side units36include at least one spout access50. In a particular example, two side units36are utilized and one or both may include the spout access50. In the assembled packaging system, the spout access50is disposed in cooperative alignment with the fitting20B. As shown inFIG. 2, the side unit36includes side panels52A and52B, bottom panel54, and top panel56. The side panels52A and52B are configured to fold along a plurality of fold zones58A and58B, respectively. The bottom panel54is configured to fold along a fold zone58C. The top panel56is configured to fold along a fold zone58D. Some or all of the fold zones58A-58D are configured to fold or bend accommodate a variety of curvatures. For example, the fold zones58A-58D may bend along an arcuate or radiused corner having a radius from about ¼ inch to about 1 foot or more. In a particular example, the cage22may include corners that curve with a radius of about 6 inches and the fold zones58A-58D. To accommodate various curvatures, each fold zone of the fold zones58A-58D may include a plurality of score lines running parallel to the fold zone. In this manner, the fold zone58A-58D may generate a plurality of facets as the panels are bent and the side unit36is assembled in the cage22. Optionally, the side unit36may include tabs60A and60B.

The bottom unit38includes a spout access68. In the assembled packaging system, the spout access68is disposed in cooperative alignment with the fitting20B. The bottom unit38further includes a plurality of retaining tabs70A to70D that are configured to fold along fold zones72A to72D. As shown and described hereinafter, the bottom unit38is configured to provide an envelope for the liner16during shipping and/or storage. The bottom unit38is further configured to provide a supporting surface on the bottom of the cage22when the liner cassette12is assembled. In this regard, the bottom unit38may be configured to cover at least a portion of the bottom of the cage22.

FIGS. 3 to 7show a folded configuration of the pre-cut, pre-scored blanks for the cover34and side unit36.FIG. 3is a plan view of the pre-cut and pre-scored blank suitable for use in the cover34. As shown inFIG. 3, the tabs42A to42H are folded up and out of the plane of the cover34as indicated by the arrows.FIG. 4is a plan view of a folded blank suitable for use in the cover34. As shown inFIG. 4, the tabs42A to42H are folded inward and down upon the cover34.

FIG. 5is a plan view of the pre-cut and pre-scored blank suitable for use in the side unit36. As shown inFIG. 5, the side panels52A and52B, bottom panel56, and top panel56of the side unit36are folded upwards and inwards out of the plane of the side unit36and then inwards and downwards upon the side unit36.FIG. 6is a plan view of a front side of the folded blank suitable for use in the side unit36. As shown inFIGS. 6 and 7, the various panels of the side unit36nest and overlap to generate a substantially smaller package that is suitable for transport and storage.FIG. 7is a plan view of a back side of the folded blank suitable for use in the side unit36. As shown inFIG. 7, the tabs60A and60B may be wrapped around the side unit36.

FIG. 8is a plan view of a partially assembled liner cassette12suitable for use in the IBC liner packaging system10ofFIG. 1. As shownFIG. 8, the bottom unit38is disposed upon the side unit36with the spout access68in cooperative alignment with the spout access50. In addition, the spout30B may be disposed in the access formed by the spout access50and68. The partially folded liner16may be aligned as shown. According to an embodiment, to prepare the cassette liner12for storage and/or transport, the side panels52A and52B and the top panel56may be folded upon the liner16as shown inFIG. 8. The bottom unit38may be folded upon the side unit36. In addition, the retaining tabs70B to70D may be folded around the side unit36as indicated by the arrows shown inFIG. 8.FIG. 9is a plan view of a back side of the liner16, side unit36, and bottom unit38folded according to an embodiment of the invention. As shown inFIG. 9, the tabs60A and60B may be wrapped around the side unit36. As shown inFIGS. 9 and 10, the various panels of the side unit36and bottom unit38nest and overlap to generate a substantially smaller package that is suitable for transport and storage.FIG. 10is a plan view of a front side of the liner16, side unit36, and bottom unit38folded according to an embodiment of the invention.

To install the liner cassette in the cage22, folded components such as those shown inFIG. 9are placed in the cage22and the spout30B is aligned with the appropriate location on the cage22. The side panels52A and52B may be unfolded against the sides of the cage22and the bottom unit38is unfolded on to the bottom of the cage22. Another side unit36may be installed on the side of the cage22opposite from the side where the first side unit36was installed. Again, the side panels52A and52B are unfolded against the sides of the cage22and generally overlap the respective side panels52A and52B from the previously installed side unit36. The spout30A may be accessed and filled with a fill hose, for example. Optionally, the cover34may be installed to cover the liner16.

FIGS. 11 to 16show steps suitable for installing the liner cassette12in the cage22. As shown inFIG. 11, a folded or compact conformation of the liner cassette12may be slid into place in the cage22with the spout30B appropriately disposed. The side panels52A and52B may be folded outwardly and the top panel56may be folded upwardly as shown inFIG. 12. InFIG. 13another side unit36is shown installed with the respective side panels52A and52B and top panel56unfolded.FIG. 14is a top view looking into the partially assembled liner cassette12. As shown inFIG. 14, the spout30A may be accessed by reaching into the cage22and attaching a fill hose thereto, for example. The retaining tabs70B-70D unfold into place in response to filling the liner16.

FIG. 15is a perspective view of the liner cassette12installed in the cage22. As shown inFIG. 15, the various components of the box18fully cover the inside of the cage22and provide a barrier between the liner16and cage22. In this manner, the liner16is protected from abrasion and/or puncture. It is another advantage that the box18provides a degree of thermal protection for the liner16. It is yet another advantage of various embodiments that, due to the overlapping components, the box18is configured to accommodate cages22of different sizes. Furthermore, the sliding overlapping components are configured to facilitate expansion and contraction with thermal and load induced changes in size and shape.

FIG. 16is a perspective view of the liner cassette12installed in the cage22and covered with the cover34. As shown inFIG. 16, the tabs42A to42H may be slid between the box18and the cage22.

FIG. 17is a plan view of the pre-cut and pre-scored blank suitable for use in the box18according to another embodiment. As shown inFIG. 17, the box18may be generated from a unitary piece of sheet stock. The box18may include a glue tab78A configured to be glued to a corresponding glue area78B. The box18further includes side panels80A to80D, top panels82A to82D, and bottom panels84A to84D.

The box18optionally includes fold zones86A to86D. If included, the fold zones86A to86D may bend along various curvatures. In addition, the fold zones86A to86D may fold in an accordion-like manner to accommodate variability in the size of the cage22. The box18may further include pre-scored fold lines88A and88B to facilitate collapsing the box18as shown inFIG. 18.

FIG. 18show steps suitable for installing the liner cassette12according to the embodiment ofFIG. 17in the cage22. As shown inFIG. 18, a pre-cut and pre-scored blank similar to the blank shown inFIG. 17may be utilized to generate the box18. As shown in step1, the blank is fabricated into an open box. To this open box, the liner16may be added. As shown in step2, the top panels82A to82D are folded inward and into the interior of the box18. The bottom panels84A to84D are also inwardly folded into the interior of the box18. As shown in step3, the side of the box18are folded inward along fold lines88A and88B shown inFIG. 17. In this manner, the liner cassette12may be collapsed or “flat-packed.” The flat-packed liner cassette12greatly facilitates storage and transportation of the liner cassette12. Furthermore, the flat-packed liner cassette12facilitates assembly of the IBC liner packing system10without removal of top straps or bars that typically extend across the top of the cage22. That is, the flat backed liner cassette12may be slid or otherwise inserted into the cage22between the top straps and assembled therein.

To assemble the IBC liner packaging system10, the liner cassette12is disposed within the cage22of the IBC14and expanded by urging the side panels80A to80D (shown inFIG. 17) outwards. The bottom may be assembled by folding the bottom panels84A to84D (shown inFIG. 17) downwards. To assemble the top, liner16may be unfolded and the spout30A may be disposed centrally within the cage22. As the top panels82A to82D are outwardly and upwardly unfolded, the spout30A may be disposed at the intersection of the top panels82A to82D and captured by the spout access40(shown inFIG. 17).

FIG. 19is a flow diagram of a method90for installing the liner cassette12in the cage22of the IBC14according to an embodiment of the invention. For illustrative purposes, some steps of the method90are depicted inFIGS. 11 to 16and/orFIG. 18. The method90is initiated at step92in response to inserting a first wall unit of the liner cassette12into the cage22.

At step94, a top flap is folded back, a bottom portion is folded down, and side portions are folded out into the cage22as shown inFIG. 12.

At step96, as shown inFIG. 13, a second wall unit is inserted into the cage22and unfolded in a manner similar to the step94.

At step98, the liner16is detached from a sidewall and folded inward and downward. Optionally, the fitting20amay be accessed to fill the packaging system. Alternatively, a cap may be accessed.

At step100, the cap is optionally removed to facilitate installation of the fitting20a.

At step102, a supply hose may be attached to the fitting20aand the packaging system10may be filled.

Following the method90, the contents of the packaging system may be discharged.