Patent Publication Number: US-2010116824-A1

Title: Bag-in-box assembly

Description:
BACKGROUND OF THE INVENTION 
     Bag-in-box (BIB) constructions for pourable liquids and flowable products are now being used as a replacement for more rigid packaging for a variety of products, including those typically provided in bulk packaging. For example, bag-in-box constructions are now being used for food and beverage products, chemicals, cosmetics, inks, paints, and coatings. Some of the existing product advertising for bag-in-box constructions list, as one of the benefits of this construction concept, being suitable for use with manual, semi-automatic, and fully automatic fill lines. Other listed benefits include using less plastic than similar capacity rigid containers, such as plastic pails and cube-shaped containers. The cube-shaped box or container for BIB constructions minimizes dead space during transport and storage, allowing more product per pallet. Prior to filling, the box is collapsed into flat form and the bag is collapsed as well, thereby minimizing shipping and warehouse space requirements, even when a spout or fitment is already assembled with the bag. Many of the prior art bag constructions are constructed and arranged for filling of the bag prior to box assembly. Accordingly, the bags are constructed with sufficient material thickness and rigidity at the edges and seams so as to be able to be handled and transported as part of the automated boxing steps. 
     When the bag is constructed and arranged to be filled before being placed in the box, there are additional requirements on the bag construction. The overall shape of the bag when filled and the material selected must be factored into the fabrication and assembly requirements for the bag. The spout construction is also a consideration. Not only must the spout have a clearance opening in the box, but the box flaps have to be configured and folded in a particular way to be able to receive the spout during the automated assembly of the filled bag into the box. Different considerations are at issue when the bag is assembled into the box first and then filled with the selected product. Under these circumstances, greater attention must be paid to the construction of the fitment (or spout) and its relationship to the box. 
     The wide range and variety of prior art constructions for bag-in-box (BIB) products suggests that there are a variety of ways to arrange and fold the box as well as a variety of suitable bag configurations. While the box is typically of a corrugated cardboard construction, the bag material or materials are selected based in part on the product to be contained and based in part on the level of barrier desired. Further considerations with regard to the bag material or materials depend on the container size and the type or manner of handling. Bag material is a further variable that can be selected from a range of options, depending on the desired result. Suitable bag materials include polyethylene and oriented-nylon for standard barrier requirements. For high barrier requirements, a co-extruded nylon/EVOH is a bag material option. 
     The third primary component as part of many bag-in-box constructions is a spout or fitment that provides the access port for both filling the bag and dispensing product from the bag. The fourth primary component for these construction is a closing cap or lid of some type that is compatible with the style of fitment for closing the dispensing outlet opening or open end of the fitting. If a separate fitment is not used as a part of the construction, the most likely construction uses a reinforced fill and discharge port. This type of bag is able to be sealed upon filling and incorporates a puncturable seal that is penetrated by insertion of a discharge spout when dispensing. 
     When a separate fitment and closing cap are used, the fitment often includes a surface, such as a flange, for attachment of the bag by either adhesive or welding. Frequently, based on prior art examples, the bag with the fitment welded into position is filled and then boxed. Since a dispensing portion or outlet of the fitment extends outwardly from the surface of the bag, an opening in the box flap or flaps needs to be provided for a portion of the fitment to be received therein. The typical prior art examples include a couple of common forms for receiving the protruding end of the fitment. One form is a circular opening in a box panel or flap for the protruding fitment end to extend through. Installation requires movement of the fitment in a generally perpendicular direction relative to the planar surface of the box panel or flap. Another form is a slot opening with a part circular end. In order to install the fitment or spout, it needs to be moved into the slot in a generally parallel direction relative to the planar surface of the box panel or flap. 
     When the nature of the packaging and the product make it acceptable to fill the bag before being boxed, the focus is on the movement of the bag into the box. Less attention is likely directed to the spout or fitment since it merely needs to extend through a clearance opening in the box. 
     When it is desired to fill the bag and fitment subassembly after assembly into the box, the fitment (or spout) and its assembly with or into the box take on added importance. One aspect of importance is that after filling the bag, the fitment opening must be closed in some fashion. Automated capping equipment for the closing cap onto the fitment generates a turning torque on the fitment and at least some component of that torque is transferred to the interface between the fitment and the box. An axial force is also introduced as the closing cap is pushed in a downward axial direction as part of the capping procedure. 
     The embodiments disclosed herein are directed to addressing these considerations for the fitment, cap, and box construction. The relationships between these components and how they function and cooperate during the boxing, filling, and capping phases are disclosed as well as their novel and unobvious constructions. 
     BRIEF SUMMARY 
     A bag-in-box assembly for receipt of a flowable product has a fitment that defines a dispensing outlet and an interfit portion having a polygon periphery. Also included is a bag which is constructed and arranged to receive the flowable product. The bag includes an opening that is defined by a surrounding lip portion. The surrounding lip portion is attached to a portion of the fitment. The box includes a plurality of panels and a plurality of fold-over flaps. One fold-over flap includes an opening and the opening is defined in part by an edge having a polygon shape. This polygon shaped edge is constructed and arranged to receive the interfit portion of the fitment and secure the fitment in a fashion such that rotation of the fitment relative to the box is restricted. 
     One object of the present disclosure is to describe an improved bag-in-box assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a top perspective view of a bag-in-box assembly according to the disclosed embodiments. 
         FIG. 2  is a top perspective view of the  FIG. 1  bag-in-box assembly with the threaded closing cap removed. 
         FIG. 3  is a front elevational view of a fitment comprising a component part of the  FIG. 1  bag-in-box assembly 
         FIG. 4  is a side elevational view of the  FIG. 3  fitment. 
         FIG. 5  is a top plan view of the  FIG. 3  fitment. 
         FIG. 6  is a bottom plan view of the  FIG. 3  fitment. 
         FIG. 7  is a front elevational view, in full section, of the  FIG. 3  fitment as viewed along line  7 - 7  in  FIG. 5 . 
         FIG. 8  is a perspective view of the  FIG. 3  fitment. 
         FIG. 9  is a partial, front elevational view of a fitment ( FIG. 3 ) and bag subassembly, the bag comprising a component part of the  FIG. 1  bag-in-box assembly. 
         FIG. 10  is a partial, side elevational view of the  FIG. 9  subassembly. 
         FIG. 11  is a partial, top plan view of the  FIG. 9  subassembly. 
         FIG. 12  is a partial, perspective view of the  FIG. 9  subassembly. 
         FIG. 13  is a front elevational view of the  FIG. 9  subassembly with a threaded closing cap applied. 
         FIG. 14  is a side elevational view of the  FIG. 13  bag, fitment, and closing cap assembly. 
         FIG. 15  is a top plan view of the  FIG. 13  assembly. 
         FIG. 16  is a front elevational view, in full section, of the  FIG. 13  assembly, as viewed along line  16 - 16  in  FIG. 15 . 
         FIG. 17  is a perspective view of the  FIG. 13  assembly. 
         FIG. 18  is a perspective view of an open box comprising a component part of the  FIG. 1  bag-in-box assembly. 
         FIG. 19  is a perspective view of the  FIG. 18  box with the  FIG. 9  fitment and bag subassembly installed. 
         FIG. 20  is a perspective view of the  FIG. 19  combination with the two interior flaps folded together. 
         FIG. 21  is a perspective view of the  FIG. 19  combination with two outer flaps folded into a closing position. 
         FIG. 22  is a perspective view of the  FIG. 19  combination with one of the last two outer flaps folded into a closing position. 
     
    
    
     DETAILED DESCRIPTION 
     For the purposes of promoting an understanding of the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alterations and further modifications in the illustrated device and its use, and such further applications of the principles of the disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the disclosure relates. 
     Referring to  FIGS. 1 and 2 , there is illustrated a bag-in-bag box assembly  20  according to the present disclosure that includes a box  21 , bag  22 , fitment  23 , and threaded closing cap  24 . Box  21  is a corrugated cardboard box with a plurality of panels and a plurality of fold-over flaps that are constructed and arranged to create the illustrated box construction. Panel  27  represents the front of the box in terms of marking and product presentation. Oblong opening  28  extends through the corresponding defining flaps of box  21  to the open interior of the box  21  that receives the bag  22 . This oblong opening  28  provides a hand hold to assist in lifting and moving the assembly  20 . This hand hold opening  28  also assists in handling the box when pouring contents out of the bag via the outlet opening  29  of fitment  23 . The box  21  construction and the sequential steps of box assembly are illustrated in drawings  FIGS. 18-22 . The final step to get from  FIG. 22  to  FIG. 2  in terms of the box construction is to fold over top flap  30  and glue it into position. In going from  FIG. 2  to  FIG. 1 , closing cap  24  is added. 
     Referring now to  FIGS. 3-8 , the details of fitment  23  are illustrated. Fitment  23  is a unitary, molded plastic component with a body defining a hollow interior and a dispensing opening  29  defined by the externally-threaded end  33  of fitment  23 . Fitment  23  is constructed and arranged with an upper flange  34 , a lower or base flange  35 , and a recessed hex (wall) portion  36 . These two flanges  34  and  35  are each axially adjacent portion  36 . Portion  36  constitutes the interfit portion for assembly into the box, as will be described in greater detail herein, and in addition to the illustrated hex shape, interfit portion  36  can have a variety of polygon periphery shapes. Fitment  23  is a generally uniform and symmetrical annular form about axial centerline  37 . Cutting plane  7 - 7  in  FIG. 5  provides the section view of  FIG. 7 . 
     With continued reference to  FIGS. 3-8 , externally-threaded end  33  extends for approximately two-thirds of the overall axial height at which location (the lower edge of end  33 ), flange  34  is positioned. In terms of axial directions and structural locations as used herein, “lower” means closer to the bag. “Upper” means farther away from the bag. “Inwardly” means closer to and in the direction of the bag. “Outwardly” means farther away from and in a direction away from the bag. Moving axially inwardly, the next section or portion is hex interfit portion  36 , followed by the lower flange  35 . Flange  34  has a generally hex shape with the hex “points”  40  being smoothly rounded. These hex “points”  40  are generally aligned (i.e., centered on the same radial line) with the hex points  41  of the hex interfit portion  36 . The flats  42  of flange  34  are generally aligned with the flats  43  of the hex interfit portion  36 . The lower flange  35  has a generally cylindrical shape and an outside diameter dimension such that its outer edge  44  extends beyond the outermost portions of upper flange  34 . The hex interfit portion  36  is radially inset or recessed relative to both flanges  34  and  35 . The inside diameter of end  33  has a smooth, straight, cylindrical form. 
     On the underside surface  47  of upper flange  34 , there are integrally molded six depending ribs  48 , extending away from flange  34  in the direction of flange  35 . These ribs  48  are constructed and arranged to press into the corrugated cardboard box flap to assist in preventing or at least limiting bag  22  and fitment  23  shifting during filling and handling. Each protruding rib  48  extends longitudinally in the generally same direction so as to be substantially parallel to each other. This arrangement enables the ribs  48  to be straight pulls from the two clamshell halves of the mold cavity. 
     Referring now to  FIGS. 9-12 , fitment  23  is illustrated as assembled with bag  22 . The bag  22  is a plastic bag with the bag material or materials selected in part based on the contents to be filled and in part on the strength required and in part on the size or capacity. In the preferred and exemplary embodiment, the bag-in-box assembly  20  is used for paint and the bag  22  is a three-layer lamination of different polymers. While these bag-in-box constructions would typically be used for capacities in the five liter to twenty liter range, the preferred embodiment, as used for paint, is a twenty liter capacity. 
     With regard to the three-layer lamination of different polymers, the inner or interior layer  50  is selected to be compatible with the product and the chemistry of the product that is filled into the bag. The material selection also needs to be compatible for welding of the material to the upper surface  51  of the lower flange  35  of fitment  23 . The middle or intermediate layer  52  provides barrier properties to the lamination to prevent ingress and egress of oxygen, moisture vapor, etc. The outer layer  53  is fabricated out of a tougher polymer for providing resistance to puncture and abrasion. While variations to this laminated structure are contemplated, the only layer that might be considered as “optional” is the intermediate layer if a barrier is not required, considering the contents to be filled in the bag. 
     Bag  22  includes an upper or top generally circular opening  56  whose diameter is just slightly larger than the dimension across the hex “points”  40  of the upper flange  34 . This particular sizing leaves an annular lip  57  with a radial width or spacing of between 1 mm and 4 mm from the opening edge  58  to the outer circular edge  59  of lower flange  35 . This annular lip  57  can be thought of as actually defining circular opening  56 . 
     Lip  57  is conduction welded onto the upper surface  51  of lower flange  35  so as to create a continuous circular seal completely around the hex portion  36  of fitment  23  on the upper surface  51 . The nature of the conduction weld also securely attaches the bag  22  to fitment  23  with the requisite structural integrity and strength for the intended function. 
     Referring now to  FIGS. 13-17 , the assembled combination of the bag  22 , fitment  23 , and threaded closing cap  24  is illustrated. It is assumed for these drawings that the bag  22  is conduction welded to the upper surface  51  of the lower flange  35  as already described for drawing  FIGS. 7-12 . The bag  22  and fitment  23  subassembly, as illustrated in  FIGS. 7-12 , remains the same for  FIGS. 13-17 . The only change is the addition of internally-threaded closing cap  24  which is fully threaded onto the externally-threaded end  33  of fitment  23 . As would be understood, it is common for the closing cap  24  to be applied to fitment  23  only after the bag has been filled with the desired product. This in turn would mean that at the time of filling, and prior to attaching closing cap  24 , the fitment  23  and bag  22  are assembled into the box. However, for these drawing figures, the box  21  has been eliminated as a way to more clearly illustrate the relationship between the bag  22 , the fitment  23 , and the closing cap  24 . In this regard, the section view of  FIG. 16  is based on the  16 - 16  cutting plane of  FIG. 15 . 
     Closing cap  24  is a unitary, molded plastic component that includes a generally cylindrical body  62 , substantially flat circular to panel  63 , and a pair of opposite-disposed protrusions  64  and  65 . The generally cylindrical body  62  is internally-threaded and is formed with a closely spaced series of axial ribs  66  on the outer surface. The inner surface  63   a  of top panel  63  is formed with a depending revolved protrusion  67  that plugs the inside diameter surface  68  of end  33 . The annular, depending construction and arrangement of protrusion  67  is spaced radially inwardly from the wall defining cylindrical body  62  so as to create an inverted annular channel  69  for receipt of the upper edge  70  of end  33 . The upper edge  70  seats into the base of channel  69  before the lower edge  71  bottoms out against the upper surface  72  of flange  34 . 
     The pair of protrusions  64  and  65  provide additional leverage for generating removal torque. These protrusions  64  and  65  can also be utilized as part of the fixturing for automated handling and capping equipment. The radial extent of each protrusion does not extend beyond the outer edge of the flats  42  on upper flange  34 . 
     Referring now to  FIGS. 18-22 , the box assembly steps for receiving the bag  22  and fitment  23  and for completing the construction of the box are illustrated. Box  21  begins with a construction that provides four sidewalls or panels  27 ,  76 ,  77 , and  78  surrounding a bottom panel  79 . It should be understood that prior to the  FIG. 18  illustration, box  21  would be in a flat form and folded into the illustrated construction with the bottom panel  79  typically being formed from adjoined flaps that are glued together. 
     Included as a part of the box  21  construction are four top flaps  30 ,  80 ,  81 , and  82 . These four top flaps are outer or exterior flaps and complement the two interior or inner flaps  83  and  84 . The specific construction in terms of how the panels and flaps are shaped, cut, and folded is to some degree optional, so long as a structurally sound box is able to be constructed and includes the four top flaps  30 ,  80 ,  81 , and  82  and the two inner flaps  83  and  84 . It is also to be understood that the overall construction of box  21  is selected such that it has an interior volume suitable for holding bag  22  as filled with the desired product and the desired volume or quantity of product. 
     Given the fact that the four side panels  27 ,  76 ,  77 , and  78  and the bottom panel  79  can be configured and secured together in a variety of ways, the focus in terms of the assembly sequence is on the top flaps  30 ,  80 ,  81 , and  82  and the two inner flaps  83  and  84 . Flap  83  includes a notched out opening  88  that has a part-hex edge shape including four ( 88   a,    88   b,    88   c,  and  88   d ) of the six flats for a full hex contour. Flap  84  defines oblong opening  28  and the inner edge  89  of flap  84  is constructed and arranged with the other two flats  89   a  and  89   b  for the full hex contour. The size, shape, and location of flaps  83  and  84  is such that when these two are folded flat, they cooperate to define a full hex contour for the resulting opening. Flap  30  includes a clearance opening  90  that overlaps and generally concentrically surrounds the hex opening formed by the folded together combination of flaps  83  and  84 . The four top flaps and the two inner flaps are all considered to be fold-over flaps in terms of their use, construction, and the manner in which they are manipulated to complete the box construction as disclosed herein. 
     Starting with the  FIG. 18  box construction status, the bag  22  and fitment  23  subassembly, as a welded combination as illustrated in  FIGS. 9-12  and without the closing cap  24  threaded on, is installed, see  FIG. 19 . In order to achieve the  FIG. 19  assembly, the partial hex form of opening  88  receives the hex shape of interfit portion  36 . As described, interfit portion  36  is identified in this manner since this is the portion that fits into the opening in flap  83 . While the hex shape of interfit portion  36  matches the part-hex shape of the opening in flap  83  when flap  84  is closed into position, those two flaps  83  and  84  cooperate to define a hex opening that closely matches the hex periphery of interfit portion  36 . The close cooperating fit of the box hex opening around interfit portion  36  secures the fitment so that it does not rotate or spin relative to the box when the closing cap is applied. The upper flange  34  is positioned on top of flap  83  and is in direct contact with the upper surface  91  of flap  83  such that the depending ribs  48  are able to press into the corrugated cardboard surface  91  of flap  83  to assist in preventing, or at least limiting, any bag  22  and fitment  23  shifting during filling and handling. When flap  84  is closed into position, the portions of the ribs  48  contacting the upper surface of flap  84  press into that corrugated cardboard surface. The upper surface  51  of flange  35  is positioned in direct contact with the underside (interior) surface of flap  83  and of flap  84 . 
     After the bag  22  and fitment  23  subassembly is fitted into the partial hex form of opening  88 , as illustrated in  FIG. 19 , flap  84  is folded into position in order to complete the hex shape of the receiving opening and thereby completely capture the hex interfit portion  36  of fitment  23  (see  FIG. 20 ). This assembly of the fitment (and bag) into the cardboard flaps  83  and  84  is achieved without the need for any glue or adhesive and without the need for any mechanical fasteners. The hex-to-hex interfit in combination with the upper and lower flanges  34  and  35  is sufficient to lock the fitment  23  into the matching hex opening defined by the combination of cardboard flaps  83  and  84 . The mating form of flap  84  that completes the hex shape for the opening is positioned as part of center portion  92 . Slits  93  and  94  separate the sides of portion  92  from the remainder of flap  84 . These slits  93  and  94  provide added flexibility to portion  92  in order to facilitate its movement into position against interfit portion  36 . 
     Following the assembly stage represented by  FIG. 20 , flaps  80  and  82  are folded over to partially close the top of the box and these two flaps are glued in position, as is illustrated in  FIG. 21 . The next step is to fold over and glue flap  81 , as illustrated in  FIG. 22 . The final stage in completing box  21  is to fold over and glue flap  30 . This results in the final construction, as illustrated in  FIG. 2 . The next step is to fill the bag with the desired product in the desired volume or quantity and thereafter apply closing cap  24  in order to complete and create the  FIG. 1  structure. 
     As described, fitment  23  slides into the partial hex form of flap  83  without the use of glue or adhesive. Further, no portion of bag  22  is adhesively attached to any portion of the box. After the bag and fitment are assembled and the box construction completed, the bag is filled, in this embodiment with paint, then capped using closing cap  24 , and is ready to be shipped. The matching hex shapes of the portion  36  periphery and of the edge for the opening defined by flaps  83  and  84  prevents rotation of the fitment  23  relative to the box in either direction during capping, removal, and recapping. The upper and lower flanges  34  and  35  prevent axial movement of the fitment  23  relative to the box flaps, in either direction, as the bag  22  is filled and the assembly handled. 
     While portion  36  is described as preferably having a hex peripheral shape that matches the hex opening defined by flaps  83  and  84 , other shapes are contemplated, so long as the anti-rotation feature and relationship between fitment  23  and the opening in flaps  83  and  84  is maintained. For example, an octagon shape can be provided as another polygon periphery for portion  36  and similar changes would then be made to the opening defined by the combination of flaps  83  and  84 . If an octagon is selected for the polygon periphery of portion  36 , then flap  83  would typically include five of the eight flats while flap  84  would complete the matching octagon shape by providing the other three flats. Since the selected shape can be any one of a variety of polygons, that becomes one way to describe the peripheral shape of portion  36  as well as describing the matching opening defined by flats  83  and  84 . The portion  36  has a polygon periphery, with the number of flat sides selected to lock into a matching opening so as to create a non-rotational relationship for the fitment  23  relative to the receiving flaps of box  21 . The upper and lower flanges  34  and  35  cooperate with this overall construction so as to prevent any noticeable axial movement of the fitment  23  relative to flaps  83  and  84 . 
     While the preferred embodiment of the invention has been illustrated and described in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that all changes and modifications that come within the spirit of the invention are desired to be protected.