Patent Description:
Bag-in-box packaging is commonly used to store and dispense a range of flowable material, for example consumable liquids such as wine or orange juice. Such low filling volume packaging (typically less than <NUM> litres) can typically be assembled and filled with an automatic process. A bag is filled with the flowable material prior to the product being sold. Typically, the bag is filled and emptied through a single opening in the bag. The box provides support and protection for the bag.

For larger filling volumes (typically higher than <NUM> litres - for example, <NUM> or <NUM> litres), however, a manual, complex and time consuming assembly process is required prior to filling of the bag. Particular problems occur in applications where the bag-in-box packaging is filled from above without specialised filling equipment. In order to fill the bag-in-box packaging, complex arrangements of, for example, connections, hoses and/or brackets are typically required. The complexity of the assembly and filling process can also result in incorrect assembly of the bag-in-box packaging.

Further, in order to fill the bag-in-box package, an opening in the bag needs to be connected to a supply of the flowable material. It is important to avoid contamination of the material, which can lead to deterioration of the filling material and reduce its lifespan.

<CIT> discloses a container for fluent material having a bag of flexible material within a container. The bag is fixed to top and bottom plates. <CIT> also discloses a fluent container. The container contains a bag with a valve so material can be discharged from the bag. The present teachings seek to overcome or at least mitigate the problems of the prior art.

A first aspect of the invention provides a filling module configured to locate on an open container to produce a bag-in-box package for storing bulk flowable material. The filling module comprises: a lid portion having a filling opening; a base portion fixed to the lid portion; and an expandable bag located between the lid portion and the base portion. The bag comprises: an inlet for introducing flowable material into the bag, the inlet being in communication with the filling opening of the lid portion; and an outlet for conveying flowable material out of the bag. The bag is configured to expand when flowable material is introduced into the bag through the inlet. The base portion is configured to be separated from the lid portion, such that the bag can expand into the open container.

By providing an expandable bag inside a self-contained filling module, filling of an open container is simplified. A user simply needs to locate the filling module on the open container. Once the base portion is separated from the lid portion, bulk flowable material can be introduced through the filling opening into the inlet of the bag, which will expand to form a bag-in-box package. The filling module also acts as a closure for the bag-in-box package, which can then be used to store and transport the flowable material within.

The base portion may be configured to automatically separate from the lid portion at a predetermined threshold, as a result of the bag being filled with flowable material, such that the bag can expand into the open container.

As the lid portion separates automatically from the base portion due to the force applied by the mass of the bag being filled, the point of separation can remain consistent as desired.

The outlet of the bag may be fixed relative to the base portion of the filling module.

As the outlet of the bag is fixed relative to the base portion of the filling module, as the bag expands and the base portion separates from the lid, the outlet of the bag falls into the open container under gravity, for example, to align with an outlet opening in the open container.

The outlet of the bag may comprise an opening and a conduit connecting the opening to an internal volume of the bag. The conduit may be extendable and/or rotatable.

This allows the location of the opening to be adjusted depending on the dimensions of the open container.

The opening of the outlet of the bag may comprise an outlet valve.

The outlet valve prevents the flowable material from being conveyed out of the bag until desired by the user, as well as limiting air ingress into the bag as the flowable material is conveyed from the bag.

The base portion may comprise a tunnel portion to at least partially enclose the conduit of the outlet. The tunnel portion may be fixed or integral with the base portion.

The tunnel portion helps to protect the conduit as well as locate the outlet of the bag, for example to ensure it is aligned with an outlet opening in the open-topped container.

The conduit and the opening of the outlet may be of the same material as the bag.

The lid portion may have a top surface and at least one side wall extending generally perpendicular from the top surface. The side wall may be configured to engage with a corresponding side wall of the open-topped container to locate the filling module on the open container before a filling process is started.

The dimensions of the lid portion can be varied as required to ensure a correct locating of the filling module on a range of different open containers, depending on, for example, the volume of bag to be filled.

The base portion may have a bottom surface and at least one side wall extending generally perpendicular to the bottom surface. The base portion nests with the lid portion. This reduces the need for an additional lid for the open container and helps to protect the bag from damage as the bag is enclosed.

The nesting of the lid portion and base portion reduces the space requirements of the filling module for transport and storage.

The bag may have an unfilled state wherein the bag is folded.

The folding of the bag reduces the space required before the bag expands.

In the unfilled state, the bag may comprise at least two surfaces that are attracted to one another.

This reduces the possibility of air being sucked into the bag during filling. Reduction of air ingress during filling is desirable to protect the product integrity.

In the unfilled state, the bag may be folded back on itself at least once, to divide the bag into at least a first internal volume and a second internal volume.

This enables the first internal volume to be filled with flowable material while the second internal volume remains compressed, further reducing air ingress as the bag is filled.

The inlet may be in a top surface of the bag.

This enables the bag to be filled easily, for example under gravity.

The filling opening of the lid portion may comprise a closure arrangement. The closure arrangement may comprise a neck portion fixed to the inlet of the bag and a cap fixed to the neck portion.

The closure arrangement closes off the bag-in-box package once the bag has been filled with flowable material. Advantageously, the closure arrangement can also help to tamper proof the package and protect the contents as the package is stored and transported.

The closure arrangement may further comprise an anti-rotation collar fixed to the inlet of the bag. The anti-rotation collar may comprise the neck portion and be non-rotationally fixed to the lid portion. The lid portion may comprise at least one anti-rotation formation to engage an anti-rotation formation on the collar to limit relative rotation of the anti-rotation collar and the lid portion.

As relative rotation of the collar and lid portion is limited, the bag is not mislocated or damaged when, for example, the bag is filled or the cap is fixed onto the neck portion.

The inlet and the outlet may be located on the same side of the bag.

Emptiability of the bag is also increased. Further, as the shortest force line possible is between the inlet and outlet, there is reduced air ingress when the bag is filled.

The base portion may comprise at least one formation for aiding in emptying of the bag. The formation may be a bottom surface sloped towards the outlet.

The emptiability of the bag is further increased.

A further aspect of the invention provides a method of producing a bag-in-box package for storing bulk flowable material. The method comprises: providing a filling module comprising: a lid portion having a filling opening; a base portion fixed to the lid portion; and an expandable bag located between the lid portion and the base portion. The bag comprises: an inlet for introducing flowable material into the bag, the inlet being in communication with the filling opening of the lid portion; and an outlet for conveying flowable material out of the bag. The bag is configured to expand when flowable material is introduced into the bag through the inlet. The base portion is configured to be separated from the lid portion, such that the bag can expand into the open container. The method further comprises locating the filling module on an open container; separating the lid portion of the filling module from the base portion of the filling module; and introducing flowable material into the filling opening of the filling module to expand the bag into the open container in order to produce a bag-in-box package for storing bulk flowable material.

<FIG> shows a bag-in-box package of an embodiment of the present teachings generally indicated at <NUM>, including a filling module <NUM> located on top of an open container <NUM>. The bag-in-box package of this embodiment is suitable for storing bulk flowable material, for example a liquid such as a beverage or paint. Any reference in the following description to relative terms like "upper", "lower", "top", "bottom", "left", "right" is in relation to the orientation of the figures, is for description purposes only and should not be interpreted as limiting in any way.

The open container <NUM> in this embodiment is generally cuboidal. However, it shall be appreciated that in alternative embodiments, the open container <NUM> may be any suitable shape, for example cylindrical or prismic. in this embodiment, as shown best in <FIG>, the open container <NUM> has a rectangular base <NUM>. As shown best in <FIG>, four side walls 16a-16d extend perpendicular from the base <NUM> in an upward direction. The four side walls 16a-16d define an opening <NUM> opposite the base <NUM>. In this embodiment, the opening <NUM> has substantially the same area as the base <NUM>. The side wall 16a includes a foldable portion <NUM> located towards a lower edge of the side wall 16a opposite the opening <NUM>. An upper edge of each of the side walls 16a to 16d defines a top surface <NUM> of the open container <NUM> that acts as a rim to locate the filling module <NUM>.

The foldable portion <NUM> in this embodiment is formed from a cut away section of the side wall 16a and acts as a flap that can be moved in an upward direction. In order to empty the bag-in-box package <NUM>, as described in more detail below, the foldable portion <NUM> is folded upwardly about a fold line. In an alternative embodiment, there may be no foldable portion <NUM> at all - instead, there may simply be an opening in the side wall 16a. In a further alternative embodiment, there may be an opening in the side wall 16a that is exposed by removing a part of the side wall 16a that is fixed to the remainder of the side wall 16a with a frangible connection, for example a perforated line.

Although not illustrated in the Figures, the open container <NUM> may include at least one stiffening formation, such as one or more additional walls or ribs, or inlay parts on the side walls 16a to 16d and/or in the corners of the open container <NUM>.

The filling module <NUM> locates on the open container <NUM> when the bag-in-box package <NUM> is assembled. The filling module <NUM> locates over the opening <NUM> so as to close off the opening <NUM> of the open container <NUM>. The filling module <NUM> generally has a cross-sectional profile corresponding to the cross-sectional profile of the opening <NUM> of the open container <NUM>. In this embodiment, the cross-sectional profile of the filling module <NUM> is rectangular, but it will be appreciated that in alternative embodiments, the filling module <NUM> may have any suitable cross-sectional profile that corresponds to the open container <NUM>, such as circular or polygonal.

As illustrated most clearly in <FIG>, <FIG> and <FIG>, the filling module <NUM> includes a lid portion <NUM>, a base portion <NUM> fixed to the lid portion <NUM>, and an expandable bag <NUM>. The expandable bag <NUM> is located between the base portion <NUM> and the lid portion <NUM>.

The expandable bag <NUM> is configured to expand when flowable material is introduced to the expandable bag <NUM>. The base portion <NUM> is configured to be separated from the lid portion <NUM>. In this embodiment, the base portion <NUM> is configured to automatically separate from the lid portion <NUM> as the expandable bag <NUM> expands and applies a force to the base portion <NUM>, such that the expandable bag <NUM> can expand into the open container <NUM>. The base portion <NUM> separates from the lid portion <NUM> when the mass of flowable material in the expandable bag <NUM> exceeds a predetermined threshold. This applies a force to the base portion <NUM>, for example, due to gravity, urging the base portion <NUM> away from the lid portion <NUM>.

The open container <NUM>, the lid portion <NUM> and the base portion <NUM> may be manufactured from any suitable material, for example corrugated board, cardboard or plastics. The open container <NUM>, lid portion <NUM> and/or base portion <NUM> do not need to be manufactured from the same material as one another, but this may increase recyclability.

As described in more detail below, the expandable bag <NUM> is folded within the filling module <NUM>. The expandable bag <NUM> may be manufactured from any suitable flexible material for containing the bulk flowable material, for example a flexible plastic. An example of a suitable flexible plastic is a polyolefin such as polyethylene or polypropylene. The expandable bag <NUM> may include a single-layer or multi-layer material. Each layer may be a mono-extruded or co-extruded material. Preferably, internal surfaces of the expandable bag <NUM> are in contact with one another until product is introduced into the expandable bag <NUM>, to minimise the amount of unfolding and thus the amount of air that is sucked into the expandable bag <NUM> during assembly and filling of the bag-in-box package <NUM>. Although not shown in the Figures, the internal surfaces of the expandable bag <NUM> may include a material such as a polyisobutylene admixture to make the internal surfaces 'sticky', to keep them in contact as long as possible. Alternatively, the internal surfaces can be made sticky by using electrostatic charging to give each surface a charge such that they attract one another and stay in contact.

The base portion <NUM> includes a bottom surface <NUM> and at least one side wall extending perpendicular from the bottom surface <NUM> in an upward direction. In this embodiment, there are four side walls 60a to d extending from the bottom surface <NUM>. A tunnel portion <NUM> is fixed to the bottom surface <NUM>. Typically, the bottom surface also includes at least one formation for aiding emptying the expandable bag <NUM>. The formation may be, for example, a sloped or stepped bottom surface (not shown).

The side walls 60a to d and the bottom surface <NUM> together define the shape of the base portion <NUM>, which is substantially cuboidal in this embodiment.

The tunnel portion <NUM> is illustrated most clearly in <FIG>, <FIG> and <FIG>. The tunnel portion <NUM> may be fixed to the base portion <NUM>, or alternatively the tunnel portion <NUM> may be integral with the base portion <NUM>. The tunnel portion <NUM> is configured to align with the foldable portion <NUM> (or corresponding opening in the side wall 16a of the open container <NUM>) when the expandable bag <NUM> is in a filled state. The tunnel portion <NUM> of this embodiment has a substantially semi-circular cross-sectional profile, however in alternative embodiments the tunnel portion <NUM> may have any suitable cross-sectional profile, for example circular or square. As described in more detail below, the tunnel portion <NUM> has the function of protecting and locating an outlet of the bag <NUM>.

The lid portion <NUM> includes a top surface <NUM> and at least one side wall extending perpendicular to the top surface <NUM> in a downward direction. In this embodiment, the lid portion <NUM> has four side walls 28a to d extending from the top surface <NUM>. The side walls 28a to d and the top surface <NUM> together define the shape of the lid portion <NUM>, which is substantially cuboidal in this embodiment.

As shown in <FIG>, the filling module <NUM> is configured to locate on top of the open container <NUM> before a filling process is initiated. In this embodiment, the top surface <NUM> of the open container engages the filling module <NUM>. More specifically, the top surface <NUM> of the open container <NUM> engages an underside of the top surface <NUM> of the lid portion <NUM>. The side walls 16a to d of the open container <NUM> locate between the side walls 28a to d of the lid portion <NUM> and the side walls 60a to d of the base portion <NUM>. In this way, as the base portion <NUM> separates from the lid portion <NUM>, the base portion <NUM> falls into the open container <NUM>. In alternative embodiments, however, the top surface <NUM> of the open container <NUM> could, for example, engage a bottom surface of the side walls 28a to d of the lid portion <NUM> to locate the filling module <NUM> in the correct location.

Due to the corresponding shapes of the base portion <NUM> and the lid portion <NUM>, the base portion <NUM> nests within the lid portion <NUM> when the expandable bag <NUM> is in the unfilled state. It shall be appreciated that in alternative embodiments, however, the lid portion <NUM> may nest within the base portion <NUM>.

The base portion <NUM> and the lid portion <NUM> are separate components releasably connected when the filling module <NUM> is assembled. This enables the base portion <NUM> to be separated from the lid portion <NUM> when desired, such that the base portion <NUM> falls into the open container and provides space for the bag <NUM> to expand into as it is filled. In this embodiment, the releasable connection is an adhesive connection. The lid portion <NUM> and the base portion <NUM> are connected by adhesive strips <NUM> (see <FIG>). The adhesive strips are applied to a top edge of the side walls 60a to d of the base portion <NUM>. The adhesive strips may be positioned at discrete locations on the side walls 60a to d, or may extend continuously or partially along the side walls 60a to d. The adhesive strips engage with the underside of the top surface <NUM> of the lid portion <NUM>. As described in more detail below, however, there are a range of different types of releasable connection that could be used to releasably connect the lid portion <NUM> to the base portion <NUM>.

As shown most clearly in <FIG> and <FIG>, the lid portion <NUM> includes a filling opening <NUM> having a closure arrangement <NUM>, and first and second anti-rotation formations <NUM>, <NUM> for engaging corresponding formations on the closure arrangement <NUM>. The filling opening <NUM> is located on the top surface <NUM> of the lid portion <NUM>. The filling opening <NUM> may be any suitable shape, for example circular, and enables a source of flowable material to be connected to an inlet of the bag <NUM> to introduce material into the bag (described in more detail below).

The closure arrangement <NUM> is illustrated in most detail in <FIG> and <FIG>. In this embodiment, the closure arrangement <NUM> includes a neck portion <NUM>, a cap <NUM> to be fixed to the neck portion <NUM>, an anti-rotation collar <NUM>, and first and second anti-rotation formations <NUM>, <NUM> for engaging the anti-rotation formations <NUM>, <NUM> on the lid portion <NUM>. In this embodiment, the closure arrangement <NUM> is fixed to the expandable bag <NUM> so as to enable flowable material to enter the expandable bag <NUM>. More specifically, an underside of the closure arrangement <NUM> is fixed to the bag <NUM>, as described in more detail below. The neck portion <NUM> is threaded and the cap <NUM> has a corresponding internal thread such that it can be screwed onto the neck portion <NUM> to close off an opening defined by the neck portion <NUM>. It shall be appreciated in alternative embodiments, any suitable arrangement may be used to connect the neck portion <NUM> and the cap <NUM>, such as a snap-fit connection.

In this embodiment, the anti-rotation collar <NUM> is integral with and encircles the neck portion <NUM>. The anti-rotation collar <NUM> is, therefore, indirectly fixed to the bag <NUM>. The anti-rotation collar <NUM> includes a flange portion <NUM>, a tapered body portion <NUM>, a recessed portion <NUM>, and the anti-rotation formations <NUM>, <NUM>. The flange portion <NUM> is configured to locate on the top surface <NUM> of the lid portion <NUM>, to generally surround the filling opening <NUM> of the lid portion <NUM>. Extending in a generally downward direction, as shown show most clearly in <FIG> is the tapered body portion <NUM>. The tapered body portion <NUM> is intended to help locate the anti-rotation collar <NUM> in the filling opening <NUM> to help guide the flowable material into the expandable bag <NUM> during a filling operation. At the distal end of the tapered body portion <NUM> is a sealing surface <NUM>, planar with the flange portion <NUM>. The sealing surface <NUM> contacts the expandable bag <NUM>, as described below, to fix the closure arrangement <NUM> to the bag <NUM>.

As shown most clearly in <FIG>, in this embodiment, the first anti-rotation formation <NUM> on the anti-rotation collar <NUM> is in the form of a blade portion projecting from an underside of the flange portion <NUM> and the first anti-rotation formation <NUM> on the lid portion <NUM> is a slot configured to receive the blade portion of the anti-rotation collar <NUM>. In this embodiment, the second anti-rotation formation <NUM> on the anti-rotation collar <NUM> is a protrusion projecting from the underside of the flange portion <NUM> and the second anti-rotation formation <NUM> on the lid portion <NUM> is a corresponding T-shaped recess configured receive the protrusion. The anti-rotation formations <NUM>, <NUM>, <NUM>, <NUM> engage with one another to inhibit relative rotation of the anti-rotation collar and the lid portion <NUM>. As described in more detail below, as the anti-rotation collar <NUM> is fixed to the expandable bag <NUM>, twisting and damage during a filling operation can be minimised.

The expandable bag <NUM> is shown most clearly in <FIG>. When fully expanded, the expandable bag <NUM> includes a bottom surface <NUM>, a top surface <NUM>, and at least two side surfaces 106a, 106b connecting the bottom surface <NUM> to the top surface <NUM>. The expandable bag <NUM> of this embodiment is substantially cuboidal, to substantially correspond to the shape of the open container <NUM>. However, in alternative embodiments, the expandable bag <NUM> may be any suitable shape. For example, an upper portion of the expandable bag <NUM> may be substantially triangular in cross-section.

As shown most clearly in <FIG>, the expandable bag <NUM> includes an inlet <NUM> for introducing flowable material into the expandable bag <NUM>, and an outlet <NUM> for conveying flowable material out of the expandable bag <NUM>. The expandable bag <NUM> defines an internal volume <NUM> for storing the flowable material.

The inlet <NUM> is secured to the closure arrangement <NUM>, in this embodiment to the sealing surface <NUM> of the tapered body portion <NUM> of the closure arrangement <NUM>. In this embodiment, the inlet <NUM> is welded to the tapered body portion <NUM> at the sealing surface <NUM>. However, the inlet <NUM> could be secured to the tapered body portion <NUM> using an adhesive, or any other suitable securing mechanism may be used. In alternative embodiments, the tapered body portion <NUM> could be integral with the bag <NUM>. A flow path is therefore defined between the closure arrangement <NUM> and the inlet <NUM> to internal volume <NUM>, to facilitate the flow of flowable material into the bag. The shape of the inlet <NUM> corresponds to the cross-sectional shape of the neck portion <NUM> and the tapered body portion <NUM>, in order to create a seal and inhibit product from leaking during filling. In this embodiment, the inlet <NUM>, the tapered body portion <NUM> and the neck portion <NUM> are substantially circular in cross-section. When the expandable bag <NUM> is in the filled state, the inlet <NUM> is located towards a top of the expanding bag <NUM>. In this embodiment, the inlet <NUM> is located on the top surface <NUM> of the expandable bag <NUM>.

The outlet <NUM> is illustrated most clearly in <FIG>. In this embodiment, the outlet <NUM> is an extendable tube projecting from the expandable bag <NUM>. In this embodiment, the outlet <NUM> includes an outlet flange <NUM> that engages with an interior surface of the expandable bag <NUM> to retain the outlet <NUM> on the bag <NUM>. In this embodiment, the inlet <NUM> and the outlet <NUM> are located on the same side of the expandable bag <NUM>. The outlet <NUM> is located on a side wall of the expandable bag <NUM>, however in alternative embodiments, the outlet <NUM> may be located at any suitable location on the expandable bag <NUM>, for example on a base surface.

When the expandable bag <NUM> is in the filled state, the outlet <NUM> is located towards the bottom surface <NUM> of the expandable bag <NUM>. When the expandable bag <NUM> is in the filled state, the outlet <NUM> is aligned with the tunnel portion <NUM> of the base portion <NUM> for conveying flowable material out of the expandable bag <NUM>. A flow path is therefore defined between the internal volume <NUM> of the bag <NUM> and the outlet for conveying flowable material out of the expandable bag <NUM>.

The outlet <NUM> includes an opening <NUM> at its distal end, a conduit <NUM> connecting the opening <NUM> to the internal volume <NUM> of the expandable bag <NUM> and an attachment plate <NUM>. In this embodiment, the conduit <NUM> is of the same material as the expandable bag <NUM>. The outlet <NUM> may also include an outlet valve (not shown) so product can be selectively dispensed from the bag <NUM>. The outlet valve may be of any suitable configuration. For example, the outlet valve may include an actuable mechanism, and actuation of the actuable mechanism facilitates the conveying of flowable material out of the expandable bag <NUM>. The outlet valve can help to minimise the ingress of air into the expandable bag <NUM>.

The outlet <NUM> is located within the tunnel portion <NUM> of the base portion <NUM> such that the tunnel portion <NUM> at least partially encloses the conduit <NUM>. In this embodiment, the attachment plate <NUM> locates in a corresponding groove (not shown) in an internal surface of the tunnel portion <NUM>. However, it should be noted that any suitable fastening may be used that fixes the position of the conduit <NUM> relative to the tunnel portion <NUM>, and therefore fixes the position of the conduit <NUM> relative to the base portion <NUM>. The shape of the attachment plate <NUM> can correspond to the shape of the tunnel portion <NUM>. Therefore, in this embodiment, the attachment plate <NUM> is substantially semi-circular.

The conduit <NUM> may be extendable and/or rotatable. This enables the conduit <NUM> to be extended/contracted when the user wishes to empty the expandable bag <NUM>, whilst helping to ensure the bag-in-box package <NUM> is compact. For example, the conduit <NUM> may be concertinaed, as shown in <FIG>, or telescopic. Alternatively, an outer sleeve (not shown) may be threaded to the conduit <NUM> such that rotation of the outer sleeve on the conduit <NUM> causes the outer sleeve to move axially relative to the conduit <NUM> to lengthen the outlet <NUM>.

In the unfilled state, the expandable bag <NUM> is folded back on itself at least once, to divide the expandable bag <NUM> into at least a first internal volume <NUM> and a second internal volume <NUM>. The folding of the expandable bag <NUM> within the lid portion <NUM> and the base portion <NUM> provides a compact solution, making the filling module <NUM> easier to transport and store. When the expandable bag <NUM> is in the unfilled state, as illustrated, for example, in the embodiment shown in <FIG>, the expandable bag <NUM> includes first, second and third pairs of surfaces 94a, 94b, 96a, 96b, and 98a, 98b that are attracted to one another, to keep the bag <NUM> compact until it is filled, and minimise the amount of air that can enter the bag <NUM>.

In the embodiment of <FIG>, the bottom surface <NUM> of the expandable bag <NUM> is located on an interior surface of the bottom surface <NUM> of the base portion <NUM>. The side surface 106b of the bag <NUM>, located on an opposing side of the expandable bag <NUM> to the outlet <NUM>, is folded over so as to overlie the bottom surface <NUM>. The interior surface 98a of the side wall 106b and interior surface 98b of the bottom surface <NUM> are attracted to one another, as described above. The remainder of the expandable bag <NUM>, i.e. the remainder of the side surface 106a, the side surface 106b and the top surface <NUM> are folded together such that the respective interior surfaces 96a, 96b, 98a, 98b are attracted to one another. When the expandable bag <NUM> is folded in this arrangement, there are three pairs of attracted surfaces 94a, 94b, 96a, 96b, 98a, 98b, and three different folds. The advantage of folding the expandable bag <NUM> in this arrangement is that the first internal volume <NUM> begins to fill with flowable material without the fold defining the first internal volume <NUM> unfolding, which reduces the amount of air sucked into the expandable bag <NUM> as the expandable bag <NUM> is filled.

With reference to <FIG>, a method of assembling and filling the bag-in-box package <NUM> from the filling module <NUM> into the open container <NUM> will now be described. The method will be described with reference to the embodiment shown in <FIG>, but it shall be appreciated that any alternative embodiments (for example, as described below) may use substantially the same, or a similar method.

The expandable bag is folded as shown in <FIG>, and described above. in this embodiment, the adhesive strips <NUM> are applied between the base portion <NUM> and the lid portion <NUM>. A supply of flowable material (not shown) is connected to the neck portion <NUM> of the closure arrangement <NUM>,. The supply of flowable material conveys flowable material through the inlet <NUM> and into the expandable bag <NUM>. Due to the location and form of the neck portion <NUM> and the inlet <NUM> of the bag <NUM>, no separate attachment devices are necessary.

When a predetermined mass of flowable material has entered the bag, the mass of flowable material applies a force that causes the base portion <NUM> and the lid portion <NUM> to separate, e.g. due to gravity. At this point, the force applied by the mass of flowable material has exceeded the force of the adhesive connection between the lid portion <NUM> and the base portion <NUM>. Typically, the triggering force will be approximately <NUM> to <NUM> times the weight of the base portion <NUM> plus the bag <NUM>, but this can be varied as required. Due to the weight of the contents of the bag <NUM>, the base portion <NUM> falls into the open container <NUM> until the outlet <NUM> is aligned with the foldable portion <NUM>. The first loop of the expandable bag <NUM> unfolds, however the majority of the expandable bag <NUM> remains folded, thereby reducing the ingress of air into the expandable bag <NUM> during the filling process. The first internal volume <NUM> is filled with flowable material, followed by the second internal volume <NUM>. The expandable bag <NUM> is filled to a predetermined level, until the expandable bag <NUM> reaches the filled state, e.g. as shown in <FIG>.

The cap <NUM> is screwed onto the neck portion <NUM> to close the expandable bag <NUM>. Any appropriate type of tamper-proof seal may also be added at this point. The bag-in-box package <NUM> can then be stored or transported as desired, until a consumer wishes to dispense product from it, which can be done through the outlet <NUM>, e.g. by opening the valve in the outlet <NUM>. The product will be dispensed from the bag <NUM> until the product remaining in the bag <NUM> is below the height level of the outlet <NUM>.

Although the invention has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.

For example, in one alternative embodiment, the lid portion <NUM> and the base portion <NUM> may instead be integrally formed or fixed to one another but connected by a frangible portion. The frangible portion may be, by way of example, a series of perforations providing an area of reduced weakness. The perforations would be arranged such that the lid portion <NUM> separates from the base portion <NUM> when the mass of flowable material exceeds a predetermined threshold.

Alternaively, the lid portion <NUM> and the base portion <NUM> may be separated by a force exerted by the user that exceeds a predetermined threshold, e.g. prior to the expandable bag <NUM> being filled. For example, the lid portion <NUM> may include any suitable type of actuating member, and actuating the member may cause the lid portion <NUM> and the base portion <NUM> to separate.

In a further alternative embodiment, the lid portion <NUM> may be mechanically fastened to the base portion <NUM> in any suitable way. For example, the lid portion <NUM> or base portion <NUM> may be bridged by one or more snap fit noses. The snap fit noses secure the lid portion <NUM> and base portion <NUM> together, but can be configured to separate when the mass of flowable material exceeds a predetermined threshold or when a user manually moves the lid portion <NUM> and the base portion <NUM> away from one another. For example, the snap fit noses may have a curved edge, so when the side walls of the lid portion <NUM> or base portion <NUM> flex, the base portion <NUM> moves past the curved edge and is released from the lid portion <NUM>.

Alternatively, the mechanical fastening may be in the form of a series of fasteners extending through corresponding holes in both the lid portion <NUM> and the base portion <NUM>. The fasteners may extend through the top surface <NUM> of the lid portion <NUM>, through one or more of the side walls 28a to d of the lid portion <NUM>, through the top edge of the base portion <NUM>, or through one of the side walls 60a to d of the base portion <NUM>. The fasteners can be configured to deform or break at a predetermined threshold to allow the base portion <NUM> to separate from the lid portion <NUM>.

In a further alternative embodiment, any suitable arrangement for folding the expandable bag <NUM> may be used. For example, as illustrated in <FIG>, the side surfaces 106a, 106b may be folded multiple times so as to form a cascading arrangement of folds. Alternatively, the remainder of the side surface 106b and the side surface 106a may be placed vertically against the inlet and outlet side of the filling module <NUM>. As a further alternative, the bottom surface <NUM> may be located on the bottom surface <NUM> of the base portion <NUM>, and the expandable bag <NUM> may be compressed vertically.

Claim 1:
A filling module (<NUM>) configured to locate on an open container (<NUM>) to produce a bag-in-box package (<NUM>) for storing bulk flowable material, the filling module (<NUM>) comprising:
a lid portion (<NUM>) having a filling opening (<NUM>);
a base portion (<NUM>) fixed to the lid portion (<NUM>), wherein the base portion (<NUM>) nests with the lid portion (<NUM>); and
an expandable bag (<NUM>) located between the lid portion (<NUM>) and the base portion (<NUM>), the bag (<NUM>)comprising:
an inlet (<NUM>) for introducing flowable material into the bag (<NUM>), the inlet (<NUM>) being in communication with the filling opening (<NUM>) of the lid portion (<NUM>); and
an outlet (<NUM>) for conveying flowable material out of the bag (<NUM>),
wherein the bag (<NUM>)is configured to expand when flowable material is introduced into the bag (<NUM>) through the inlet (<NUM>),
wherein the base portion (<NUM>) is configured to be separated from the lid portion (<NUM>) at a predetermined threshold, such that the bag (<NUM>) can expand into the open container (<NUM>).