BAG IN BOX CONTAINER HAVING A PROTECTIVE OUTER COVERING AND METHOD OF MANUFACTURING SAME

Field of the Invention

The invention relates in general to bag in box containers and more particularly to a bag in box assembly having a cartridge having a bag coupled thereto, wherein a protective outer covering is provided over the bag in box container to increase strength and durability of the resulting container.

The present application claims priority from U.S. Provisional Patent Application Serial No. 60/897,614 filed January 26, 2007, entitled "Bag In Box Container Having A Protective Outer Covering And Method Of Manufacturing Same," the entire specification of which is hereby incorporated by reference in its entirety.

Background to the Invention

The use of bag in box assemblies is well known in the art. Typically, a bag filled with a flowable material is positioned within a rigid outer carton. While such containers have been quite well received, there have nevertheless been deficiencies related to filling, transport and dispensing of same.

Certain solutions have been developed to overcome these deficiencies. Amongst other solutions has been the introduction of a bag in box container which includes a bag that is coupled to a collar which is then coupled to the outer carton. Such bag in box containers and assembly methods are disclosed in each of PCT/GB04/002609 entitled Bag in Box, PCT/GB05/000570 entitled Automatic Bag in Box Assembly and Contents Fill, PCT/GB2005/004313 entitled Bag Cartridge with Ami Torque Collar and PCT/GB2006/004284 entitled Bag in Box

Assembly and Method For Assembling A Bag In Box Assembly all of which share a common inventor with the instant application. Each of the foregoing applications, as well as the underlying priority applications are incorporated herein by reference in their entirety.

It would be advantageous to provide a protective covering about the bag in box container which increases strength and durability. It would be advantageous if a water-resistant covering could be applied prior to or after filling to one of the above-identified bag-in-box containers without requiring the use of expensive or unduly difficult to apply systems. Furthermore, it would be advantageous to have such a protective covering which is easily separable from the other components of the bag in box container.

It is an object of the present invention to provide a protective covering.

It is another object of the present invention to provide a protective covering that is substantially water resistant.

It is another object of the invention to provide a protective covering which increases .the durability and the strength of the underlying bag in box container.

These objects as well as other objects of the present invention will become apparent in light of the present specification, claims, and drawings.

Summary of the Invention

A bag in box container comprising an outer container, a collar member and a protective cover. The outer container includes a plurality of walls. The walls cooperate to define a cavity. At least one of the walls has a cartridge opening defining an outer perimeter of the cartridge opening which provides ingress into the cavity. The collar member is positioned within the cartridge opening with a bag appended thereto. The protective cover encompasses a plurality of the plurality of walls of the outer container.

In a preferred embodiment, the outer container comprises a substantially

rectangular cubic configuration having a top wall, a bottom wall, a front wall, a back wall, a first side wall and a second side wall. The cartridge opening spans a portion of the top wall and the front wall. The protective cover comprises a first shrink wrap member configured to encompass the entirety of the top wall, the bottom wall, the front wall, the back wall and at least the outer perimeter of the first and second side walls.

In another preferred embodiment, the collar member is positioned within the cartridge opening after the application of the first shrink wrap member. Further, the first shrink wrap member includes one of cuts and perforations proximate the cartridge opening so that upon insertion of the collar member, the first shrink wrap member is folded over the outer perimeter of the cartridge opening. In turn, the outer perimeter of the cartridge opening is substantially encased by the first shrink wrap member. In one such preferred embodiment, the protective cover further comprises a second shrink wrap member configured to encompass the entirety of the top wall, the bottom wall, the first side wall and the second side wall and at least the outer perimeter of the front wall and the back wall. The second shrink wrap member extends over the collar member.

In another preferred embodiment, the protective cover further comprises a second shrink wrap member configured to encompass the entirety of the top wall, the bottom wall, the first side wall and the second side wall and at least the outer perimeter of the front wall and the back wall. In such an embodiment, the collar member is positioned within the cartridge opening after the application of the first shrink wrap member and the second shrink wrap member. The first and second shrink wrap members each include one of cuts and perforations proximate the cartridge opening so that upon insertion of the collar member, the first and second shrink wrap members are folded over the outer perimeter of the cartridge opening. In turn, the outer perimeter of the cartridge opening is substantially encased.

In a preferred embodiment, the collar member and the bag member are configured to define a cartridge.

In another preferred embodiment, a handle member is coupled to the protective

cover,

In another aspect of the invention, the invention comprises a method of assembling a bag in box container comprising the steps of assembling an outer container having a cartridge opening; providing a bag within the cavity of the outer container; inserting a collar into the cartridge opening in the outer container wherein upon assembly; and applying a protective cover over at least a portion of the outer container, wherein the step of applying can occur either before or after the step of insertion of the cartridge into the cartridge opening.

In one preferred embodiment, the step of applying further comprises the steps of: applying a first shrink wrap member to the outer container, the first shrink wrap member configured to encompass the entirety of .a top wall, a bottom wall, a front wall, a back wall and at least an outer perimeter of a first and a second side wall; and shrinking the first shrink wrap member against the outer container.

In another preferred. embodiment, the method further comprises the step of cutting a portion of the first shrink wrap member after the step of shrinking. Additionally, the step of inserting occurs after the step of applying a protective cover.

In another preferred embodiment, the method further comprises the step of: applying a second shrink wrap member to the outer container. The second shrink wrap member is configured to encompass the entirety of the top wall, the bottom wall, the first side wall and the second side wall and at least the outer perimeter of the front wall and the back wall. The method further includes the step of shrinking the second shrink wrap member against the outer container.

hi one such preferred embodiment, the method further comprises the step of cutting a portion of the second shrink wrap member after the step of shrinking the second shrink wrap member. Additionally, the step of inserting occurs after the step of applying a protective cover.

In another preferred embodiment, the step of applying a handle member to the

protective cover.

In yet another embodiment, the method further comprises the step of assembling the collar to bag to form a cartridge such that the step of positioning the bag and inserting the collar occur simultaneously.

In one such preferred embodiment, the method includes the steps of folding the bag and securing the folded bag to the collar to minimize the size of the bag.

hi a preferred embodiment, the method further comprises the step of filling the bag with a flowable material.

Brief Description of the Drawings

The invention will now be described with reference to the drawings wherein:

Figure 1 of the drawings is a perspective view of an embodiment of the bag in box container of the present invention;

Figure 2 of the drawings is a perspective view of a cartridge of the bag in box container of the present invention, in an exploded view;

Figure 3 of the drawings is a side elevational view of an embodiment of the bag in box container of the present invention, showing, in particular, the application of the first shrink wrap member prior to heating;

Figure 4 of the drawings is a side elevational view of an embodiment of the bag in box container of the present invention, showing, in particular, the application of the second shrink wrap member prior to heating;

Figure 5 of the drawings is a perspective view of an embodiment of the bag in box container of the present invention, showing, in particular, the scoring and/or cutting of a portion of the first and/or second shrink wrap member after shrinking and before the insertion of the cartridge;

Figure 6 of the drawings ^' is a perspective view of an embodiment of the bag in box container of the present invention showing a container utilizing only a first shrink wrap member;

Figure 7 of the drawings is a schematic representation of one manufacturing and filling method of an embodiment of the bag in box container of the present invention; and

Figure 8 of the drawings is a schematic representation of another manufacturing and filling method of an embodiment of the bag in box container of the present invention.

Detailed Description of the Preferred Embodiment

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail a specific embodiment with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.

It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of the invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.

Referring now to the drawings and in particular to Figure. 1 , bag in box container assembly is shown generally at 10. The particular bag in box container includes outer container 12, cartridge member 14, and handle member 18. While not specifically limited to any particular bag in box containers, the present invention is quite suitable for use in association with the bag in box containers described in any one of the following patent applications: PCT/GB04/002609 entitled Bag in Box, PCT/GB05/00570 entitled Automatic Bag in Box Assembly and Contents Fill, PCT/GB2005/004313 entitled Bag Cartridge with Anti Torque Collar and

PCT/GB2006/004284 entitled Bag in Box Assembly and Method For Assembling

A Bag In Box Assembly, all of which share a common inventor with the instant application. Each of the foregoing applications, as well as the underlying priority applications are incorporated herein by reference in their entirety.

Most generally, the aforementioned incorporated applications disclose, amongst other embodiments, an outer container 12 having top wall 22, bottom wall 24, front wall 26, back wall 28, first side wall 30 and second side wall 32. Generally, the outer container defines a rectangular cubic configuration and a cavity 21. Each of the walls may comprise a single panel, or may be formed from a plurality of panels which are positioned, typically, in an overlaying configuration. Typically, such a container is formed from a paperboard material, and most typically from a corrugated paperboard. Of course, it is not limited to such a material or to paperboard materials whatsoever.

A cartridge opening 34 extends through the outer container 12 so as to provide ingress into cavity 21 defined by the walls of the outer container. In the embodiment shown, the cartridge opening 34 includes two regions, a top wall portion 36 and a contiguous front wall portion 38. The two portions cooperate to releasably retain cartridge 14 (which will be described below), and in particular, portions of the collar thereof.

Cartridge 14 is shown in Figure 2 as comprising collar 50, bag 52 and retaining wrap 54. The collar comprises a rim 55 and an aperture 56. The bag includes body 57 and spout/neck 58. The spout 58 extends through aperture 56 and is secured thereto. In certain embodiments, the bag body is folded so as to be positioned below the collar, and retaining wrap 54 is extended therearound to maintain the folded configuration. In certain embodiments, the retaining wrap is omitted; the bag remains in an unfolded condition (thus defining a cartridge which has collar with an attached bag attached thereto). In other embodiments, the retaining wrap comprises a tape member which is adhered to multiple regions of the bag. The aforementioned incorporated applications include further description of the cartridge and/or the collar and the bag components.

Protective covering 16 comprises a first shrink wrap member 72 and a second shrink wrap member 74. The first shrink wrap member 72 comprises a hoop of material (See, Figure 3), which is heated so as to shrink around the outer container. The first shrink wrap member is positioned such that when shrunk, the member covers substantially the entirety of each of the top wall, the bottom wall, the front wall and the back wall. Additionally, the first shrink wrap member overlaps to cover at least the outer perimeter of the first side wall and the second side wall. In certain embodiments, the entirety of the first and/or second side walls may be encapsulated by the first shrink wrap member. As will be understood, the first shrink wrap member 72 extends over cartridge opening 34. It is contemplated that the shrink wrap members may be transparent, translucent or opaque and that they may have graphics and/or indicia applied thereto.

The second shrink wrap member 74 comprises a hoop of material (See, Figure 4), which is positioned in a different orientation man the first shrink wrap member. Upon heating, the second shrink wrap member encapsulates the entirety of each of the top wall, the bottom wall, the first side wall and the second side wall. Additionally, the first shrink wrap member overlaps to cover at least the outer perimeter of the front wall and the back wall. In certain embodiments, the entirety of the front and/or back wall may be encapsulated by the second shrink wrap member. The second shrink wrap member likewise preferably extends over the top wall portion 36 and the front wall portion 38 of the cartridge opening 34. .

Due to the properties of shrink wrap film, upon heating, the film shrinks so as to relatively closely follow the contours of the outer container. Indeed, the grasp of the shrink wrap about the outer container is preferably rather tight around the contours of the outer container, especially about the comers and edges formed by the intersection of the various walls.

In certain embodiments, only one of the first and second shrink wrap members may be utilized. For example, and with reference to Figure 6, the first shrink wrap member can be utilized without the second shrink wrap member, where, for example, the outer container rests on the ground. Inasmuch as the shrink wrap member extends about the outer perimeter of the first and second side walls, even

where the floor or ground is wet, the moisture will be precluded from contacting the lower region of the container. Similarly, the second shrink -wrap member can be utilized without the first shrink wrap member.

hi other embodiments, additional shrink wrap members may further encapsulate the outer container. However, it has been found that the first and second shrink wrap members substantially adequately render the outer container substantially impervious under most operating conditions.

With reference to Figure 1, again, handle member 18 comprises a polymer strip having grasping region 40, first attachment region 42 and second attachment region 44. ^' The first attachment region is coupled to the first and/or the second shrink wrap member which overlies the first side wall. . Similarly, the second attachment region is coupled to the first and/or second shrink wrap member which overlies the second side wall. The handle member may be coupled ^' to the respective shrink wrap member through adhesive, heat sealing, IR welding, RF welding, among other means. Advantageously, due to the properties of the slirink wrap material, any number of different attachment systems can be utilized to secure the handle member to the protective covering. Of course, in other embodiments, it is contemplated that the handle member may be coupled to the underlying outer container.

A number of different methods of forming the bag in box container. In one embodiment, as is shown in Figure 7, the outer container can first be formed. Once formed, the cartridge can be inserted. Finally, the cartridge bag can be uncapped, filled and recapped. Once the container is fully formed and filled, the first and second shrink wrapping can be applied to the container. Specifically, outer container can be positioned as desired within the first hoop of material which comprises the first shrink wrap member. The entire package can be heated whereupon the first shrink wrap member will shrink to follow the contours of the outer container.

Subsequently, and optionally, the container with the first shrink: wrap member already applied can be positioned within the second hoop of material which

comprises the second shrink wrap member. The entire package is again heated whereupon the second shrink wrap member will shrink to follow the contours of the outer container. The handle member can then be applied if desired.

Through the proper design and positioning of the shrink wrap members prior to heating, wrinkles and excessive material can be minimized, whereupon the completed container will have a relatively smooth appearance.

In. the foregoing embodiment, the cartridge is covered by both the first and second shrink wrap members. In turn, to dispense from the container, the user must cut . the first and second shrink wrap members so as to expose the cap of the filled flexible bag. In essence, the first and second shrink wrap members define a tamper evident assembly, inasmuch as they must be compromised proximate the cartridge prior to dispensing.

In another embodiment of manufacture, and with reference to Figure 8, the outer container is first formed. Once formed, the first and second shrink wrapping can be applied to the container. Specifically, outer container can be positioned as desired within the first hoop of material which comprises the first shrink wrap member. The outer container -with the first shrink wrap member can be heated whereupon the first shrink wrap member will shrink to follow the contours of the outer container.

Subsequently, and optionally, the container with the first shrink wrap member already applied can be positioned within the second hoop of material which comprises the second shrink wrap member. The entire package is again heated whereupon the second shrink wrap member will shrink to follow the contours of the outer container.

Once the desired shrink wrap members are applied to the outer container, the shrink wrap members can be scored or 'cut, at for example lines 76 shown in Figure 5 so as to facilitate the insertion of the cartridge. In essence, once the shrink wrap members are scored and/or cut, the insertion of the cartridge breaks the shrink wrap members. Advantageously, by scoring and/or cutting the shrink

wrap members inboard of the perimeter of the cartridge opening, upon insertion of the cartridge, the shrink wrap is folded over the outer perimeter of the cartridge opening (i.e., the edge of the cartridge opening) and retained in such a position by the cartridge assembly. As such, the shrink wrap essentially renders the edge of the cartridge opening impervious. Finally, the assembled container can be uncapped, filled and recapped. With such an embodiment, the cap of the flexible bag is ready to dispense upon filling.

In other embodiments, one of the shrink wrap members can be applied to the outer container prior to insertion of the cartridge member, and the other shrink wrap member can be applied after insertion of the cartridge member and the filling of the cartridge. Such a, essentially, hybrid process provides both the edge sealing of the cartridge opening and the tamper evidence of the initially described method.

With any of the foregoing methods, the handle member is coupled to either or both of the shrink wrap member after the shrink wrap members have shrunk due to heating.

The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.