U.S. patent application number 10/128974 was filed with the patent office on 2003-10-23 for preformed bag-in-a-box container.
Invention is credited to Muise, Herbert D., Muise, Herbert JR..
Application Number | 20030197051 10/128974 |
Document ID | / |
Family ID | 29215544 |
Filed Date | 2003-10-23 |
United States Patent
Application |
20030197051 |
Kind Code |
A1 |
Muise, Herbert D. ; et
al. |
October 23, 2003 |
PREFORMED BAG-IN-A-BOX CONTAINER
Abstract
A shipping container having an internal plastic bag is
described, as is the method of forming the container A flat
container blank if first formed This differs from a conventional
blank only in that it has blind score lines centered vertically on
each of the end panels. Adhesive strips are placed on or adjacent
the major score lines separating the face and end panels of the
container Either a flat or gusseted bag is then laid on the blank
with a sealed bottom edge adjacent the outside edges of the bottom
flaps of the container. An open end of the bag extends beyond the
upper edge of the container The blank is then folded along the
blind score lines to form a partially assembled container that can
be shipped flat Final assembly can be readily done in the field.
The container eliminates the need for field insertion of the bag
where one is required
Inventors: |
Muise, Herbert D.;
(Tumwater, WA) ; Muise, Herbert JR.; (Mira Loma,
CA) |
Correspondence
Address: |
WEYERHAEUSER COMPANY
INTELLECTUAL PROPERTY DEPT., CH 1J27
P.O. BOX 9777
FEDERAL WAY
WA
98063
US
|
Family ID: |
29215544 |
Appl. No.: |
10/128974 |
Filed: |
April 23, 2002 |
Current U.S.
Class: |
229/117.32 ;
229/117.27 |
Current CPC
Class: |
B31B 2120/408 20170801;
B31B 2105/00 20170801; B65D 5/606 20130101 |
Class at
Publication: |
229/117.32 ;
229/117.27 |
International
Class: |
B65D 005/56 |
Claims
1 A method of forming a semi-finished corrugated shipping container
having an integrally contained liquid impermeable bag which
comprises providing a supply of flat container blanks, the blanks
having face panels, end panels, and a narrow manufacturers joint
strip adjacent one end of the blank, the blanks having top and
bottom closure flaps and top-to-bottom score lines between the face
and end panels and along the manufacturers joint strip, each end
panel further having a centered top-to bottom blind score line, the
closure flaps having outer edges oriented transversely to the score
lines, providing a supply of liquid impermeable bags, the bags
having a longitudinal axis, the bags further having a sealed edge
and an open edge, the bags being longer than the distance between
the outer edges of the top and bottom closure flaps, applying an
adhesive to the container blanks in the area of the face and end
panels; placing a bag upon the adhesive treated container blanks,
the longitudinal axis of the bags being parallel to the score lines
so that the sealed edge of the bags is located generally adjacent
the outer edge of the bottom closure flaps, and folding the panels
along the blind score lines to enclose the bag and bond it to the
container blank.
2 The method of claim 1 that further includes applying adhesive to
the manufacturers joint panel and sealing that joint when the
panels are folded
3 The method of claim 1 in which the bags are supplied from a
continuous end-to-end source, the bags having a separable
perforated but unsealed trailing edge; and thereafter separating
the bag units from one another
4 The method of claim 1 in which the adhesive is applied to the
container blanks along or adjacent the score lines between the face
and end panels.
5 The method of claim 5 in which a small spot of adhesive is
additionally placed in the center portion of the bottom flaps
6 The method of claim 1 in which the bags have a face portion and
gusseted edges, the width of the face portion being essentially
equal to the interior edge-to-edge length of the face panels of the
container blank and the extended width of the gusseted portion
being essentially equal to the interior edge-to-edge width of the
end panels of the container blank
7 The method of claim 6 in which the edges of the bags are placed
on the container blank along the score lines defining one of the
face panels.
8 The method of claim 1 in which the bags are of flat construction
with opposing face portions, the combined width of the face
portions being essentially equal to the combined width of the face
and end panels of the container blank
9 The method of claim 8 in which the edges of the bags are placed
on the container blank along the blind score lines on the end
panels of the container blank
10 A semi-finished corrugated shipping container having an
integrally contained plastic bag which comprises. a flat container
blank, the blank having face panels, end panels, and a narrow
manufacturers joint strip adjacent one end of the blank, the blank
having top and bottom closure flaps and top-to-bottom score lines
between the face and end panels and along the manufacturers joint
panel, each end panel further having a centered top-to bottom blind
score line, the closure flaps having outer edges oriented
transversely to the score lines, a flexible liquid impermeable bag
bonded within the blank, the bag having a longitudinal axis
parallel to the score lines, the bag further having a sealed lower
edge and an open upper edge, the bag being longer than the distance
between the outer edges of the top and bottom closure flaps, the
bag being bonded to the container blank in the area of the face and
end panels, the sealed leading edge of the bag being located
adjacent the outer edge of the bottom closure flaps, the blank
being folded along the blind score lines to enclose the bag
11 The corrugated shipping container of claim 10 in which the
adhesive is used only along the score lines between the face and
end panels.
12 The corrugated shipping container of claim 10 in which the bags
have a face portion and gusseted edges, the width of the face
portion being essentially equal to the interior edge-to-edge length
of the face panels of the container blank and the extended width of
the gusseted portion being essentially equal to the interior
edge-to-edge width of the end panels of the container blank
13 The corrugated shipping container of claim 12 in which the edges
of the bags are located on the container blank along the score
lines defining one of the face panels
14 The corrugated shipping container of claim 10 in which the bags
are of flat construction with opposing face portions, the combined
width of the face portions being essentially equal to the combined
length of the face and end panels of the container blank
15 The corrugated shipping container of claim 14 in which the edges
of the bags are located on the container blank along the blind
score lines on the end panels of the container blank
16 The corrugated shipping container of claim 10 in which the bag
is bonded to the container blank along or adjacent to the score
lines
17 The corrugated shipping container of claim 16 in which the bag
is additionally bonded by small spot of adhesive placed in the
center portion of the bottom flaps
18 The corrugated shipping container of claim 10 which is set up as
a box to receive its intended contents.
Description
[0001] The present invention relates to a corrugated shipping
container having an integral plastic bag The container is formed so
that the bag does not have to be inserted separately when the box
is set up for use While not in any way so limited, the container is
particularly useful for products such as moist fresh vegetables
that are loaded in the field and then are subject to a vacuum
cooling step
BACKGROUND OF THE INVENTION
[0002] The miracle of modern transportation and storage systems has
made fresh fruit and produce of the highest quality available year
round. Even delicate off-season produce such as strawberries and
raspberries find their way from growers in South America to tables
in the United States and Canada while still in prime condition.
Apples and pears are crisp and juicy six to nine months after they
were picked thanks to controlled atmosphere cold storage in which
oxygen level is reduced and carbon dioxide is increased Highly
perishable products are fumigated periodically with sulfur dioxide
during storage to prevent deterioration due to botrytis growth
Field crops, such as celery and broccoli, may be stored for several
days before they are shipped to market If the latter two crops may
be used as examples, a critical part of maintaining them in good
condition is rapid chilling as soon as possible after harvest The
temperature may be brought down in chillers adjacent the growing
fields Sometimes crushed ice is applied to the produce in the
container to maintain the quality When ice is used, this requires a
waxed container or one otherwise made water resistant, such as the
one described in U.S. Pat. No 6,338,234
[0003] One method of cooling involves field packing the produce in
a shipping container lined with a separate plastic bag Liquid water
is added, the amount depending on the ambient temperature of the
produce when packed A free end of the plastic bag is then tucked in
over the produce providing a loose closure Thereafter the package
is palletized and inserted into a vacuum chamber where the produce
temperature is rapidly reduced to its desired level for storage and
shipping. A process of this type is described in detail in U.S. Pat
Nos. 5,421,138 and 5,619,841
[0004] Some problems have arisen in conjunction with the above
described procedure. One is that it generally requires one worker
doing nothing but inserting the plastic bags into the boxes for use
by the pickers. Another problem relates to the endemic windy
conditions in the growing fields It is quite common for the bags to
blow out of the boxes before the produce is added necessitating a
new bag to be supplied An additional problem is the telescoping of
the bag into the box as it is filled leaving an inadequate amount
of the top portion of the bag for the required closure
[0005] The container of the present invention has addressed all of
the above problems and now provides a solution
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a corrugated shipping
container containing an integral plastic bag and to the method of
its formation The method requires providing a supply of flat
container blanks These blanks will have the usual face panels and
end panels defining the sides of the container and most usually a
narrow panel at one end to provide a manufacturers joint when the
box is formed The blanks will also have the usual top and bottom
closure flaps that may be any of several commonly used designs The
terms "face panel" and "end panel" are used based on the usual box
design that is rectangular in cross section. If the ultimate box is
of square cross section one set of panels may be arbitrarily
assigned as "face panels" and the other set as "end panels". The
usual top to bottom score lines will be present between the face
and end panels. In addition, a so-called top-to-bottom "blind"
score line will be placed down the center of each of the end panels
and adjacent flaps. The critical function of these blind score
lines will be described later
[0007] In the usual method of preparation, the blanks will be fed
from a stack onto a conveyor Adhesive will be appropriately applied
to the blanks in the desired areas of the face and end panels. The
preferred area for adhesive application is along or adjacent to the
score lines separating the face and end panels. Optionally,
adhesive may also be applied at this time to the area of the narrow
panel forming the manufacturers joint Normally no adhesive will be
applied to the flaps at this time However, an optional small spot
of adhesive, e g, about 1 cm or less in diameter, may be used in
the interior center of each flap to assist in opening the bag when
the box is erected The bottom flaps may then be glued or otherwise
closed when the box is ultimately set up to receive its
contents
[0008] Plastic bags will be fed from a roll and laid down on the
blanks as they advance down the conveyor line. Each bag will be
longer than the distance from the outer edges of the top to bottom
flaps by the amount the plastic bag is to extend from the top of
the set up container Similarly, each container blank will be spaced
apart from its adjacent blank on the conveyor a distance similar to
that just noted This provides a sufficient length at the open top
of the bag to form the ultimate loose closure. The bags are
typically supplied end-to-end from the roll attached to each other.
They will have a heat sealed closure at one and a perforated tear
line at the open end, similar to the produce bags commonly supplied
in grocery stores. Preferably the leading end will be the
heat-sealed end However, it should be considered to be within the
scope of the invention to use the opposite arrangement; i e, the
heat-sealed end trailing. Whether leading or trailing, the
heat-sealed end will be laid down roughly adjacent the outer edge
of the lower flaps Down the line the blanks with the now attached
bags can be accelerated to separate the bag units along the
transverse perforations
[0009] As a final step in the process, the container blanks are now
folded over upon themselves along each of the blind score lines
This brings the adhesive into contact with both sides of the
plastic bag It is convenient also to glue the manufacturer's joint
at this time. The still flat containers may then be stacked for
storage and shipping
[0010] Either flat or gusseted plastic bags may be used If flat
bags are used, they will be placed on the container blank with
their edges lying along the blind score lines When gusseted bags
are chosen, they will be placed on the container blank with their
edges lying along the score lines defining one of the face panels.
With gusseted bags, the width of the face portion should be
essentially equal to the interior edge-to-edge length of the face
panels of the container blank. Similarly, the extended width of the
gusseted portion should be essentially equal to the interior
edge-to-edge width of the end panels of the container blank If flat
bags are chosen, the combined width of both sides should be
essentially equal to the inner perimeter of the container
[0011] When the container is ultimately erected for use the end
panels, which were initially folded along the blind score lines,
will be extended as normal flat panels. The initial folding along
the blind score lines makes box set up convenient and easy.
[0012] It is a principal object of the invention to provide a
corrugated shipping container with an integral plastic bag, the
container being especially useful for shipping moist products
[0013] It is another object to provide a method of forming the
above container
[0014] These and many other objects will become readily apparent
upon reading the following detailed description taken in
conjunction with the drawings
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 represents a corrugated container blank of a type
generally useful with the invention
[0016] FIG. 2 shows a container blank with a gusseted bag being
applied
[0017] FIG. 3 is a similar figure showing a flat bag being
applied
[0018] FIG. 4 shows how bags might be applied to container blanks
on a production line
[0019] FIGS. 5 and 6 show how the container blank is folded for
shipping.
[0020] FIG. 7 shows a stack of folded container blanks
[0021] FIG. 8 indicates the set up container ready for filling
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The invention can be readily understood by reference to the
Figures In FIG. 1 is seen a corrugated container blank 2 having
major or side panels 4, minor or end panels 6, and a tab or strip 8
for forming a manufacturers joint. Blank 2 further has bottom
closure flaps 10 and top closure flaps 12 Major score lines 14, 16,
18 and 20 define and separate the face and end panels Blind score
lines 22 and 24 bisect each of the end panels 6 A "blind score
line" is one that is folded temporarily during the container
manufacturing sequence but is not functional when the container is
ultimately set up for use Slots, not numbered, are formed as
projections of the score lines in the top and bottom closure
flaps
[0023] As seen in FIG. 2, glue strips 26, 28, 30, and 32 are laid
along and/or adjacent to each of major score lines 14, 16, 18, and
20. Similarly glue 34 is applied to the tab 8 that will ultimately
form the manufacturers joint Alternatively, this joint may be made
internally and the glue would be applied to the outer edge of right
hand panel 4 rather than to tab 8 A gusseted plastic bag 36 is
shown being laid down with its edges along score lines 16 and 18 so
as to be in contact with glue strips 28 and 30. When extended, the
width of the gusseted sections 38 are essentially equal to the
width of end panels 6 The bottom of bag 36 is closed at 40, as by
heat sealing, and lies closely adjacent the outer edges of the
bottom flaps The top 42 of bag 36 is open
[0024] An alternative configuration is shown in FIG. 3 where a flat
bag 50 is employed The edges of this bag lie along blind score
lines 22 and 24 and it is again in contact with glue strips 28 and
30 Again, the bottom 52 of the bag is sealed and the top 54 remains
open
[0025] FIG. 4 shows how the bags may be applied in a production
situation The container blanks 2 are on a conveyor line 6, here
moving from left to right. A supply of bags 62 is provided from a
roll located above the conveyor In the present case flat bags are
being supplied These are pressed against the container blanks by a
roll 64 to bond them to the adhesive lines 28 and 30 which have
been applied immediately upstream by an applicator, not shown.
Individual bag units are supplied end-to-end and are defined by the
sealed end and a perforated tear section at the opposite end In
this regard they are similar to the familiar produce bags supplied
in grocery stores The perforated end of one unit will be closely
adjacent the sealed end of the following unit As the container
blanks with the bags now partially attached reach the right hand
end of the conveyor line an acceleration section generally
indicated at 66 moves the container blanks 2' with bags 50 now
attached so that the bag perforations are torn and the bags
individualized
[0026] There may be cases where the lower flaps might be somewhat
shortened so that they leave a gap when folded In this situation
the lower sealed edge of the bag should extend somewhat beyond the
edges of the lower flaps The amount of this bag extension can be
easily determined for short flaps since the bag should extend one
half of the box width past the interior score line of the lower
flaps
[0027] FIGS. 5 and 6 show the next steps of forming the container
units FIG. 5 shows the right hand end of container blank 2 about to
be folded over along blind score line 22 so that glue strip 26 now
overlies glue strip 28 on opposite sides of bag 50. Similarly, as
seen in FIG. 6, the left portion of container blank 2 is being
folded over along blind score line 24 so that glue strip 32
overlies glue strip 30, again on opposite sides of the bag At the
same time the manufacturer's joint is formed when glue coated tab 8
contacts the outer edge portion of face panel 4 As was noted
earlier, the manufacturer's joint may be made internally rather
than on the exterior of the container The open upper portion 56 of
bag 50 protrudes beyond the upper flaps 12 of container blank 2
[0028] FIG. 7 shows a stack of blanks 60 folded as in FIGS. 5 and 6
ready for shipment to the user and ready to be further set up at or
near the point of use When the container is thus set up, a bottom
portion of either bags 36 or 50 that initially lay over the lower
flaps expands to overlie the bottom of the shipping container.
Simultaneously, the gussets 37 of bag 36 or unglued edges of bags
50 are opened to cover the end portions of the container. To
further set up the container for use the bottom flaps are glued or
otherwise secured and the bag is in place as indicated at 70 in
FIG. 7 The container is now ready for filling with produce or other
material.
[0029] Other configurations of bottom flaps could be used rather
than those shown As an example, one pair could have locking tabs
fitting into slots in the opposite pair so that the container can
be set up into its configuration seen in FIG. 7 without the use of
additional glue
[0030] Referring back to FIG. 3, it should be noted that the open
ends of the bags are to the left of each individual unit and the
sealed end adjacent the right edge of the container blank. An
equally suitable method of assembly might have the sealed end of
the bag adjacent the left hand edge and the open end extending to
the right
[0031] Having thus described the invention and its method of
assembly, it will be readily seen that some variations that have
not been herein described would be apparent to those skilled in the
art. It is the intention of the inventors that all such variations
should be included within the scope of the invention if included
within the breadth of the following claims
* * * * *