U.S. patent application number 10/590096 was filed with the patent office on 2008-02-21 for automated bag in box assembly and contents fill.
Invention is credited to John Stephenson.
Application Number | 20080041018 10/590096 |
Document ID | / |
Family ID | 34878528 |
Filed Date | 2008-02-21 |
United States Patent
Application |
20080041018 |
Kind Code |
A1 |
Stephenson; John |
February 21, 2008 |
Automated Bag in Box Assembly and Contents Fill
Abstract
A BIB carton (150) conjoins a bag (12) with a carton (11)
preparatory to carton fill, with an intervening locating collar
(14) upon a bag neck upstand (52); an assembly and fill process
brings successive individual cartons (41) into juxtaposition with a
bag (51) in a continuous bag web (55), using the neck (52) for
alignment and registration; a locating retention collar (14) is
applied to secure bag neck (52) to carton (41), to create a
sub-assembly web stack (71) of conjoined flat-pack BIB cartons
(20); an inflation (test) station (110) retrieves these
sub-assemblies (20) and inflates/fills them via successive valve
caps (111) secured to collars (14); bag (51) inflation/fill causes
carton (41) formation around it, before a taping machine closes and
seals top (56, 42, 48) and bottom (57, 58) carton flaps.
Inventors: |
Stephenson; John; (Warwick,
GB) |
Correspondence
Address: |
THE WATSON INTELLECTUAL PROPERTY GROUP, PLC
3133 HIGHLAND DRIVE, SUITE 200
HUDSONVILLE
MI
49426
US
|
Family ID: |
34878528 |
Appl. No.: |
10/590096 |
Filed: |
February 16, 2005 |
PCT Filed: |
February 16, 2005 |
PCT NO: |
PCT/GB05/00570 |
371 Date: |
May 25, 2007 |
Current U.S.
Class: |
53/449 ;
53/167 |
Current CPC
Class: |
B31B 2120/408 20170801;
B31B 2105/00 20170801; B31B 50/98 20170801; B65B 3/02 20130101;
B65B 3/045 20130101; B65D 77/065 20130101; B31B 50/84 20170801;
B31B 50/87 20170801 |
Class at
Publication: |
53/449 ;
53/167 |
International
Class: |
B65D 77/04 20060101
B65D077/04; B65B 17/00 20060101 B65B017/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 17, 2004 |
GB |
0403439.3 |
Claims
1. A BIB carton assembly process comprising the steps of: wrapping
a carton (41) element around a bag (51) element and securing these
together, with a locating retention collar (14), to create a
sub-assembly (20), capable of being flat-packed for efficient
transport or storage.
2. A BIB carton assembly process of claim 1, further comprising the
step of: securing a handle (13) to sub-assembly (20).
3. A BIB carton assembly process of claim 1, wherein locating
retention collar (14), is integrated with a handle (13)
element.
4. A BIB carton assembly process of claim 1, further comprising the
steps of: inflating and/or filling sub-assembly (20), by supporting
collar (14), to allow bag (51) inflation and/or fill and attendant
surrounding carton (41) configuration; and completion by closure
and sealing of top (56,42, 48) and bottom (57,58) carton flaps.
5. A BIB carton assembly process of claim 4, further comprising the
step of: injecting air into bag (51), to act as a leak test, prior
to contents fill.
6. A BIB carton assembly process of claim 1, further comprising the
step of: erecting sub-assembly (20) into a completed pack after
transfer to a remote fill line.
7. A BIB carton assembly process of claim 1, further comprising the
step of: erecting sub-assembly (20) into a completed pack at a
local fill line.
8. A BIB carton assembly process of claim 1, further comprising the
step of: erecting sub-assembly (20) into a completed pack
preparatory to filling.
9. A BIB carton assembly process of claim 1, further comprising the
steps of: erecting sub-assembly (20), by selective holding and
folding of carton (41) flaps; sealing top (56,42, 48) and bottom
(57,58) carton flaps ; and inflating and/or filling bag (51).
10. (canceled)
11. A BIB carton assembly machine, with wrap means to wrap a carton
(41) element around a bag (51) element and secure these together,
with a locating retention collar (14), to create a sub-assembly
(20).
12. A BIB carton assembly machine of claim 11, with securing means
to secure a handle (13) onto sub-assembly (20).
13. A BIB carton assembly machine of claim 11, with collar fitting
means to fit an integrated locating retention collar (14), and
handle (13) element.
14. A BIB carton assembly machine of claim 11, with further means
to inflate and/or fill sub-assembly (20), by supporting collar
(14), and allowing bag(51) inflation and/or fill and attendant
surrounding carton (41) configuration; and means to close and seal
top (56,42, 48) and bottom (57,58) carton flaps.
15. A BIB carton assembly machine of claim 14, with further means
to inject air into bag (51), to act as a leak test, prior to
contents fill.
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. (canceled)
21. (canceled)
22. (canceled)
23. (canceled)
24. (canceled)
25. (canceled)
26. (canceled)
27. A BIB carton assembly process comprising the steps of: erecting
a carton element with a profiled opening, inserting a collar
element with attached bag element into said opening, such that the
bag is disposed inside the carton and the collar secures the bag
and carton elements together.
28. A BIB carton assembly process of claim 27, wherein the collar
is integrated with the bag.
29. A BIB carton assembly process of claim 27, wherein bag and
collar elements are attached in a pre-assembly step.
30. (canceled)
31. (canceled)
32. (canceled)
33. (canceled)
34. (canceled)
35. (canceled)
36. (canceled)
37. (canceled)
38. (canceled)
Description
[0001] In GB0314815.2, the Applicant has proposed a particular
implementation of a so-called Bag-In-Box (BIB) container.
[0002] Generally, BIB designation is applied to an impermeable bag
liner within a carton.
[0003] To that broad proposition, the Applicant has contributed an
intervening neck collar locating, bracing and support element.
[0004] This collar feature allows: [0005] accurate mutual
registration or (self-)alignment of bag liner and carton outer;
[0006] transfer, distribution or sharing of bag and carton loading
by bag neck capture through a collar--itself supported in a bespoke
carton recess or cut-out; and [0007] retention of the bag neck to
allow torque closure of a screw cap.
[0008] Bag Contents Fill
[0009] GB0314815.2 sets out fill issues.
[0010] Thus, bag contents fill is a prime consideration for a
contents manufacturer.
[0011] Generally, dedicated automated filling lines are employed
for a bespoke BIB configuration.
[0012] Traditional bag fill typically prefaces insertion of a
filled bag into a pre-formed carton assembly.
[0013] Insertion and cartoning themselves can be a mix of manual
and mechanised steps.
[0014] Fill Machinery
[0015] Resources commitment inhibits packaging change, if
incompatible with established filling machinery.
[0016] Hitherto, fill machinery for (semi-)rigid walled containers,
such as blow moulded Jerrycans, has (often) been incompatible with
that for BIB containers.
[0017] A wet fill environment, with contents spillage, and risk of
degrading cardboard cartons is a factor.
[0018] Mechanised Erection
[0019] Mechanised carton case erection generally is well developed
for closing and joining carton flaps with tape and/or adhesive
bonding.
[0020] However, cartoning mechanisation has not hitherto been
integrated with automated bag filling.
[0021] Indeed bag presentation for fill and fill itself have
traditionally been undertaken as separate steps, preparatory to bag
insertion in a largely completed carton, aside from top closure
flaps.
[0022] Bag Pre-Fill
[0023] In conventional BIB production, a bag is pre-filled and
inserted (or dropped) into a partially erected carton, which is
then closed around it.
[0024] An object of the present invention is to admit alternative
BIB fill and erection techniques.
STATEMENT OF INVENTION
[0025] Some aspects of the present invention address refinement in
production, assembly, erection and filling of BIB containers and
component elements.
[0026] Certain variants in BIB design and construction are also
envisaged.
[0027] Particular instances include: [0028] supplementary
pre-fabricated handles--desirably a `lay-flat`, single sheet,
fabrication; [0029] a deformable cushion floor able to withstand
crushing, collapse and failure upon dropping; [0030] a bracing
liner or sleeve; [0031] top and bottom end stacking plates; [0032]
air cushion bag; [0033] pressure release valve effect; [0034]
integrated neck collar and handle moulding; [0035] plastics sheet
carton; [0036] neck collar integration with plastics sheet carton;
[0037] integrated bag neck and location collar.
[0038] According to one aspect of the invention, a BIB is assembled
from a bag liner and carton, juxtaposed--and mutually
entrained--such as by a bag neck retention rim--prior to bag
(contents) fill.
[0039] Rectangular 3-D Bag
[0040] A preferred bag format has a generally rectangular, flat
bottom, 3-D erect configuration, for closer conformity with a
rectangular carton outer case.
[0041] Continuous Bag Web & Discrete Carton Blanks
[0042] A continuous web of collapsed bag portions with respective
fill/discharge necks is conjoined with a succession of multiple
discrete formative carton elements such as collapsed carton
blanks.
[0043] Locating Collar
[0044] A locating collar, such as of GB0314815.2, is desirably
fitted upon a bag neck.
[0045] Such a collar can overlie an inset step or recess in a
carton (top) end flap, and sit beneath a neck retention rim, flange
or lip.
[0046] This gives an anti-torque seat, which resists bag neck
turning upon screw closure cap fitting and removal.
[0047] Side wall panels of carton blanks are wrapped around
collapsed bags, preparatory to flap joining.
[0048] Local adhesive bonding, taping and/or interlocking edge
profiling may be employed.
[0049] Handle
[0050] An optional pre-fabricated handle element may be attached to
the carton top or side panels.
[0051] The handle is desirably a `lay-flat`, single sheet,
fabrication.
[0052] Alternatively, an integrated handle and collar top-plate may
be fitted to the carton.
[0053] Sub Assembly
[0054] This creates an intermediate sub-assembly which may adopt
and preserve a compact, 2-D collapse-folded, flat-pack,
configuration preparatory to final erection into a 3-D enclosure,
assembly and fill.
[0055] This sub-assembly lends itself to compact storage and
transport to a remote final erection, assembly and fill stage.
[0056] Erection by Bag Inflation
[0057] BIB container 3-D erection, from a collapsed 2-D form, is
achieved by introducing fluid--say air--under pressure through a
bag neck, to inflate the bag.
[0058] Bag inflation takes a carton shell along with it--through
snap-action erection about pre-formed carton edge
creases/folds--until the carton assumes a pre-disposed
(rectangular) volumetric form.
[0059] Thus a collapsible flat-pack, but otherwise (sub) assembled
BIB configuration can be contrived.
[0060] This preserves compact collapsed flat-pack (sub-) assembled
format for space-efficient storage and shipment--rather than
shipping a bulky container void, as with, say, a traditional
Jerrycan.
[0061] On-site erection could be undertaken at a fill station.
[0062] That said, pre-assembly and erection to an empty BIB carton
form can be undertaken preparatory to shipment to a remote fill
station.
[0063] Bag/Carton Clearance Void
[0064] Generally, it is advantageous to preserve a certain
`clearance void` between carton and bag, to allow relative bag
displacement upon impact.
[0065] Cushion Floor
[0066] A collapsible cushion floor pad insert may be inset between
an outer carton and inner bag to bolster shock absorbency in the
event of carton drop.
[0067] A deep or multi-layer corrugated cardboard sheet sandwich
layer may fulfil this role.
[0068] Otherwise there is a risk of bag rupture and contents
bursting upon local carton wall deformation or failure.
[0069] Cushion (Air) Bag
[0070] Features of a clearance void and cushion floor could be
combined in a cushion bag--that is a discrete, say air inflated,
capsule between contents bag proper and carton base and/or top.
[0071] Such a cushion bag could also be integrated with a contents
bag proper.
[0072] An example would be a double-wall or skin.
[0073] Effectively, a bag would constrain contents within an inner
liner and entrain (cushion) air between inner and outer liner.
[0074] Such an air capsule could compress more readily than liquid
contents and so form an intermediate, energy dissipating, shock
absorbing buffer.
[0075] Such a configuration may be particularly useful for
relatively large capacity (eg some 25 litre) BIB variants.
[0076] Alternatively, a discrete self contained subsidiary (air)
cushion bag could be carried or attached to the contents bag
proper.
[0077] Preferably, such a cushion bag would be inflated prior to
insertion into a carton.
[0078] Release Valve
[0079] A preset blow-off valve could allow controlled discharge of
a buffer capsule upon a certain compression load threshold.
[0080] In practice, a carton top recess or step, for a locating
collar, could serve as a safety displacement element upon BIB
drop.
[0081] Thus, upon carton crush from below (i.e. upon drop) the bag
within is displaced upward.
[0082] This in turn forces outward a carton recess and entrained
neck collar and bag neck--for less constrained bag
displacement.
[0083] Otherwise, were a carton a solid rectangle, a bag would have
nowhere to redistribute--and would be forced against the carton
top, with risk of carton and/or bag burst.
[0084] Reinforcement/Bracing Sleeve
[0085] A supplementary reinforcement or bracing sleeve or collar
may be fitted between carton and bag, to help absorb shock impact
load.
[0086] A deep or multi-layer corrugated cardboard sheet sandwich
sleeve may fulfil this role.
[0087] This obviates changing entire carton wall gauge for
exceptional conditions.
[0088] Corrugated Carton
[0089] Indeed an entire carton could be fabricated from corrugated
thick wall cardboard for an inherently very robust
construction--which could obviate the need for a bracing liner.
[0090] Plastics Sheet Carton
[0091] Thin sheet, laminated or corrugated synthetic plastics
material might be employed for specialist application where
economics justify.
[0092] Features such as a neck collar and/or handle could be
integrated into such plastics sheet, say by local (vacuum) moulding
or die cutting, with judicious use of heat to soften material.
[0093] Rectilinear Grouped Form
[0094] A regular, rectilinear, and in particular rectangular,
carton format, with neck inset within a neck collar in a top panel
recess or cut-out allows closely inter-nested rectilinear grouped
stacking and packing.
[0095] Such rectilinear grouping admits of more orderly shipment
than, say, rounded edge Jerrycans with irregular top surfaces with
protruding fill necks.
[0096] Mixed Carton Sizes
[0097] Mixed size cartons of proportionate scaled relative volume
and size multiples can be stacked together--without undermining
stability or space utilisation.
[0098] Cluster Pack
[0099] Clustered or grouped multi-packs can be part enshrouded by a
common wrap, sleeve or minimal opposed (top and bottom) cluster or
stacking plates, say entrained by tie bands.
[0100] Shrink Wrap Palletisation
[0101] Larger and multi-layered stacks can be grouped upon a common
pallet.
[0102] Collective shrink-wrapping of such a palletised stack
creates a unified, robust, load shipping format.
[0103] A strictly rectangular outer profile and careful relative
sizing and proportions allow intimate wall surface contact--and so
mutual bracing in a stack.
[0104] Collective Scaled Print Image
[0105] With homogenous, abutting, carton forms, an entire carton
surface can be over-printed, so a grouped carton collection can
portray an enlarged graphic image from individual carton
elements.
[0106] Such a jigsaw image effect could be used to cross-check
correct carton grouping and alignment.
[0107] Leak Test
[0108] Bag pre-inflation could be used as a pressurised leak test,
by monitoring inflated bag sealing integrity, prior to filling.
[0109] To this end a bag could be subjected, albeit temporarily, to
somewhat higher pressures--or pressure differentials across a
boundary wall--than it would normally be expected to withstand.
[0110] Aside from identifying (and so preempting from operational
use) rupture and burst vulnerabilities, such as along heat weld
seams, lesser, albeit longer term insidious leakage, such as
between neck and bag joint, can be assessed, by monitoring the
ability of a bag to sustain a given start pressure.
[0111] A valve in a fill head could allow both functions in a
single bag neck capture through one-way fill and opposite way
exhaust, with a measurement gauge tapping to the bag interior.
[0112] Such functionality could be achieved by bespoke design or
adapting an otherwise conventional so-called `plunging or diving
head` filler.
[0113] A fill head, with integrated check valve, makes temporary
sealing contact with a bag neck or neck collar for a fill
cycle.
[0114] Reject Disposal--Recycling
[0115] In an automated erection and test line, provision could be
made to off-load a rejected `failed` bag, say by releasing it to a
waste collection hopper.
[0116] Collected bags could be disposed of by plastics
recycling.
[0117] The nature of the bag plastic lends itself to recycling more
than, say, semi-rigid walled Jerricans.
[0118] Any entrained carton with a rejected bag could be released
and, if undamaged, returned to a sub-assembly line for re-use--or
simply disposed of by cardboard recycling.
[0119] Contents Fill Inflation
[0120] Although bag inflation for outer carton erection can be
undertaken as an intermediate step, preparatory to contents fill,
that fill step could itself be used for initial inflation and
erection.
[0121] That is, the bag could remain collapsed until final
fill.
[0122] Progressive Fill
[0123] Uninflated bag capacity is initially at a minimum and offers
modest resistance until an inflated internal void is created upon
bag erection.
[0124] To reflect this, a progressively increasing fill pressure
and/or flow regime could be adopted.
[0125] This would obviate bag shock, fill line blow back and
trigger of over-pressure release valves.
[0126] This also allows the inflating bag to take an outer carton
form along with it from a collapsed 2-D flat-pack to an erect 3-D
form.
[0127] If fill rate is a priority, more abrupt and faster,
pre-erection, such as by air inflation can be employed.
EMBODIMENTS
[0128] There now follows a description of some particular
embodiments of automated BIB assembly and contents fill according
to the invention, by way of example only, with reference to the
accompanying (diagrammatic and schematic) drawings, in which:
[0129] FIG. 1 shows a flow chart of principal operational steps in
BIB constituent element assembly;
[0130] FIGS. 2A and 2B show a BIB sub-assembly sequence;
[0131] More specifically,
[0132] FIG. 2A shows a schematic BIB sub-assembly sequence;
[0133] FIG. 2B shows a flow chart of principal operational steps in
the sub-assembly sequence of FIG. 2A;
[0134] FIGS. 3A and 3B show BIB erection and final assembly;
[0135] More specifically,
[0136] FIG. 3A shows a schematic BIB erection assembly from the
sub-assembly of FIG. 2A;
[0137] FIG. 3B shows a flow chart of principal operational steps in
the erection and final assembly sequence of FIG. 3A;
[0138] FIG. 4 shows multiple simultaneous pre-inflation and/or fill
detail in the erection and final assembly sequence of FIGS. 3A and
3B;
[0139] FIGS. 5A and 5B show variant BIB sub-assembly and erection
sequences;
[0140] More specifically,
[0141] FIG. 5A shows a continuous segmented carton web fed variant
BIB sub-assembly sequence to that shown in FIG. 2A;
[0142] FIG. 5B shows a variant BIB erection sequence to that shown
in FIG. 3A in continuation of FIG. 5A sub-assembly;
[0143] FIGS. 6A and 6B show optional insertion of elements during
the erection and final assembly sequence of FIG. 5B;
[0144] More specifically,
[0145] FIG. 6A shows insertion of a cushion floor into the carton
before final end flap closure;
[0146] FIG. 6B shows insertion of a reinforcement or bracing sleeve
into the carton before end flap closure;
[0147] FIGS. 7A and 7B show optional rectilinear grouping of erect
BIB assemblies employing top and bottom stacking plates entrained
by tie bands;
[0148] More specifically,
[0149] FIG. 7A shows the rectilinear grouping of similar sized BIB
cartons;
[0150] FIG. 7B shows the rectilinear grouping of different sized
BIB cartons;
[0151] FIGS. 8A and 8B show further variant BIB sub-assembly and
erection sequences;
[0152] More specifically,
[0153] FIG. 8A shows a variant BIB sub-assembly sequence to that
shown in FIG. 5A, from respective rolled carton and bag webs;
[0154] FIG. 8B shows a variant BIB erection sequence to that shown
in FIG. 5A, employing the sub-assembly of FIG. 8A;
[0155] FIGS. 9A through 9H show a variant BIB assembly
sequence;
[0156] More specifically,
[0157] FIG. 9A shows a carton blank element;
[0158] FIG. 9B shows the carton blank of FIG. 9A configured to form
a tube wrap or sleeve;
[0159] FIG. 9C shows the carton of FIG. 9B with closed top
flaps;
[0160] FIG. 9D shows (pre-) inflated and/or filled bag insertion
into the bottom of the carton of FIG. 9C;
[0161] FIG. 9E shows the combined carton and bag of FIG. 9D with
closed bottom flaps and a collar fitment;
[0162] FIG. 9F shows the assembly of FIG. 9E with collar in
place.
[0163] FIG. 9G shows the assembly of FIG. 9F with optional handle
attachment;
[0164] FIG. 9H shows the assembly of FIG. 9G with optional
integrated handle and collar top-plate;
[0165] FIG. 10 shows a further variant BIB assembly sequence of
multiple discrete carton wrap and fold around respective discrete
pre-inflated/filled bags--before collar and optional handle
attachment;
[0166] FIGS. 11A through 11C show a variant BIB sub-assembly
sequence to that shown in FIGS. 2A, 5A, and 8A;
[0167] More specifically,
[0168] FIG. 11A shows in detail an unrolled web of contiguous bags
overlaid by individual carton blanks before collar attachment;
[0169] FIG. 11B shows a carton blank wrap around a bag;
[0170] FIG. 11C shows the arrangement of FIG. 11B with completed
carton wrap around a bag and edge joined;
[0171] FIGS. 12A and 12B show entrained box or carton and bag
sub-assemblies, in a stackable flat-pack configuration, ready for
transport, storage or erection and contents fill;
[0172] More specifically,
[0173] FIG. 12A shows an individual carton and bag set upright--in
this instance with bag outside a carton wrap ready for insertion
through a top opening;
[0174] FIG. 12B shows stacked cartons and respective bags--allowing
a bag set within a carton wrap;
[0175] FIGS. 13A through 13C elaborate upon bracing sleeve
insertion into a carton of FIG. 6B;
[0176] More specifically,
[0177] FIG. 13A shows an erected bracing sleeve liner juxtaposed
for insertion into an open-ended top of a carton;
[0178] FIG. 13B shows a completed BIB carton with internal bracing
sleeve depicted in broken lines;
[0179] FIG. 13C shows an enlarged view of a corner of the bracing
sleeve of FIG. 13A, showing corrugated material;
[0180] FIGS. 14A and 14B show a robust carton variant fabricated
entirely of corrugated card (or plastics);
[0181] More specifically,
[0182] FIG. 14A shows a corrugated carton with open top flaps;
[0183] FIG. 14B shows an enlarged view of the corrugations in the
carton of FIG. 14A;
[0184] FIGS. 15A and 15B show an inset collar recess or step
outward reversal, acting as a safety valve upon BIB (drop)
impact;
[0185] More specifically,
[0186] FIG. 15A shows initial BIB drop impact with resultant carton
bottom (corner) crush deformation;
[0187] FIG. 15B shows resulting collar recess ejection and support
step outward hinge, admitting bag displacement;
[0188] FIG. 16 shows a BIB variant with internal top cushion (air)
bag;
[0189] FIGS. 17A through 17C show insertion of an integrated bag
and collar into an erect carton;
[0190] More specifically,
[0191] FIG. 17A shows bag and carton juxtaposition;
[0192] FIG. 17B shows bag profile squeeze insertion through a
carton top opening; and
[0193] FIG. 17C shows a final bag in carton assembly;
[0194] FIG. 18 details collar and bag anti-torque restraint within
a carton recess for screw closure cap tightening and loosening;
[0195] FIGS. 19A and 19B show a synthetic plastics sheet carton
variant with integral moulded collar;
[0196] More specifically,
[0197] FIG. 19A shows a sheet plastics carton blank with integral
moulded collar;
[0198] FIG. 19B shows the sheet plastics carton blank of FIG. 19A
fully erected;
[0199] FIGS. 20A and 20B show a variant of the sheet plastics
carton of FIGS. 19A and 19B--with additional handle cut-out;
[0200] More specifically,
[0201] FIG. 20A shows a sheet plastics carton blank with integral
moulded collar and handle cut-out;
[0202] FIG. 20B shows the sheet plastics carton blank of FIG. 20A
fully erected.
[0203] Referring to the drawings . . .
[0204] Constituents
[0205] FIG. 1 depicts an assembly sequence flow chart of principle
constituent BIB elements, namely: [0206] box or carton 11; [0207]
bag 12; [0208] locating neck collar 14--per GB0314815; [0209]
(optional) discrete (side/top) handle 13;
[0210] The bag 12 features an integral neck pourer or spout for
contents fill and discharge.
[0211] A preferred bag manufacture (not shown) produces a
continuous web of mutually edge-entrained, collapse folded
bags.
[0212] That said, discrete bags (say either produced individually
or separated from a web) can be used, as discussed in later
embodiments.
[0213] Handle--Handling
[0214] Generally, for handling ergonomics, discrete neck collar 14
and handle 13 are disposed at opposite sides of a carton body
11.
[0215] A handle allows a user both to support filled weight and
control the angle of tipping--and so rate of pouring.
[0216] A tall (say, pull-up) handle upstand at the neck collar 14
is feasible.
[0217] Supplementary handle cut-outs in the body (that is top
and/or side walls) of carton 11 are readily provided upon carton
blank die cutting.
[0218] In some variants, the collar 14 and handle 13 could be
integrated--say by adopting a common (vacuum) moulding plate or
strip.
[0219] Such an integrated handle and neck collar could form an
overall carton top plate, providing shape bracing and support to a
stacked overlying carton.
[0220] Flat Pack Sub-Assembly
[0221] These various elements are brought together in a compact
collapsed, flat-pack sub-assembly 20--for `dense` (ie space
efficient) bulk stacking and packing, to supply a remote fill
station.
[0222] Final pack erection and completion (closure and sealing), to
a pre-fill assembly 30, can be undertaken upon sub-assembly 20 in a
subsequent distinct step at a fill station, on a user's premises,
upon draw-down from a local store or repository.
[0223] Thus a fully erect 3-D volumetric form is not assumed until
necessary to accommodate contents.
[0224] In this schema no wasteful void space is consumed in
transport or storage until call-off just preparatory to fill.
[0225] However, if space is not at a premium, empty erected forms
can be transported and stored--relieving the fill plant of the need
for an inflation/erection station.
[0226] Automated Assembly
[0227] Although special-purpose machinery and operation is involved
with BIB, certain (sub-)assembly steps can be derived by adaptation
of conventional case erection packaging machines and
technology.
[0228] This represents an economic advantage if a user is
converting from traditional semi-rigid walled cartons to BIB, but
already has certain packaging equipment.
[0229] The drawings are thus intentionally merely indicative and
illustrative of broad principles, rather than necessarily detailed
engineering solutions.
[0230] Sub-Assembly
[0231] FIGS. 2A (conveyor side elevation) and 2B (sequenced flow
chart) depict in more detail creation of sub-assembly 20 of FIG.
1.
[0232] Bag Web
[0233] Bags are produced as continuous web 55 of conjoined
individual bag elements 51.
[0234] A web 55 of conjoined bags 51 is stored concertina-folded in
a cassette store or repository 50.
[0235] The bags 51 are progressively retrieved from the store 50 by
orderly unfolding and presented in a line, with necks 52 uppermost,
upon a conveyor bed 80.
[0236] Carton Stack
[0237] Multiple discrete cartons 41 are stacked, one above another
in corresponding orientation, as individual cut pre-folded carton
blanks, in a cassette store 40, ready for individual pick-off and
deposit upon a corresponding individual bag 51.
[0238] Carton Blank
[0239] FIG. 9A shows laid-flat carton blank detail, with extended
top 42, 48, 56 and bottom 57, 58 closure flaps and optional handle
cut-outs 44.
[0240] The span of bottom side flaps 57 allows mutual overlap upon
flap fold up--to cover the whole of the base area.
[0241] Bottom end flaps 58 then fold over--to provide three
complete layers of material on the base and thus bolster carton
robustness.
[0242] End flaps 58 are off-set (i.e. one longer than the other) to
mirror the off-set of the top flaps 42, 48 in accommodating the
collar 14.
[0243] Thus a single off-set tape machine (not shown) may be used
(simultaneously) to seal both top 42, 48 and bottom 58 flaps.
[0244] Neck Aperture
[0245] A carton top flap 42 has a pre-cut neck aperture 43 to
receive and locate a neck 52 of a bag 51.
[0246] Neck aperture 43 diameter is sufficient to pass, with modest
local distention, and remain entrained under, a retention rim (not
shown) upon bag neck 52.
[0247] Radial slits (not shown) about aperture 43 create locally a
segmented periphery for such distension.
[0248] Pick'n Place
[0249] A pick'n place arm (not shown) deposits an individual carton
41 upon an associated bag 51, with the help of lateral conveyor
guides 81 and an index locator finger (not shown) for a bag neck
52.
[0250] By drawing bag web 50, successive bags 51 are 00indexed,
incrementally or continuously, over conveyor bed 80, through
successive work stations for carton 41, collar 14 and (optional)
handle 13 fitment.
[0251] Collar
[0252] A cassette store 60 of stacked pre-fabricated (eg vacuum
moulded shell) neck collars 14 is disposed over the conveyor 80 to
deposit an individual collar upon an upstanding bag neck 52.
[0253] Collar 14 is superimposed upon a carton top flap 42.
[0254] A collar aperture 61 is sufficient to pass, with modest
temporary local deformation, over neck retention rim--so that both
carton top flap 42 and collar 14 are held captive between retention
rim and bag 51.
[0255] Collar aperture 61 profile can be adapted--say with radial
peripheral slits or otherwise segmented--to facilitate local
distension for fitment and to secure bag neck 52 when a screw cap
is applied.
[0256] The effect is to impart an anti-torque or torque resistant
entrainment of bag neck in relation to (screw) cap closure
fitment.
[0257] Handle
[0258] A supplementary discrete handle 13, can be fitted to a
carton top flap 42 and side edge 45 at a handle installation
station 90.
[0259] A pre-fabricated (moulded) `lay-flat` profile is convenient
for handle 13.
[0260] Such a handle 13 can be secured by local adhesive
bonding.
[0261] In addition, or alternatively, reliance can be placed upon
handle cut-outs in the carton body.
[0262] In some variants, handle 13 could be integrated with collar
14--in which case a combined store and mounting station could be
contrived.
[0263] Concertina Stacking
[0264] Carton 41, bag 51, neck collar 14 and (optional) handle 13
are fitted to create a sub-assembly 20.
[0265] A succession of sub-assemblies 20 is mutually entrained in a
sub-assembly string or web 71,
[0266] Web 71 is drawn into a concertina-folded stack in a
sub-assembly cassette store or repository 70.
[0267] Sub-Assembly Review--Overview
[0268] Flat Pack
[0269] The overall assembly sequence involves: [0270] bringing
together into juxtaposition a collapsed bag 51 and collapsed carton
41, [0271] with insertion of an intervening location collar 14
according to GB0314815, [0272] so preserving a compact collapsed
flat pack individual sub-assembly 20 form in a sub-assembly string
71.
[0273] A bag neck 52 of an individual bag 51 is orientated upward
as an upstand for registration and location of an aperture 43 in a
top flap 42 of a carton 41.
[0274] An automated BIB carton assembly line 100 is fed by a
continuous web 55 of bags 51 and a stack 40 of collapsed cartons
41.
[0275] A conveyor 80 draws the web 55 along an assembly path, at
which successive individual cartons 41 are extracted from the stack
40 and laid upon an associated bag 51.
[0276] A carton 41 is presented to an underling bag 51 with a top
flap 42 and neck locating aperture 43 deployed in mutual
registration.
[0277] Side and/or end flaps 46 are in-turned and joined, using tab
19, to create a carton sleeve or wrap 47 about each bag 51.
[0278] This leaves top 42, 48, 56 and bottom 57, 58 (closure) flaps
to be deployed and mutually entrained--upon conversion from a 2-D
collapsed form to a 3-D erect form.
[0279] A collar storage cassette 60 with a discharge driving
plunger (not shown), delivers and installs individual collars 14 to
each bag neck 52, with a spring clip insertion and location
action.
[0280] Collar 14 effectively holds the carton top flap 42 with neck
locating aperture 43 captive with the bag neck 52--and thus
entrains overall carton 41 and bag 51.
[0281] The bag neck 52 serves as a locating upstand, to help
preserve bag 51 and carton 41 registration and alignment--also
aided by lateral conveyor guides 81.
[0282] Thus successive cartons 41 are entrained upon respective
individual bags 51 of the bag web 55.
[0283] The entrained bag web 55 and carton `string` 71 is
concertina folded in a storage cassette 70.
[0284] Storage cassette 70 is conveniently a portable container,
which can be transported to a remote final assembly and fill
station, as now described.
[0285] Collapse Folded Flat Pack Sub-Assembly
[0286] The overall outcome of FIGS. 2A and 2B sub-assembly stage is
a compact, collapsed-folded, flat-pack of mutually entrained or
captive bag 51, carton 41, neck collar 14 and (optional) handle 13,
in a sub-assembly string 71.
[0287] Final Assembly & Erection
[0288] FIGS. 3A and 3B depict final assembly and erection to
transform a 2-D collapsed flat pack sub-assembly 71 of FIG. 2 into
an erected fully assembled 3-D form 150 ready for contents
fill.
[0289] Preparatory Bag (Test) Inflation
[0290] In this schema, an intermediate preparatory bag (test)
inflation is undertaken preparatory to carton 41 closure fully to
envelop the bag 51.
[0291] Contents Fill
[0292] In an alternative schema, initial bag 51 inflation is
through contents fill--that is bypassing a preliminary test
inflation.
[0293] The sub-assembly cassette store 70 is emptied by
progressively withdrawing a sub-assembly string 71 based upon an
original bag web 55.
[0294] Individual bags 51 are presented to a preliminary inflation
test station 110 with necks 52 uppermost.
[0295] This orientation also corresponds to the stacking
orientation at the conclusion of the sub-assembly stage of FIG.
2.
[0296] Bags 51 are supported by a conveyor bed 120.
[0297] Simultaneous connection is made to multiple bag necks 52
through multiple individual valve caps 111, with respective
umbilical feed pipes 112 to an air pressure supply 113, through a
rotary swivel connector valve 114 (detailed in FIG. 4).
[0298] Individual bags 51 are captured with a valve cap 111 and a
retention rim locating collar (not shown) to bear bag 51 and
contents weight.
[0299] Until fitment of valve cap 111, and capture by a neck
retention rim location collar, successive bags 51 remain mutually
entrained in original continuous bag web 55--and are thus to an
extent self-registered.
[0300] Upon valve cap 111 and rim locator fitment, bags 51 are
mutually severed--so breaking or fragmenting the former continuous
web 55.
[0301] Severance is conveniently undertaken along a pre-scored
weakening line, using a (slicing rotary or guillotine) knife blade
(not shown).
[0302] Upon mutual severance, individual bags 51 are free to
adopted independent positions and orientations in relation to
successive, formerly adjoining, bags 51.
[0303] Whilst a bag 51 is held captive by its neck 52, its body is
free to hang down--suspended by retention rim, itself configured to
withstand such support loading.
[0304] Similarly, a carton 41 is held captive by entrapment of its
top flap 42 beneath the bag retention rim.
[0305] However, the bulk of carton 41 is free to swing down about a
top flap corner edge fold 49.
[0306] Air (Pre-Fill) Inflation
[0307] Bag 51 and carton 41 gravity suspension is triggered by air
pressure feed to cap valve 111--progressively to inflate, and so
distend bag 51 walls from a collapse folded 2-D condition to an
erect 3-D form.
[0308] Air Pulse
[0309] An air pulse can be employed to disturb initial juxtaposed
bag 51 and carton 41 disposition.
[0310] Successive individual separated bags 51 are carried upon
conveyor 120 to an end flap closure station 130 and onward to a
contents fill station 140.
[0311] Multiple Pre-inflation/Fill
[0312] FIG. 4 shows a plan view of multiple simultaneous
pre-inflation and/or fill detail in the erection and final assembly
sequence outlined in FIG. 3A.
[0313] A spider web array of fill lines 112 radiates from a common
central feed head 113 with a swivel joint and seal.
[0314] Individual fill caps 114 traverse a continuous orbital track
120.
[0315] Concertina Folded Bags and Cartons
[0316] FIG. 5A shows an alternative sub-assembly sequence to that
of FIG. 2A.
[0317] In this arrangement, both bags 51 and carton blanks 41 are
brought together from separate respective stacked concertina folded
webs.
[0318] Once a carton 41 has been correctly located onto bag 51, it
will be severed from subseqent carton 41 to enable individual
carton 41 fold around a respective bag 51, remaining in bag web
55.
[0319] As before, neck retention collar 14 is attached and the
resulting sub-assembly 71 is concertina folded for transport or
storage.
[0320] FIG. 5B shows a follow-on inflation/fill final assembly
sequence to FIG. 5A sub-assembly, with options supplementing basic
steps of FIG. 3A.
[0321] These options are depicted schematically as
interventions--themselves detailed in FIGS. 6A and 6B.
[0322] Again, concertina folded sub-assemblies 71 are drawn from
their stack and attached to an air hose/feed line before being
severed from the next in line.
[0323] A bag 51 is then inflated/filled while the assembly is
supported by its retention collar 14.
[0324] This allows carton 41 to take shape as bag 51 volume
increases.
[0325] A final step is to close and seal top 42, 48, 56 and bottom
57, 58 carton flaps.
[0326] Cushion Floor
[0327] FIG. 6A shows an optional final assembly stage--prior to
closure of bottom carton flaps 57, 58--of insertion of a cushion
floor 15.
[0328] Such a floor 15 may be comprised of corrugated cardboard or
like material, to help protect the bottom of bag 51 inside carton
41.
[0329] Thus, carton 41 base puncture or crush may be accommodated
by the cushion flooring 15 and thus preserve the bag 51 intact.
[0330] Reinforcement/Bracing Sleeve
[0331] Alternatively, or additionally, a reinforcement or bracing
sleeve or liner 16 may be inserted into carton 41 before final
closure, as depicted in FIG. 6B.
[0332] Bracing sleeve 16 bolsters overall carton strength and
rigidity for larger and heavier capacties.
[0333] This is achieved without adoption of a higher or thicker
grade cardboard for the entire carton body.
[0334] Thus, a bracing sleeve could be corrugated to provide
vertical stacking strength, whilst an outer (non-corrugated) carton
body provides splash and water protection.
[0335] Conversely, a corrugated carton body could make a bracing
sleeve redundant.
[0336] Sleeve 16 also preserves overall rectangular carton form,
for stacking consistency and protects bag 51 in the event of carton
41 side impact.
[0337] Stacking Plates
[0338] An optional step of grouping and packaging multiple BIB
cartons after individual carton (150) erection is reflected in
FIGS. 7A and 7B.
[0339] Top and bottom stacking plates 17 sandwich multiple--in this
case dual or paired--adjacent BIB cartons (150) in a rectangular
configuration.
[0340] Plates 17 are held together by tie bands 18 wrapped around
the set at several points.
[0341] A final multiple (in this dual or paired) pack cluster
option is depicted in FIG. 7A.
[0342] This principle may be employed not for mutually entraining
and securing identical BIB cartons (150)--but also sets of
different sized cartons, scaled and stacked to form a substantially
rectangular outer form--as shown in FIG. 7B.
[0343] Web Rolled Bags and Cartons
[0344] FIGS. 8A and 8B show a variant of FIGS. 5A and 5B, whereby
the bags 51 and cartons 41 are brought together from individual web
rolls 91, 92.
[0345] Thus, bags 51 are successively unravelled from roll 91,
whilst cartons--possibly of synthetic plastics material--are
unravelled from roll 92.
[0346] Roll 92 feed is like unsuitable for corrugated cardboard
material, which embodies a laid flat set in production.
[0347] However, roll feed might be tenable for single layer sheet
or card or synthetic plastics, or even corrugated plastics where
corrugations run parallel to the roll axis.
[0348] A sufficiently large roll diameter is envisaged to avoid
material adopting a set curvature.
[0349] Carton Construction (Pre-Bag Insertion)
[0350] FIGS. 9A through 9H detail alternative BIB construction
and/or (pre-)assembly--independently of and prefacing bag
introduction.
[0351] Generally, carton 11 is almost fully formed before bag 12 is
inserted and collar 14 attached.
[0352] An assembly sequence comprises: [0353] fold carton blank 11,
bringing side panels 46 around to form open-ended wrap 47; [0354]
(edge) seal side panels 46 together, using tab 19; [0355] fold down
top flaps 56, 42, 48 and seal in place; [0356] insert bag 12 into
carton 11 through open carton bottom;
[0357] {in practice, a carton collar could be lowered upon an
inflated bag} [0358] attach collar 14 to bag 12 through carton
aperture 43; [0359] close bottom flaps 57, 58 and seal in
place.
[0360] Optionally, a pre-fabricated handle could also be fitted
upon the carton--as shown in FIG. 9G.
[0361] Alternatively, an integrated handle and collar top-plate
could be fitted--as shown in FIG. 9H.
[0362] Carton Construction Around Infated/Filled Bag
[0363] FIG. 10 shows an alternative BIB assembly of bag 12
pre-inflation/fill and carton 11 build around it.
[0364] Sub-Assembly Construction
[0365] FIGS. 11 A through 11 C show sub-assembly from a bag roll 91
and individual carton blank elements 41.
[0366] Each successive individual bag 51 is overlaid with a
respective carton blank 41.
[0367] Carton 41 is then folded in half around bag 51 until side
panels 46 lie adjacent each other.
[0368] Carton side tab 19 is then glued or otherwise secured to
adjacent side panel 46 edge.
[0369] Finally, collar 14 is attached to bag 51 and carton 41 to
secure these elements together.
[0370] FIG. 12 shows a stack of multiple individual BIB
sub-assemblies 20.
[0371] Bracing Sleeve Insertion
[0372] FIGS. 13A through 13C illustrate insertion of bracing sleeve
16 into carton 41.
[0373] Bracing sleeve 16 may be of toughened cardboard material or
corrugated as detailed in FIG. 13C.
[0374] Bracing sleeve 16 is preferrably profiled to nest within
carton 41 body and provide extra strength at the edges and
corners--as illustrated in FIG. 13B.
[0375] Corrugated Carton
[0376] The entire carton body 72 may be constructed from corrugated
material--as shown in FIGS. 14A and 14B.
[0377] This may negate the need for an additional bracing sleeve in
applications where box robustness is of prime consideration.
[0378] Corrugated cartons 72 may also be useful in applications
where the carton does not require to be waterproof.
[0379] Collar Release Valve
[0380] FIGS. 15A and 15B illustrate how collar 14 recess may act as
a safety release valve when the BIB is dropped.
[0381] As a carton 41 is crushed from beneath, internal bag 51 is
forced upwards.
[0382] This forces out recess panel 73 which in turn pushes out
attached collar 14 with intrained bag neck 52.
[0383] As can be seen from FIG. 15B bag 51 then has more room in
which to move away from the crushed carton below.
[0384] This may mean bag 51 can stay intact despite carton 41
crush.
[0385] Cushion Pad
[0386] A cushion pad 74 may be accomodated within carton 41 as
shown in FIG. 16.
[0387] This cushion pad 74 may be filled with air and placed on top
of bag 51, adjacent the underside of recess panel 73.
[0388] As air or gas is more readily compressed than liquid, this
cushion pad 74 may crush before bag 51 liquid contents.
[0389] Integrated Bag & Collar
[0390] A bag may be integrated with a collar 82.
[0391] This may then be inserted into a carton 83 as shown in FIG.
17.
[0392] Carton 83 is provided with an opening 84 into which bag 82
is fed until attached collar seals opening 84.
[0393] Collar & Bag Restraint
[0394] Collar 14 and entrained bag neck 52 are restrained from
rotational movement by carton 41 recess profile.
[0395] Thus, as a screw cap 62 is applied, the resulting torque
does not twist the collar 14 or bag 51 inside the carton 41--as
illustrated in FIG. 18.
[0396] Moulded Plastic Carton
[0397] FIGS. 19A and 19B show a variant carton 93 configured from a
moulded plastics sheet.
[0398] Collar 14 is thus integrated into the carton 93 form,
negating the need for attachment of an additional collar 14
element.
[0399] Other features may also be moulded into a plastic carton
blank.
[0400] FIGS. 20A and 20B show a variant of the above with a plastic
handle cut-out incorporated into carton 94.
[0401] `Mix and Match` Features
[0402] Generally, in the embodiments, where feasible and
appropriate, features may be selectively `mixed and matched` to
suit circumstances--albeit it is not feasible to describe every
such feature combination.
Component List
[0403] 11 box/carton
[0404] 12 bag
[0405] 13 handle
[0406] 14 collar
[0407] 15 cushion floor
[0408] 16 bracing sleeve
[0409] 17 stacking plate
[0410] 18 tie band
[0411] 19 side tab
[0412] 20 sub-assembly
[0413] 30 final assembly
[0414] 40 cassette store
[0415] 41 carton
[0416] 42 top flap
[0417] 43 neck aperture
[0418] 44 handle aperture
[0419] 45 side edge
[0420] 46 end flaps
[0421] 47 wrap
[0422] 48 top closure flap
[0423] 49 top flap corner edge fold
[0424] 50 cassette store
[0425] 51 bag element
[0426] 52 bag neck
[0427] 55 bag web
[0428] 56 top closure side flaps
[0429] 57 bottom side flaps
[0430] 58 bottom end flaps
[0431] 60 cassette store
[0432] 61 collar aperture
[0433] 62 cap
[0434] 70 cassette store
[0435] 71 sub-assembly web
[0436] 72 corrugated carton
[0437] 73 recess panel
[0438] 74 cushion pad
[0439] 80 conveyor bed
[0440] 81 conveyor guides
[0441] 82 integrated bag & collar
[0442] 83 carton
[0443] 84 opening
[0444] 90 handle station
[0445] 91 bag roll
[0446] 92 carton roll
[0447] 93 moulded carton
[0448] 94 moulded carton with handle
[0449] 100 sub-assembly line
[0450] 110 inflation test station
[0451] 111 valve cap
[0452] 112 feed pipe
[0453] 113 air pressure supply
[0454] 114 rotary (swivel) connector valve
[0455] 120 conveyor
[0456] 130 end flap closure station
[0457] 140 contents fill station
[0458] 150 erect BIB
* * * * *