AU2014250720B2 - Combined box and resealable bag - Google Patents

Abstract

COMBINED BOX AND RESEALABLE BAG A method of forming a bag-in-container assembly (100) comprising the steps of: providing a mandrel (90) suitable for supporting a bag member (14) and a container member (12) thereon, placing the bag member (14) on the mandrel (90) and placing the container member (12) over the bag member (14) on the mandrel (90) at a distance from a bottom of the container (100), and applying pressure to the container member (12) to join the bag member (14) to the container member (12) to yield a bag-in-container assembly (100).

Description

1 2014250720 17 Oct 2014

TITLE OF THE INVENTION

COMBINED BOX AND RESEALABLE BAG

FIELD OF THE INVENTION

[0001] The present invention relates to packaging and containers. More particularly, the present invention relates to a combined container and bag and to its method of manufacture.

BACKGROUND OF THE INVENTION

[0002] Flowable materials including foodstuffs such as cereals and the like and numerous other products have been sold in packaging such as boxes for many years. Such packaging is desirable since the packages protect the product from spoilage and physical damage. These packages also stack easily for shipping and for display on shelves. Packages such as boxes employ an inner bag that contains the product within the box. After the bag is opened and the desired amount of product removed, the bag is resealed, usually by folding the top of the bag over upon itself. Such inner bags, however, are frequently difficult to open and almost never reseal effectively.

[0003] Recently, products have been proposed wherein the bag is outside of the box rather than inside the box. U.S. Patent No. 6,908,422, shows a paperboard box inserted into a plastic bag that has a closeable zippered top. The box is inserted while in its collapsed form and is manipulated into an open position when it is desired to fill the box. This can create problems during use since the entire box is in the bag and can damage the bag when attempting to open the box.

[0004] Published U.S. Patent Application No. U.S. 2005/0194386 is directed to a zippered, plastic bag box cover for resealing paperboard boxes. The zippered plastic bag is positioned at the top of the box. The bag has an open bottom and elastic strip around the bottom edge of the bag to secure the bag to the box. This arrangement does not appear to provide an effective seal.

[0005] A similar arrangement is shown in U.S. Patent No. 7,160,029. In the embodiment shown in Fig. 9b thereof, the lower edge of the bag includes a strip of adhesive at the bottom of the bag. While this may create a better seal in some instances, this seal does nothing to enable closure of the inner bag, nor to improve closure on the other end of the carton, thereby leaving the product

AH25(9266646_1):DJM 2 2014250720 28 Apr 2017 inside the carton to be relatively unprotected from spoilage due to moisture and oxygen infiltration.

[0006] There is, therefore, a need for a combined container and bag that is capable of effectively sealing to the container. There is also a further need for a combined container and bag wherein the bag may be resealed after the bag has been opened.

OBJECT OF THE INVENTION

[0007] It is an object of the present invention to substantially satisfy the above need or to at least provide a useful alternative.

SUMMARY OF THE INVENTION

[0008] There is disclosed herein a method of forming a bag-in-container assembly comprising the steps of: providing a mandrel suitable for supporting a bag member and a container member thereon, placing the bag member on the mandrel and placing the container member over the bag member on the mandrel at a distance from a bottom of the container, and applying pressure to the container member to join the bag member to the container member to yield a bag-in-container assembly.

[0009] In a first aspect, the present invention provides a combined box blank and resealable bag comprising: a paperboard box blank having: a front box wall, a rear box wall, a pair of side walls consisting of a left side box wall having a vertical fold at its mid-point forming a front left side box wall and a back left side box wall; and a right side box wall having a vertical fold forming a front right box side wall and a back right side box wall; and a plurality of flaps capable of forming a bottom box wall; said front box wall, rear box wall, and right rear side box walls having upper ends and lower ends and having inside surfaces and outside surfaces;

AH26( 12951430 2):JBL 3 2014250720 28 Apr 2017 said inside surfaces of said front and rear box walls contacting each other whereby said box blank lies substantially in a single plane; a bag portion made of flexible plastic material having a zippered top and downwardly extending front and rear bag walls, said front bag walls having a lower edge portion and said rear bag wall having a lower edge portion; said lower edge portion of said front bag wall being sealed to said upper ends of said outside surface of said paperboard box blank front wall, left from side box wall, and right front side box wall at a distance from the flaps capable of forming the bottom box wall and said back bag wall being sealed to said upper ends of said outside surfaces of said paperboard box blank back wall, left back side box wall, and right back side box wall at a distance from the flaps capable of forming the bottom box wall whereby said combined box blank and resealable bag portion lie in substantially the same single plane.

[0010] Preferably, said lower edge portion of said bag walls is heat sealed to said outside surfaces of said front, rear and side box walls.

[0011] Preferably, the upper ends of each of said front, rear and side walls are folded outwardly and downwardly so that the inside surface of each of the upper ends forms a strip that faces outwardly and lies in substantially the same plane as its respective outer surface. The inside surfaces of said walls, including said outwardly facing strips, preferably have a thermal plastic coating thereon. The said lower edge portions of said bag walls are preferably heat sealed to said outwardly facing strips. The combined box blank and resealable bag preferably further includes means for maintaining said steps in their folded position.

[0012] In a second aspect, the present invention provides a method of forming a combined box and resealable bag comprising the steps of: providing a paperboard box blank having a front wall, a rear wall, a pair of opposed side walls consisting of a left side wall having a vertical fold forming a front left side wall and a back left side wall; and a right side wall having a vertical fold forming a front right side box wall and a back right side box wall; the paperboard box blank having a plurality of flaps capable of forming a bottom box wall and wherein said front box wall, rear box wall, left front side box wall, left rear side box wall, right front side box wall, and right rear side box walls have upper ends and lower ends and inside surfaces and outside surfaces;

AH26( 12951430 2):JBL 4 2014250720 28 Apr 2017 providing a plastic bag portion having a recloseable zipper top and downwardly extending front and rear walls, said downwardly extending front wall having a lower edge having an inside surface and an outside surface, said downwardly extending rear wall having a lower edge having an inside surface and an outside surface; sealing said inside surface of said lower edge of said downwardly extending front bag wall to said outside of said upper end portion of said paperboard box blank front wall, left front side box wall, and right front side box wall at a distance from the flaps capable of forming the bottom box wall; sealing said inside surface of said lower edge of said bag rear wall to said outside of said upper end portion of said paperboard box blank rear wall, left back side box wall, and right back side box wall at a distance from the flaps capable of forming the bottom box wall while said blank is in a flat planar condition; and thereafter, expanding said front, rear and side walls of said box blank to form a box.

[0013] Preferably, the method further comprises the step of folding outwardly and downwardly the upper end of each of said front, rear and side walls of said box blank so that the inside surface of each of the upper ends forms a strip that faces outwardly and lies in substantially the same plane as its respective outer surface. The method also preferably includes the step of securing said strips in their folded position.

[0014] Preferably, said inside lower edges of said bag front and rear walls are sealed to said strips. The inside surfaces of said box walls, including said outwardly facing strips, preferably have a thermal plastic coating thereon. The said lower edge of said bag front and rear walls are preferably heat sealed to said strips.

[0015] Other features of the invention will be readily apparent from the following detailed description of a preferred embodiment thereof taken in conjunction with the drawings.

AH26( 12951430_2):JBL 4a 2014250720 28 Apr 2017

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For the purpose of illustrating various aspects of the invention, there is shown in the drawings forms that are preferred. It is understood, however, that this invention is not limited to the precise arrangements shown in the drawings.

[0017] FIG. 1 is a front perspective view of an embodiment of a container that includes a container member and a bag member in an assembled configuration where the bag member is disposed over a container member to produce a bag-on-container type assembly; [0018] FIG. 2 is a perspective view of a box blank for use in manufacture of a box type container member that shows outwardly extending strips at the top of the box blank;

AH26( 12951430_2):JBL 5 2014250720 17 Oct 2014 [0019] FIG. 3 is a front elevational view of a bag attached to the top of a box blank where the box blank is in a flat planar state for use in manufacture of a bag-on-container type assembly; [0020] FIG. 4 is a front elevational view of a bag-on-container type assembly where the bag member is attached to the top of a container member; [0021] FIG. 5 is a side elevational view of the bag-on-container type assembly shown in FIG. 4; [0022] FIGS. 6 and 7 are schematics that show a process for manufacture of a bag-on-container type assembly; [0023] FIG. 4 is a front elevational view of a bag-on-container type assembly where the bag member is attached to the top of a container member; [0024] FIG. 5 is a side elevational view of the bag-on-container type assembly shown in FIG. 4; [0025] FIGS. 6 and 7 are schematics that show a process for manufacture of a bag-on-container type assembly; [0026] FIGS. 8 and 12 show bag-in-container type assemblies; [0027] FIGS. 9A-9C show a bag member where the closure member is located at the corner of the bag member; [0028] FIG. 10 shows an alternative embodiment of a container member that includes an internal reinforcement member; [0029] FIG. 10A shows a box blank that includes a reinforcement member for use in manufacture of the container member shown in FIG 10.

[0030] FIG. 11 is a schematic that shows manufacture of a bag-in-container type container assembly.

AH25(9266646_1):DJM 6 2014250720 17 Oct 2014

DETAILED DESCRIPTION OF THE INVENTION

[0031] As used herein, the term "bag member" is understood to mean a receptacle formed from a material that may be sealed at one end whereby the receptacle has a closed end and an open end.

[0032] As used herein, the term airtight seal is understood to mean <0.1 liters/year of gas exchange between the seal between the bag and container and the atmosphere.

[0033] In the embodiments and variations in the bag-on-container and the bag-in-container assemblies of the invention a wide variety of materials may be employed. Materials that may be employed in manufacture of container member 12 employed in the bag-on-container and bag-in-container type assemblies include but are not limited to celluloses, metals, plastics and combinations thereof such as laminates of one or more of celluloses, metals and plastics. Laminates may include two or more layers. The materials employed in container member 12 may be metalized, coated with glass, or otherwise treated to enhance barrier properties.

[0034] Metals that may be employed to form container member 12 include but are not limited to aluminum, iron alloys such as steel, tin, and combinations thereof. Celluloses that may be employed to form container member 12 include but are not limited to celluloses such as cardboard, paperboard, cellophanes and combinations thereof. The celluloses may bear one or more coatings of materials such as one or more thermoplastics.

[0035] Thermoplastics that may be employed as coatings include but are not limited to olefins such as polyethylene, polybutylene and polypropylene, and copolymers thereof, ionomers such as ethylene copolymers that include acid groups partially neutralized with metal salts such as zinc, sodium, magnesium and lithium and combinations thereof. These ionomers are available from DuPont under the trade name Surlyn. The thickness of coatings such as thermoplastic coatings on cellulose materials such as paperboard and cardboard may vary from about 0.0001 inch to about 0.004 inches, preferably about 0.0003 inches to about 0.003 inches, more preferably about 0.0005 inches to about 0.002 inches.

[0036] Plastics that may be employed to form container member 12 include but are not limited to thermoplastics as well as thermosetting plastics. Thermoplastics that may be employed to form container member 12 include but are not limited to olefins such as polyethylene,

AH25(9266646_1):DJM 7 2014250720 17 Oct 2014 polybutylene and polypropylene as well as copolymers thereof. Other polymers that may be employed include but are not limited to polyamides such as nylons, polyesters, polyvinyl carbonates, and cellophane and combinations thereof. Thermoplastics that may be employed include but are not limited to woven polyethylene such as Tyvek from DuPont.

[0037] Thermosetting plastics that may be employed to form container member 12 include but are not limited to polyimides, epoxies and mixtures thereof.

[0038] Adhesives that may be employed in bag-on-container type assemblies as well as in bag-in-container type assemblies include but are not limited to natural adhesives, synthetic adhesives, pressure sensitive adhesives or mixtures thereof. Adhesives employed typically may be bonded at temperatures of about 0 °F to about 300 °F, preferably about 50 °F to about 200 °F, more preferably about 72 °F to about 125 °F.

[0039] The materials employed in bag member 14 for use in bag-on-container and bag-in-container type assemblies may be porous, non-porous or semi-permeable and may be made from a variety of materials. These materials include but are not limited to metals, celluloses, thermoplastics and combinations thereof such as laminates thereof.

[0040] Metals that may be employed to form bag member 14 include but are not limited to aluminum, tin, copper, silver, gold and combinations thereof such as laminates thereof. Metals may be employed in the form of foils that have a thickness of about 0. 000001 inch to about 0.003 inch, preferably about 0.0003 inch to about 0.002 inch, more preferably about 0.00035 inch to about 0.0007 inch.

[0041] Thermoplastics that may be employed to form bag member 14 include but are not limited to olefins such as polyethylene, polypropylene, polybutylene and copolymers thereof. Other polymers that may be employed to form bag member 14 include but are not limited to polyamides such as nylon, polyesters such as polyethylene terephthalate, polyvinylchloride. Typically, the thickness of thermoplastic materials employed to form bag member 14 is about 0.0005 inches to about 0.0070 inches, preferably about 0.001 inch to about 0.006 inch, more preferably about 0.0015 inch to about 0.005 inch.

[0042] Laminates that may be employed to form bag member 14 include laminates of metal and thermoplastic where the thermoplastic is in the form of a continuous coating on the metal or

AH25(9266646_1):DJM 8 2014250720 17 Oct 2014 discontinuous coating on the metal. Permeable materials such as micro-perforated thermoplastics, micro-perforated metal, semi-permeable membranes and combinations thereof also may be used in bag member 14.

[0043] Where micro-perforated thermoplastic materials are employed, the thickness of the thermoplastic material employed to form bag member 14 is sufficient to enable bag member 14 to be manipulated into a desired configuration.

[0044] Referring to FIGS 1-9 where like reference numerals designate like elements, there are shown bag-on-container and bag-in-container type assemblies. Container member 12 employed in bag-on-container assemblies, as well as in a bag-in-container type assemblies such as that described hereinafter, may have any desired cross-sectional configuration. Cross-sectional configurations of container member 12 may include but are not limited to rectangular, square, hexagonal, circular, oval and combinations thereof.

[0045] Container member 12 may be scored, as well as alternatively perforated in various locations to facilitate opening of container member 12 to expose bag member 14 as well as alternatively to gain direct access to contents within container member 12 such as where bag member 14 is disposed over container member 12.

[0046] In an illustrative but non-limiting example, container member 12 is scored or perforated vertically along the length of one or more portions of container member 12. One or more horizontal scores or perforations also may be placed on container member 12. The vertical and horizontal scores or perforations, alone or in combination, may facilitate access to the contents of container member 12. The horizontal and vertical scores or perforations may intersect. In this illustrative example, scores or perforations are placed vertically and horizontally. It is understood, however, that scores or perforations may be placed at any desired location on container member 12.

[0047] In both bag-on-container and bag-in-container type container assemblies, bag member 14 may be secured to container member 12 by a joining means such as adhesive, magnetic media, hook and claw fasteners such as Velcro. Adhesive bonding with or without application of heat.

In a bag-on-container type assembly, adhesive may be present on interior surfaces of bag member 14 and bonded to the exterior of container member 12 in both a box blank, flattened condition as well as where container member 12 is in an expanded condition. Adhesive also may

AH25(9266646_1):DJM 9 2014250720 17 Oct 2014 be present on selected portions of container member 12 or on the entire surface of container member 12.

[0048] Container member 12 employed in each of the bag-on-container and bag-in-container type assemblies may be in any desired configuration. Where a box blank such as box blank 52 is employed to produce container member 12, the edges of box blank 52 may be treated by skiving and hemming, or by hemming or flame treating to minimize presence of exposed, sharp edges and to improve resistance to fats/oils and liquids.

[0049] Container member 12 employed in each of the bag-on-container and bag-in-container type assemblies may be formed from materials that have a wide range of thicknesses. Typically, the thickness of the materials employed is about 0.003 inches or greater.

[0050] Where metals are employed to form container member 12, the thickness of the metal may be about 0.00025 inch to about 0.007 inch, preferably about 0.0003 inch to about 0.004 inch, more preferably about 0.00035 inch to about 0.001 inch.

[0051] Where celluloses such as paperboard are employed to form container member 12, the thickness of the paperboard may be about 0.008 inch to about 0.024 inch, preferably about 0.010 inch to about 0.018 inch, more preferably about 0.012 inch to about 0.016 inch.

[0052] Where plastics such as any one or more of thermoplastics and thermosetting plastics are employed to form container member 12, the thickness of the plastic may be about 0.0001 inch to about 0.004 inch, preferably about 0.0075 inch to about 0.002 inch.

[0053] Corrugated structures as well as single wall, double wall and triple wall constructions also may be employed to form container member 12. Corrugated structures that may be employed include but are not limited to structures such as micro-flute and e-flute structures as well as other grades of corrugated materials such as grades A, B, C or D and the like.

Corrugated structures may be metal fluted such as steel with paperboard and such as aluminum foil with paperboard.

[0054] Container member 12 preferably is in the form of a box that includes front wall 18, rear wall 20, opposed side walls 22 and 24 and a plurality of flaps 26, 28 and 30. Flaps 26, 28 and 30 may be folded inwardly to form the bottom wall of container member 12. The upper end of each

AH25(9266646_1):DJM 10 2014250720 17 Oct 2014 of front wall 18, rear wall 20 and side walls 22, 24 may be folded outwardly and downwardly to form attachment strips such as strips 32 and 34. Strips 32 and 34 may vary in width. Typically, the width of strips 32 and 34 is about 0.01% to about 50%, preferably about 0.05% to about 20% more preferably about 5% to about 10% of the width of one of the front, rear or side walls of container member 12. Strips 32 and 34 may be folded back onto the outer surfaces of its respective wall and may be affixed to those outer surfaces by means such as glue.

[0055] In another aspect, container member 12 may be in the form of a box that has a hermetically sealed bottom. Hermetically sealed bottom sections may be made according to procedures described in U S. Pat. 4185765, the teachings of which are incorporated by reference herein in their entirety. The hermetic seal may be formed by conduction heat sealing, induction sealing, ultrasonic sealing, drag sealing or combinations thereof.

[0056] In another embodiment of container member 12, as shown in FIG. 10, container member 12 may include reinforcing member 80. In this embodiment, reinforcing member 80 may be located, for example, to join opposing surfaces 18 and 20 of container member 12. Reinforcing member 80 may be formed of the same or different materials as container member 12.

[0057] Bag member 14 that may be employed in any of the bag-on-container and bag-in-container type assemblies includes front wall 36 and rear wall 38. The top portions of walls 36 and 38 are joined and the lower portions are open to form an open bottomed bag member 14. In this configuration, bag member 14 is adapted to envelop a desired portion of container member 12 to produce a bag-on-container assembly. Also, in this configuration, bag member 14 may be adapted to be secured to the interior of container member 12.

[0058] Front wall 36 of bag member 14 may include lower edge portions 40 for attachment to container member 12 in both bag-on-container and bag-in-container type assemblies. Similarly, rear wall 38 of bag member 14 may include lower edge portion 42 for attachment to container member 12 in both bag-on-container and bag-in-container type assemblies.

[0059] FIG. 1 shows a bag-on-container type assembly 10 that includes a container member 12 in combination with bag member 14 where bag member 14 is disposed over the exterior of container member 12. Bag member 14 may be disposed over a portion of the exterior of container member 12 or the entire exterior of container member 12. Bag member 14 may be

AH25(9266646_1):DJM 11 2014250720 17 Oct 2014 resealable or non-resealable, preferably resealable. Bag member 14 may be porous or non-porous, preferably non-porous.

[0060] Where bag member 14 is resealable, bag member 14 may be opened and resealed for multiple dispensing of product from container member 12. Where bag member 14 is resealable, bag member 14 may be resealed by means of resealable closure 16. Where zippers are employed as a resealable closure 16, the zippers may be any one or more of press-to-close zippers and slidable type zippers. Closures such as zippers may be positioned to enable opening of bag member 14 across the entire length, width or height of bag member 14. Resealable closures also may be positioned at any other location on bag member 14 such as at one or more comers of bag member 14.

[0061] Bag member 14, where employed in manufacture of a bag-on-container type assembly, may be non-sealable or resealable, preferably resealable. Where bag member 14 is resealable, bag member 14 may employ a resealable closure 16 at a desired location of bag member 14, such as the top of bag member 14 as well as at one or more comers of bag member 14 as shown in FIG 9.

[0062] A resealable closure such as a zipper may be located at, such as, any one or more of the left side or the right sides of container member 12. The resealable closures may be positioned to enable bag member 14 to open to form a spout type orifice for dispensing product from container member 12.

[0063] Bag member 14 may be secured to container member 12 by various methods such as heat sealing and adhesive bonding. Where bag member 14 is joined to a container member 12 formed from a box blank such as box blank 52, lower edge portions 40 and 42 of bag member 14 may be sealed to strips 32 and 34 on container member 12 while container member 12 is in its box blank form such as in its flattened state as shown in FIG. 3.

[0064] Lower edges 40 and 42 of bag member 14, as shown in FIG 3, may be sealed to box blank 52 such as by heat sealing such as during manufacture of bag-on-container type assemblies. Thereafter, box blank may be expanded and bottom flaps 26, 28 and 30 folded and secured together to yield container member 12.

AH25(9266646_1):DJM 12 2014250720 17 Oct 2014 [0065] A portion or all of the interior surfaces of container member 12 employed in each of the bag-on-container and bag-in-container type assemblies, such as those portions that form strips 32 and 34, may be coated with materials such as protectant materials, adhesive materials or combinations thereof. Protectant materials that may be employed include but are not limited to thermoplastics such as polyethylene or copolymers thereof. Advantageously, when the interior surfaces of container member 12 are coated with thermoplastics such as polyethylene, exposed surfaces of strips such as strips 32 and 34 that bear thermoplastic are available for bonding to bag member 14.

[0066] A portion or the entire exterior of box blank 52 employed to form container member 12 may be coated with a protective material such as a thermoplastic such as polyethylene or copolymers thereof. The protective material may function to further protect the contents in container member 12 and may enable bag member 14 to be heat sealed to container member 12.

[0067] When forming a bag-on-container type assembly, bag member 14 may be heat shrunk onto the exterior of container member 12. In this aspect, bag member 14 may be formed from heat shrinkable materials such as polypropylene or copolymers thereof. The heat shrinkable material may be employed in combination with one or more adhesives on the heat shrinkable material as well as alternatively on the exterior of container member 12 as illustrated schematically in FIG 7.

[0068] During manufacture of a bag-on-container type assembly, as illustrated schematically in FIG. 7, bag member 14 is placed over container member 12 and then bag member 14 and container member 12 are heated to cause bag member 14 to shrink onto the exterior of container member 12.

[0069] Bag member 14, where employed in manufacture of a bag-in-container type assembly, may be non-sealable or resealable, preferably resealable. Where bag member 14 is resealable, bag member 14 may employ a resealable closure 16 at a desired location of bag member 14, such as at the top of bag member 14 as well as at one or more comers of bag member 14 as shown in FIG 9.

[0070] Bag member 14 may be adhered to a portion of one or more interior surfaces of container member 12, or to all of the interior surfaces of container member 12, to produce a bag-in-container type container assembly 100. The top of bag member 14, when employed in

AH25(9266646_1):DJM 13 2014250720 17 Oct 2014 bag-in-container assembly 100, may extend above the top surface of container member 12. The top of bag member 14 also may be flush with the top of container member 12 or may lie below the top of container member 12. The bottom of bag member 14, when employed in a bag-incontainer type assembly 100, may extend up to the bottom of container member 12.

[0071] Various portions of container member 12, when employed in a bag-in-container type assembly, may be opened to expose bag member 14 within container member 12 for removal of product from container member 12. Container member 12 may be resealed over bag member 14. Resealing of container member 12 may be achieved by adhesives such as low tack adhesives such as rubber type adhesives, organic copolymer adhesives, acrylic adhesives or mixtures thereof. These adhesives may be distributed on desired portions of container member 12 where resealing of those portions of container member 12 is desired.

[0072] Resealable closure 16, where employed in a resealable bag member 14 for use in any of bag-on-container assemblies and bag-in-container assemblies, may be in a wide variety of forms such as zippers, magnetic media, adhesive tape, loop and hook fasteners such as Velcro or combinations thereof. Zippers for use with bag member 14 may be press to close type, slider type or combinations thereof depending on the type of container system and the product intended for storage in container member 12 employed in the container system. Press to close type zipper and slider type zipper closures are available from Zip-Pak Co. and from Pactiv Corp.

[0073] FIGS 6 and 7 schematically illustrate a process for producing a bag-on-container type assembly 10 that includes container member 12 in the form of a box and bag member 14 disposed on container 12. During manufacture of a bag-on-container type assembly as illustrated in FIG. 6, rolls 44 and 46 of bag forming material are arranged to be used to form front wall 36 and rear wall 38 of bag member 14 on box blank 52. Male and female components 48 and 50 of a closure member 16 such as a zipper are arranged on rolls 44 and 46 of bag forming materials. A box blank 52 with the upper ends folded to form strips 32 and 34 is positioned at the lower edge of rolls 44 and 46 of the bag forming materials.

[0074] After having positioned rolls 44, 46 of bag forming materials and box blank 52, opposed heat sealing dies 54 and 56 are employed to heat seal components 48 and 50 of closure member 16 to bag forming materials provided by rolls 44 and 46. Heat sealing dies 54,56 enable heat sealing of bag forming materials provided by rolls 44 and 46 to any of adhesives, thermoplastic

AH25(9266646_1):DJM 14 2014250720 17 Oct 2014 coatings or combinations thereof present on strips 32 and 34 of box blank 52. Container member 12 may include a reinforcement member such as reinforcement 80 as shown in FIG. 10. In this aspect, container member 12 may be made with box blank 52A as shown in FIG. 10A. Reinforcement member 80 may be present in box blank 52 at a desired location. Bag member 14 then may be secured to container member 12 to produce a bag-on-container type assembly. Where adhesive bonding is employed to adhere bag member 14 to container member 12 employed in each of the bag-on-container and bag-in-container type assemblies, the adhesive may be applied as an overall coating, or in a pattern where desired. Heat sealing of bag member 14 to container member 12 may be performed at about 200 °F to about 450 °F, preferably about 250 °F to about 425 °F, more preferably about 300 °F to about 400 °F. Heat sealing may be performed for about 0.1 sec to about 2 sec, preferably about 0.3 sec to about 1 sec, more preferably about 0.5 sec to about 0. 75 sec. Heat sealing may be performed in one step or a plurality of steps, preferably in one step. Heat sealing may be performed by generation of heat by well-known techniques such as conduction, induction, ultrasonic vibration and combinations thereof. Preferably, heat sealing is performed by conduction such as by use of heated rollers. Where heated rollers are employed, pressure applied during heat sealing may vary from about 5PSI to about 1000PSI, preferably about 50PSI to about 700PSI, more preferably about 150PSI to about 500PSI.

[0075] As shown in FIG. 7, cutting means such as laser, mechanical knives or combinations thereof, preferably mechanical knives such as knife blades 58 and 60, may be used to sever the bag forming materials provided by rolls 44 and 46 to form bag member 14. Thereafter, box blank 52 is expanded and filled with product 62 that may be fed through supply means such as hopper 64.

[0076] During manufacture of a bag-in-container type container assembly, as shown schematically in FIG. 11, a bag member 14 is placed onto mandrel 90. Bag member 14 preferably includes resealable closure 16. Mandrel 90 is configured to be able to conform to the interior of container member 12. Bag member 14 may, such as on lower edges 40, 42 thereof, include an adhesive. Alternatively, as well as in addition to adhesive present on bag member 14, the interior of container member 12 may be coated with a bondable material such as a thermoplastic, adhesive or combinations thereof.

AH25(9266646_1):DJM 15 2014250720 17 Oct 2014 [0077] In manufacture, pressure may be applied to container member 12 while mounted on the mandrel. The amount of pressure may vary depending on the material employed in container member 12, as well as the temperature of the mandrel 90 over bag member 14. The pressure and time of application is sufficient, however, to cause container member 12 to intimately conform to the shape of mandrel 90 and to bond bag member 14 to at least a portion of the interior surfaces of container member 12. Typically, the temperature of mandrel 90 is about 200 °F to about 450 °F, preferably about 250 °F to about 425 °F, more preferably about 300 °F to about 400 °F, the pressure is about 5PSI to about 1000PSI, preferably about 50PSI to about 700PSI, more preferably about 150PSI to about 500PSI and is applied for about 0.1 sec to about 2 sec, preferably about 0.3 sec to about 1 sec, more preferably about 0.5 sec to about 0.75 sec. Mandrel 90 may be heated or cooled, preferably heated. Mandrel 90 also may be employed independent of heating or cooling. Mandrel 90 may be expanded while heating to enable bonding of bag member 14 to at least a portion of the interior surfaces of container member 12 such as where interior surfaces of container member 12 are coated with a thermoplastic. Bag member 14 also may be bonded to interior surfaces of container member 12 by coating bag member 14 with an adhesive and placing container member 12 onto bag member 14 disposed on mandrel 90.

[0078] Alternatively, a bag-in-container type assembly may be made by first securing bag member 14 that preferably include a closure means thereon, such as a zipper type closure, to the interior surface of a box blank and then applying glue to the side seams of the box blank to retain bag member 14 within container member 12 at a desired location within container member 14. Opposing sides of the box blank then may be folded and secured to each other. Container member 12 optionally may be devoid of top flaps to enable bag member 14 to extend beyond container member 12. In either embodiment where container member 12 includes top flaps or is devoid of top flaps, bag member 14 may be folded back into container member 12. Where container member 12 includes top flaps, those flaps may be closed to conceal bag member 14 within container member.

[0079] The bag-on-container type assemblies of the invention are able to achieve very high levels of protection against permeation of gases such as water vapor into product present in bag member 14 within container member 12. To illustrate, a bag-on-container assembly was made by adhering a resealable bag member 14 to the exterior of a container member 12 where container member 12 is in the form of box that has a rectangular cross-section and a heat-sealed hermetic bottom.

AH25(9266646_1):DJM 16 2014250720 17 Oct 2014 [0080] As an illustration of the protection provided against permeation of gases, a bag-on-container assembly is pressurized with one-PSI air pressure. Air flow is controlled by a precision regulator and an in-line flow meter for delivery to via a needle. An adhesive backed foam is used to minimize possible leakage around the needle. The bag on the bag-on-container assembly inflated under the supplied air pressure to register a one-PSI internal pressure. The flow meter, delineated in 0-30 liters/hour, fell to about zero, confirming that an airtight seal is achieved. This decrease in flow rate shows a level of protection not achievable by known packaging.

AH25(9266646_1):DJM

Claims (12)

1. A combined box blank and resealable bag comprising: a paperboard box blank having: a front box wall, a rear box wall, a pair of side walls consisting of a left side box wall having a vertical fold at its mid-point forming a front left side box wall and a back left side box wall; and a right side box wall having a vertical fold forming a front right box side wall and a back right side box wall; and a plurality of flaps capable of forming a bottom box wall; said front box wall, rear box wall, and right rear side box walls having upper ends and lower ends and having inside surfaces and outside surfaces; said inside surfaces of said front and rear box walls contacting each other whereby said box blank lies substantially in a single plane; a bag portion made of flexible plastic material having a zippered top and downwardly extending front and rear bag walls, said front bag walls having a lower edge portion and said rear bag wall having a lower edge portion; said lower edge portion of said front bag wall being sealed to said upper ends of said outside surface of said paperboard box blank front wall, left from side box wall, and right front side box wall at a distance from the flaps capable of forming the bottom box wall and said back bag wall being sealed to said upper ends of said outside surfaces of said paperboard box blank back wall, left back side box wall, and right back side box wall at a distance from the flaps capable of forming the bottom box wall whereby said combined box blank and resealable bag portion lie in substantially the same single plane.

2. The combined box blank and resealable bag portion as claimed in claim 1 wherein said lower edge portion of said bag walls is heat sealed to said outside surfaces of said front, rear and side box walls.

3. The combined box blank and resealable bag portion as claimed in claim 1 wherein the upper ends of each of said front, rear and side walls are folded outwardly and downwardly so that the inside surface of each of the upper ends forms a strip that faces outwardly and lies in substantially the same plane as its respective outer surface.

4. The combined box blank and resealable bag as claimed in claim 3 wherein said inside surfaces of said walls, including said outwardly facing strips, have a thermal plastic coating thereon.

5. The combined box blank and resealable bag as claimed in claim 4 wherein said lower edge portions of said bag walls are heat sealed to said outwardly facing strips.

6. The combined box blank and resealable bag as claimed in claim 3 further including means for maintaining said strips in their folded position.

7. A method of forming a combined box and resealable bag comprising the steps of: providing a paperboard box blank having a front wall, a rear wall, a pair of opposed side walls consisting of a left side wall having a vertical fold forming a front left side wall and a back left side wall; and a right side wall having a vertical fold forming a front right side box wall and a back right side box wall; the paperboard box blank having a plurality of flaps capable of forming a bottom box wall and wherein said front box wall, rear box wall, left front side box wall, left rear side box wall, right front side box wall, and right rear side box walls have upper ends and lower ends and inside surfaces and outside surfaces; providing a plastic bag portion having a recloseable zipper top and downwardly extending front and rear walls, said downwardly extending front wall having a lower edge having an inside surface and an outside surface, said downwardly extending rear wall having a lower edge having an inside surface and an outside surface; sealing said inside surface of said lower edge of said downwardly extending front bag wall to said outside of said upper end portion of said paperboard box blank front wall, left front side box wall, and right front side box wall at a distance from the flaps capable of forming the bottom box wall; sealing said inside surface of said lower edge of said bag rear wall to said outside of said upper end portion of said paperboard box blank rear wall, left back side box wall, and right back side box wall at a distance from the flaps capable of forming the bottom box wall while said blank is in a flat planar condition; and thereafter, expanding said front, rear and side walls of said box blank to form a box.

8. The method of forming a combined box and resealable bag as claimed in claim 7 further comprising the step of folding outwardly and downwardly the upper end of each of said front, rear and side walls of said box blank so that the inside surface of each of the upper ends forms a strip that faces outwardly and lies in substantially the same plane as its respective outer surface.

9. The method of forming a combined box and resealable bag as claimed in claim 8 further including the step of securing said strips in their folded position.

10. The method of forming a combined box and resealable bag as claimed in claim 8 wherein said inside lower edges of said bag front and rear walls are sealed to said strips.

11. The method of forming a combined box and resealable bag as claimed in claim 10 wherein said inside surfaces of said box walls, including said outwardly facing strips, have a thermal plastic coating thereon.

12. The method of forming a combined box and resealable bag as claimed in claim 11 wherein said lower edge of said bag front and rear walls are heat sealed to said strips.