MXPA06009428A - Automated bag in box assembly & contents fill. - Google Patents

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.

Description

AUTOMATED BAG IN A BOX ASSEMBLY AND FILL OF CONTENTS DESCRIPTION OF THE INVENTION In GB0314815.2, the Applicant proposed a particular implementation of a so-called In-the-Box container (BIB). Generally, the BIB designation applies to a waterproof bag liner with a cardboard box. To that broad proposal, the Applicant contributed a neck collar location, which encompasses and supports the element. This collar feature allows: Adjust the manual registration or (auto) -align the bag and outer liner of cardboard box; • Transfer, distribution or participation of bag and cardboard box that is loaded by bag neck capture through a collar, by itself supported in a cardboard box hole ordered or cut; and Retention of the bag neck to allow the closing of torque of a screw cap.

Filling of Contents of Bag GB0314815.2 establishes filling emissions. In this way, the filling of stock market contents is a prime consideration for a content manufacturer.

Generally, dedicated automated filling lines are used for an ordered BIB configuration. The traditional bag filling introduces the insertion of a full bag into a pre-formed cardboard box assembly. The insertion and cartoning by themselves can be a mixture of manual and mechanized steps.

Filling Machinery The commitment of resources inhibits the change of packaging, if it is not compatible with the established filling machinery. So far, the filling machinery for containers with (semi) rigid wall, such as Jerrycans molded with blown, (frequently) are incompatible with that of containers of BIB A wet filling environment, with spillage of contents, and risk of degrading cardboard boxes is a factor.

Mechanized Erecting A mechanized carton erecting generally develops well to close and join cardboard box tabs with tape and / or adhesive bond. However, the mechanization of cardboard boxes has not yet been integrated with automated bag filling. In fact, the filling bag presentation and the same traditional filling have been taken as separate steps, preparatory to bag insertion in a widely completed carton, apart from the upper closing tabs.

Bag Pre-Fill In conventional BIB production, a bag is pre-filled and inserted (or dropped) into a partially upright cardboard box, which is then closed around it. An object of the present invention is to support alternative BIB filling and erecting techniques.

Statement of the Invention Some aspects of the present invention are directed to refining in production, assembly, erecting and filling of BIB containers and component elements. Certain variants are also envisaged in the design of BIB and construction. Particular cases include: • Supplementary pre-fabricator handles, desirably a "flat layer", single sheet, fabrication; • A deformable cushion floor capable of withstanding shock, collapse and failure after the fall; • A wrapper or sleeve; • Top and bottom end stacking plates; • Air cushion bag; • Effect of pressure release valve; • Integrated neck collar and handle mold; • plastic sheet cardboard box; • neck collar integration with plastic sheet cardboard box; • Integrated bag neck collar and location. In accordance with one aspect of the invention, a BIB is assembled from a juxtaposed, mutually trained bag and carton liner, such as by a bag neck retention edge, prior to filling of (contents) of the bag. .

Rectangular 3-D Bag A preferred bag format has a generally rectangular, flat-bottomed, upright 3-D configuration for near compliance with an outer rectangular carton box.

Continuous Bag Band and Discrete Cardboard Stencils A continuous band of collapsed bag portions with respective fill / discharge necks is joined with a succession of multiple separate formative carton elements such as collapsed cardboard box templates.

Location Collar A location collar, such as GB0314815.2, desirably fits over a bag neck.

Such a collar can be on an inserted or hollow passage in a cardboard box (upper) end tab, and rest under an edge, flange or collar retaining edge. This provides an anti-torque seat, which resists the bag neck turning over the adjustment and removal of the screw closure cap. The side wall panels of the cardboard box templates are wrapped around collapsed bags, preparatory to the joining of the tab. The local adhesive bonding profile, glued and / or closed can be used.

Handle A pre-fabricated handle element can be attached to the side or top carton panels. The handle is desirably a "laying", single sheet, fabrication. Alternatively, an integrated handle and collar top plate can be adjusted to the carton.

S u b - E n s a m b I e This creates an intermediate sub-assembly that can adopt and retain a compact configuration, bent into 2-D collapse, flat pack, preparatory to final erecting in a 3-D enclosure, assembly and filling.

This sub-assembly is provided to a compact storage and transports to a remote final erecting, assembly and filling stage.

Ergimiento by Inflation of the Bag The 3-D erecting of the BIB container, in a collapsed 2-D shape, is achieved by introducing fluid, said air, under pressure through a bag collar, to inflate the bag. Bag inflation takes a cardboard box cover along with it, through an adjustment action erecting, on pre-formed cardboard box edge folds / folds, until the cardboard box assumes a shape (rectangular ) volumetric predisposed. In that way a flat pack collapsible, but otherwise BIB configuration (sub) assembled can be engineered. This preserves compact (collapsed) flat pack (sub) assembly for efficient storage space and shipping, rather than embarking on a bulky container vacuum, say as with a traditional Jerrycan. An erection of a site can be submitted to a filling station. That is, pre-assemble and erect so that a blank BIB carton shape prepares to boarding at a remote filling station.

Vacuum Cleaning Bag / Cardboard Box Generally, this is advantageous to preserve a certain "cleaning vacuum" between cardboard box and bag, to allow a relative bag displacement on impact.

Cushion Floor A collapsible cushion floor cushion insert can be inserted between an outer cardboard box and an inner bag to support shock absorbency in the event of a cardboard box fall.

A sandwich layer of deep corrugated cardboard or multiple layer can fulfill this role. Otherwise there is a risk of bag rupture and bursting of contents on deformation or failure of the local carton wall.

Cushion Bag (Air) The characteristics of a cleaning vacuum and cushion floor can be combined in a cushion bag, ie a separate capsule, said inflated by air, between appropriate contents bag and base and / or top of box of cardboard. Such a cushion bag can also be integrated with an appropriate content bag. An example would be a double wall or cover. Effectively, a bag could limit contents within an inner liner and ship air (cushion) between the inner and outer lining. Such an air capsule could compress more easily than liquid contents and thus form an intermediate buffer, energy dissipator, shock absorber. Such a configuration can be particularly useful for BIB variants of relatively large capacity (eg, 25 liters). Alternatively, a separate self-contained subsidiary cushion (air) bag can be transported or attached to the appropriate content bag. Preferably, such a cushion bag could be inflated prior to insertion into a carton.

Release Valve A present blow valve allows controlled discharge of a shock absorber capsule over a certain compression load threshold. In practice, a top gap of cardboard box or step, for a location collar, could serve as a safe displacement element over BIB drop. In that way, with the cardboard box crash from the bottom (ie, falling) of the bag inside it moves up. This in turn forces out a cardboard box and neck collar hollow and bag collar for less limited bag displacement.

Otherwise, where there is a solid cardboard box, a bag would have no place to redistribute, and it would be forced against the top of the cardboard box, with the risk of bursting of cardboard box and / or bag.

Reinforcement Sleeve / Securing A supplementary reinforcement or securing sleeve or collar can be adjusted between carton and bag, to help absorb impact shock load. A sandwich sleeve of deep corrugated cardboard or multiple layer can fulfill this role. This highlights the change of measurement of full cardboard box wall for exceptional conditions.

Corrugated Cardboard Box In fact, a full cardboard box could be made of corrugated board wallboard for an inherently very robust construction, which would highlight the need for an insurance coating.

Plastic Sheet Cardboard Box Thin sheet, laminate or corrugated synthetic plastic material can be used for specialist application where economics justifies it. Features such as a neck collar and / or handle could be integrated into such plastic sheet, said by local mold (vacuum) or dead cut, with judicious use of heat to soften material.

Rectilinear Grouped Shape A regular, rectilinear, and in particular rectangular, carton box format with neck inlet inside a neck collar in an upper panel recess or cut allows stacking or grouped rectilinear packing to be closely inter-nested. Such a rectilinear grouping allows more orderly boarding than, say, rounded-edge Jerrycans with irregular top surfaces with bulging fill necks.

Mixed Cardboard Sizes Mixed size and size cartons of mixed size can be stacked together, regardless of stability or space utilization.

Pagúete de Grupo Multiple assembled or grouped packages can be part hidden by a common envelope, sleeve or minimum opposite group (top and bottom) or stacking plates, said on board by joining bands.

Shrink Wrap Palletizing Larger, multilayer piles can be grouped on a common pallet. The collective shrink wrapping of such palletized stack creates a unified, robust, load-loading format. A strictly rectangular and careful external profile relative to the fit and proportions allows intimate wall surface contact, and thus mutual securing in a stack.

Collective Classified Printing Image With homogeneous, constraining carton shapes, a full cardboard box surface can be overprinted, so that a grouped cardboard box collection can portray an elongated graphic image of individual carton elements. Such an image effect of the jig saw can be used for the correct cardboard box grouping of the crossing and alignment check.

Exhaust test Bag pre-inflation could be used as a pressurized exhaust test, by monitoring the integrity of the integrated bag seal, before filling. Up to this point a bag could be attached, albeit temporarily, to pressures of some form higher, or pressure differentials through a limiting wall, what would normally be expected to be supported. Apart from identifying (and thus pre-emptied operational use) rupture and bursting of vulnerabilities, such as along minor, heat-sealing seams, although insidious long-term escape, such as between neck and bag joint, can value, by monitoring the capacity of a bag to sustain a given start pressure. A valve in a filling head could allow both functions in an individual bag neck capture through filling in a direction and exit from the opposite direction, with a measuring standard cover inside the bag. Such functionality could be achieved by orderly design or adaptation of another form of a so-called "sinking or diving head" filler. A lienadota head, with integrated check valve, makes temporary sealing contact with a bag neck or neck collar for a filling cycle.

Disposal of Rejection - Recycling In an automated standstill and test line, provision could be made to remove load from a rejected "failed" bag, that is, by releasing it for a waste collection feeder tank. The collected bags could be disposed by recycling plastic.

The origin of the plastic of the bag lends itself to recycle more than, that is, Jerricans with semi-rigid walls. Any cardboard box shipped with a rejected bag would be released and, if not damaged, be returned to a sub-assembly line for re-use or simply disposed by the recycling of cardboard box.

Content Filling Inflation Although bag inflation for external carton erection can be taken as an intermediate step, preparatory to content filling, that filling step by itself could be used for initial inflation and erecting. That is, the bag could remain collapsed until the final filling.

Progressive Fill The initially uninflated bag capacity is at a minimum and offers modest resistance until an inflated internal vacuum is created up to bag uplift. To reflect that, a progressively increasing filling pressure and / or flow rate could be adopted. This would expose the bag crash, blow-back of fill line and detonator of over-pressure release valves. This also allows the inflation bag to take an external cardboard box shape along with it from a flat 2-D package collapsed to an upright 3-D shape. If filling speed is a priority, pre-erecting can be used more abruptly and faster, such as by air inflation.

Modalities Now follows a description of some particular embodiments of automated BIB assembly and filling of contents according to the invention, by way of example only, with reference to the accompanying drawings (diagrammatic and schematic), in which: Figure 1 shows a flow chart of major operational steps in the constituent assembly of BIB; Figures 2A and 2B show a sub-assembly sequence of BIB; More specifically, Figure 2A shows a schematic BIB sub-assembly sequence; Figure 2B shows a flow chart of major operational steps in the sub-assembly sequence of Figure 2A; Figures 3A and 3B show the erecting of BIB and final assembly; More specifically, Figure 3A shows a schematic BIB erecting assembly for the sub-assembly of Figure 2A; Figure 3B shows a flow chart of major operational steps in the assembly and final assembly sequence of Figure 3A; Figure 4 shows multiple simultaneous pre-inflation and / or fill detail in the assembly and final assembly sequence of Figures 3A and 3B; Figures 5A and 5B show variant BIB sub-assembly and erecting sequences; More specifically, Figure 5A shows a sequence of BIB sub-assembly sequence of segmented cardboard box band feed continuous to that shown in Figure 2A; Figure 5B shows a variant BIB erecting sequence to that shown in Figure 3A in continuation of the sub-assembly of Figure 5A; Figures 6A and 6B show optional insertion of elements during the erecting and final assembly sequence of Figure 5B; More specifically, Figure 6A shows the insertion of a cushion floor into the carton before the end closure of the carton; Figure 6B shows the insertion of a reinforcing or securing sleeve in the carton before the end tongue closure; Figures 7A and 7B show optional rectilinear grouping of upright BIB assemblies employing upper and lower stack plates shipped by tie strips; More specifically, Figure 7A shows the rectilinear grouping of similar adjusted BIB cartons; Figure 7B shows the rectilinear grouping of different adjusted BIB cartons; Figures 8A and 8B show other variant BIB subassembly and erecting sequences; More specifically, Figure 8A shows a sub-assembly sequence of BIB variant to that shown in Figure 5A, of respective rolled cardboard box and bag bands; Figure 8B shows a BIB sequence variant to that shown in Figure 5A, which employs the sub-assembly of Figure 8A; Figures 9A to 9H show a variant BIB assembly sequence; More specifically, Figure 9A shows a cardboard box template element; Figure 9B shows the cardboard box template of Figure 9A configured to form a tube or sleeve wrap; Figure 9C shows the cardboard box of Figure 9B with closed upper tabs; Figure 9D shows bag insertion (pre-inflated and / or filled in the lower part of the carton of Figure 9C; Figure 9E shows the cardboard box and combined bag of the Figure 9D with closed bottom tabs and collar adjustment; Figure 9F shows the assembly of Figure 9E with collar in place. Figure 9G shows the assembly of Figure 9F with optional handle joint; Figure 9H shows the assembly of Figure 9G with optional integrated handle and collar top plate; Figure 10 shows another separate BIB variant carton assembly multiple bundle assembly and that is folded around respective separate pre-inflated / filled bags, before collar and optional handle joint; Figures 11A to 11C show a BIB subassembly sequence variant to that shown in Figures 2A, 5A, and 8A; More specifically, Figure 11A shows in detail a non-rolled band of contiguous bags that lie by individual carton templates prior to collar joining; Figure 11 B shows a cardboard box template wrapped around a bag; Figure 11C shows the arrangement of Figure 11B with full cardboard box wrapped around a bag and attached edge; Figures 12A and 12B show packed box or carton and bag sub-assemblies, in a stackable flat pack configuration, ready for transport, storage or uprighting and content filling; More specifically, Figure 12A shows a single cardboard box and vertical bag group, in this case with a bag outside a wrapped carton ready for insertion through a top opening; Figure 12B shows stacked cartons and respective bags, which allow a group of bag inside a wrapped carton; Figures 13A to 13C are made on insertion of the securing sleeve in a cardboard box of Figure 6B; More specifically, Figure 13A shows an upright assurance sleeve lining juxtaposed for insertion into an open end upper part of a carton; Figure 13B shows a BIB carton completed with an internal securing sleeve illustrated in the separate lines; Figure 13C shows an enlarged view of a corner of the securing sleeve of Figure 13A, showing corrugated material; Figure 14A and 14B show a variant of a robust cardboard box made entirely of corrugated (or plastic) card; More specifically, Figure 14A shows a corrugated cardboard box with open upper tabs; Figure 14B shows an enlarged view of the corrugations in the cardboard box of Figure 14A; Figures 15A and 15B show an insertion recess or outward reverse passage, which acts as a safe valve on BIB impact (fall); More specifically; Figure 15A shows impact of initial BIB drop with the lower shock (corner) deformation of the resulting carton; Figure 15B shows ejection of the resulting collar gap and hinge out of the support passage, which admits bag displacement; Figure 16 shows a variant of BIB with the internal upper cushion (air) bag; Figures 17A to 17C show the insertion of an integrated bag and collar in an erect cardboard box; More specifically, Figure 17A shows juxtaposition of bag and carton; Figure 17B shows bag profile tightening insert through a cardboard box top opening; and Figure 17C shows a final bag in the carton assembly; Figure 18 details the collar and anti twist bag restriction within a cardboard box gap for adjustment and loss of screw closure cap; Figures 19A and 19B show a variant of synthetic plastic sheet cardboard box with integral molded collar; More specifically, Figure 19A shows a sheet-plastic cardboard box template with integral molded collar; Figure 19B shows a sheet plastic cardboard box template of Figure 19A fully upright; Figures 20A and 20B show a variant of the sheet plastic carton of Figures 19A and 19B, with additional handle cutting; More specifically, Figure 20A shows a sheet plastic cardboard box template with integral molded collar and handle cut; Figure 20B shows the sheet plastic carton template of Figure 20A fully upright. Referring to the drawings ... Constituents Figure 1 illustrates an assembly sequence flow chart of BIB elements of principle constituent, namely: • box or carton 11; • bag 12; • neck collar of location 14, by GB0314815; • handle (side / top) separated (optional) 13; The bag 12 features an integral neck strainer or spout for filling and unloading contents. A preferred bag fabrication (not shown) produces a continuous band of mutually bordered edge bags, folded by collapse. That is, separate bags (that is, produced individually or separated from a band) can be used, as discussed in later embodiments.

Handle-Support Generally, to handle ergonomics, a discrete neck collar 14 and a handle 13 are provided on opposite sides of a cardboard box body 11. A handle allows a delivery user to support the filled weight as the handle of the tip angle and thus the casting speed. A high handle (ie, lifting) straight on the neck collar 14 is feasible. Supplementary handle cuts in the body (ie, top and / or side walls) of cardboard box 11 are easily provided over dead cutting of cardboard box template. In some variants, the collar 14 and handle 13 could be integrated, by adopting a common mold plate or strip (vacuum).

Such an integrated handle and neck collar could form an upper total cardboard box plate, which provides form and support assurance to a stacked cardboard box.

Sub-Assembly of Flat Payout These various items are carried together in a compact, collapsed, flat pack subassembly 20, for stacking and "dense" (ie space-efficient) package packaging, to supply a remote filling station. The erecting and final package term (closing and sealing), for a pre-filled assembly 30, can be taken on the subassembly 20 at a different subsequent step in a filling station, in a user's permit, on the presentation of a storage or local deposit. In this way a completely upright 3-D volumetric form is not assumed until it is necessary to accommodate contents.

In this scheme, no wasteful empty space in transportation or storage is consumed until the just call preparatory to fill. However, if the space is not in upper erect, empty shapes can be transported and stored, relieving the filling plant of the need for an inflation / erection station.

Automated Assembly Although special purpose machinery and operation is involved with BIB, certain (sub-) assembly steps can be derived by adapting machines and conventional box erecting packaging technology. This represents an economic advantage if a user is converting from cardboard boxes with traditional semi-rigid walls to BIB, but already has some packaging equipment. The drawings of that form are intentionally only indicative and illustrative of broad principles, rather than necessarily detailed engineering solutions.

Sub-Assembly Figures 2A (lateral conveyor elevation) and 2B (sequential flow chart) illustrate in more detail the creation of subassembly 20 of Figure 1.

Bag Band The bags are produced as a continuous band 55 of attached individual bag elements 51. A band 55 of bags unit 51 is stored folded folded into a storage of cassette or reservoir 50. The bags 51 are progressively recovered from storage 50 upon unfolding neatly and presented in a line, with top necks 52, on a transporting bed 80.

Pile of Cardboard Box Multiple separate cardboard boxes 41 are stacked, one on top of the other in corresponding orientation, as pre-bent, individually cut cardboard box templates, in a cassette storage 40, ready for individual lifting and deposit on a corresponding individual bag 51.

Cardboard Box Template Figure 9A shows detail of the flat cardboard box template, with the upper closing tabs 42, 48, 56 and lower 57, 58 extended and optional handle cuts 44. The lower side tab space 57 allows mutual overlap on bent tab to cover the total of the base area. The lower end tabs 58 are then bent, to provide three full layers of material at the base and thus a volume of cardboard carton. The end tabs 58 are equivalent (ie one longer than another) to reflect the equivalent of the upper tabs 42, 48 in accommodating the collar 14. In that way an individual equivalent tape machine (not shown) can be used ( simultaneously) to seal both the upper tongues 42, 48 and lower 58.

Neck Opening A cardboard box upper tab 42 has a neck opening 43 for receiving and locating a neck 52 of a bag 51. The neck opening diameter 43 is sufficient to pass, with modest local expansion, and remains embarked low. a retaining edge (not shown on the bag neck 52. Radial grooves (not shown) on the aperture 43 locally create a segmented periphery for such expansion.

Place of Elevation An arm of place of elevation (not shown) deposits an individual carton 41 on an associated bag 51, with the help of side carrier guides 81 and an index locator finger (not shown) for a bag neck 52 When tracing a bag band 50, successive bags 51 are 00 indexed, incrementally or continuously, on the conveyor bed 80, through the successive work stations for carton 41, collar 14 and handle adjustment 13 (optional ) Collar A cassette storage 60 of a pre-fabricated neck collar 14 (eg, vacuum molded cover) stacked is disposed on the conveyor 80 to deposit an individual collar on a straight bag neck 52. The collar 14 is overlapped on a carton upper tab 42. A collar opening 61 is sufficient to pass, with modest temporary local deformation, over the neck retaining edge, so that both the upper carton tab 42 and the collar 14 are retained captive between the retaining edge and bag 51. The collar opening profile 61 can be adapted, i.e. with radial or otherwise segmented peripheral grooves, to facilitate local expansion for fit and to secure the bag neck 52 when applied a screw cap. The effect is to impart an anti-torque or torquing-resistant shoulder of the bag neck in relation to the lid closure adjustment (screw.

Handle A supplementary separate handle 13, can be fitted to an upper carton 42 tab and side edge 45 in a handle installation station 90. A prefabricated (molded) "flat layer" profile is suitable for handle 13. Such 13 handle can be secured by local adhesive bond. In addition, or alternatively, the securing can be placed on handle cuts in the carton body. In some variants, the handle 13 can be integrated with the collar 14, in which case a combined storage and assembly station could be invented.

Stacking Folded Cardboard box 41, bag 51, neck collar 14 and handle (optional) 13 are adjusted to create a sub-assembly 20. A succession of subassemblies 20 is shipped to each other in a sub-assembly or band row 71. Band 71 is presented in a folded bent stack in a sub-assembly cassette storage or bin 70.

Review-Review of Sub-Assembly Flat Package The total assembly sequence involves: • juxtaposing a collapsed bag 51 and collapsed cardboard box 41, • with insertion of a collar of intervention location 14 according to GB0314815, • retains a single collapsed compact package 20 sub-assembly form in a sub-assembly row 71. A bag neck 52 of an individual bag 51 is oriented upwardly as a straight for registration and location of an opening 43 in a tab 42 of a carton 41. 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. A conveyor 80 has web 55 a along the assembly path, in which successive individual cardboard boxes 41 are removed from the stack 40 and lie on an associated bag 51. A cardboard box 41 is presented to a fundamental bag 51 with an upper tab 42 and neck location opening 43 deployed in mutual register. The side and / or end tabs are tuned and joined, using the tongue 19, to create a cardboard box sleeve or wrapper 47 over each bag 51. This leaves the upper tabs 42, 48, 56 and lower tab 57, 58 (locking) to unfold and ship to each other, upon conversion of a collapsed 2-D shape to an upright 3-D shape. A collar storage cassette 60 with a discharge drive piston (not shown), releases and installs individual collars 14 to each bag neck 52, with a spring fastener insert and location action. The collar 14 effectively holds the upper tab of the carton 42 with the captive neck location opening 43 with the bag neck 52, and thus ships the total carton 41 and bag 51. The bag neck 52 serves with a location straight, to help preserve the registration and alignment of the bag 51 and carton 41, also assisted by lateral conveyor guides 81.

The successive cardboard boxes 41 are shipped on respective individual bags 51 of the bag band 55. The onboard bag band 55 and "row" of the cardboard box 71 are folded into a storage cassette 70. The storage cassette 70 it is conveniently a portable container, which can be transported to a remote end assembly and filling station, as described now.

Sub-Assembly of Paginate Folded Plane of Collapse The total result of the stage of sub-assembly of the Figures 2A and 2B is a compact bag 51, folded collapsed, flat or mutually shipped or captive package, carton 41, collar collar 14 and handle (optional) 13, in a sub-assembly row 71.

Final Assembly and Erecting Figures 3A and 3B illustrate final assembly and erecting to transform a collapsed flat pack subassembly 2-D 71 of Figure 2 into a fully assembled 3-D form 150 ready for content filling.

Prepackaged Bag Inflation In this scheme, preparatory intermediate preparatory bag inflation (proof) is taken to completely enclose the carton 41 to cover the bag 51.

Filling of Contents In an alternative scheme, the initial stock market inflation 51 is through the filling of contents, that is, to overcome a pre-elimination test inflation. The sub-assembly cassette storage 70 is emptied by removing a sub-assembly row 71 based on an original bag band 55. The individual bags 51 are presented to a preliminary inflation test station 110 with top necks 52. This orientation also corresponds to the stacking orientation at the conclusion of the sub-assembly stage of Figure 2. The bags 51 are supported by a conveyor bed 120.

The simultaneous connection is made to multiple bag collars 52 through multiple individual valve covers 111, with respective umbilical feed tubes 112 for an air pressure supply 113, through a rotatable rotary connector valve 114 (detailed in FIG. Figure 4). The individual bags 51 are captured with a valve cover 111 and a retaining edge location collar (not shown) for supporting the bag 51 and contents weight. Until the adjustment of the valve cover 111, and capture by a collar retention location collar, successive bags 51 remain mutually shipped in original continuous bag band 55, and thus to a point of self-registration . On the valve cover 111 and edge locator adjustment, the bags 51 serve each other, to break or fragment the forming band 55. The severity is conveniently taken along a pre-marked weakening line, which uses a knife blade (rotary sliding or guillotine) (not shown). On mutual severity, the individual bags 51 are free for adopted independent positions and orientations in relation to successive bags before joined 51. While a bag 51 is held captive by its neck 52, its body is free to hang, suspended by retaining edge, by itself configured to support such a support load. Similarly, a carton 41 is held captive by trap of its upper tab 42 under the bag retaining edge. However, the carton box bulk 41 is free to swing down on an upper tab corner edge fold 49.

Air Inflation (Pre-Filling) The gravity suspension of bag 51 and carton 41 is detonated by feeding air pressure to the cap valve 111, progressively to inflate, and thus expand the bag walls 51 of a collapsed 2-D condition of collapse to an upright 3-D shape.

Air Pulse One pulse of air can be used to disturb the initial juxtaposed bag 51 and carton box arrangement 41. The successive individual separate bags 51 are transported on the conveyor 120 to an end tab closure station 130 on top of a station. Content filling 140.

Pre-Inflation / Multiple Filling Figure 4 shows a plan view of multiple details of pre-inflation and / or simultaneous filling in the erecting and final assembly sequence outlined in Figure 3A. A spider web arrangement of fill lines 112 radiates from a common center feed head 113 with a rotary seal and union. The individual filler flaps 114 pass through a continuous orbit trace 120.

Folded Folded Cardboard Bags and Boxes Figure 5A shows an alternative sub-assembly sequence to Figure 2A. In this arrangement, both the bags 51 and the cardboard box templates 41 are joined together from respective stacked folded bent bands.

Once a carton 41 is correctly located in the bag 51, it will serve the subsequent carton 41 to allow the individual carton 41 to be folded around a respective bag 51, which remains in the bag band 55. As above, the collar retention collar 14 is joined and the resulting subassembly 71 folded folded for transport or storage. Figure 5B shows a final inflation / fill sequence followed by the sub-assembly of Figure 5A, with options that supplement basic steps in Figure 3A. These options are schematically illustrated as interventions, themselves detailed in Figures 6A and 6B. Again, folded bent sub-assemblies 71 are presented from their stack and attached to an air hose / feed line before being served from the next in line. A bag 51 is then inflated / filled while the assembly is supported by its retaining collar 14. This allows the carton 41 to take shape while the volume of the bag 51 increases. A final step is to close and seal the upper cardboard box tabs 42, 48, 56 and lower 57, 58.

Cushion Floor Figure 6A shows an optional final assembly stage, before enclosing the lower cardboard box tabs 57, 58, for insertion of a cushion floor 15. Such floor 15 may be composed of corrugated cardboard or similar material, to help protect the lower part of the bag 51 inside the carton 41. In that way, the carton base puncture 41 or shock can be accommodated by the cushion floor 15 and thus retains the bag 51 intact Reinforcement Sleeve / Securing Alternatively, or additionally, a reinforcing and securing sleeve or liner 16 can be inserted into the carton 41 before final closure, as illustrated in Figure 6B. The securing sleeve 16 holds the strength and rigidity of the total carton for larger and heavier capacities. This is achieved without adoption of a higher grade or thicker cardboard for the full cardboard box body. In that way, an assurance sleeve could be corrugated to provide vertical stacking resistance, while an outer (non-corrugated) cardboard body provides splash and water protection. Conversely, a corrugated cardboard box body could make a redundant belay sleeve. The sleeve 16 also retains the shape of the total rectangular cardboard box, for stacking consistency and protects the bag 51 in the event of lateral impact of the carton 41.

Stacking Plates An optional step of grouping and packing multiple BIB cartons after individual carton erection (150) is reflected in Figures 7A and 7B. The multiple upper and lower stacking plate sandwiches 17, in this case double or par, adjacent BIB cardboard boxes (150) in a rectangular configuration. The plates 17 are held together by joining bands 18 wrapped around the group at several points. A multi-packet group option (this is double or par) is illustrated in Figure 7A. This principle can be used not to mutually enter and secure identical BIB cartons (150), but also groups of different adjusted cartons, sorted and stacked to form a substantially rectangular shape, as shown in Figure 7B.

Bandaged Bags and Cardboard Boxes Figures 8A and 8B show a variant of Figures 5A and 5B, whereby the bags 51 and cartons 41 are joined from individual band rollers 91, 92. In this way, the bags 51 are successively unraveled from the roller 91, while the cardboard boxes, possibly made of synthetic plastic material, untangle from the roller 92. The roller feed 92 is similarly inadequate for corrugated cardboard material, which represents a flat group at rest in production. However, the roll feed can be sustainable for single layer sheet or card or synthetic plastic, or even corrugated plastic where the corrugations run parallel to the roll axis. A sufficiently long roll diameter is provided to avoid material adopting a group curvature.

Cardboard Box Construction (Pre-Bag Insertion) Figures 9A through 9H detail construction and / or (pre) assembly of alternative BIB, independently of a preface bag introduction. Generally, the carton 11 is almost completely formed before the bag 12 is inserted and the collar 14 is attached.

An assembly sequence comprises; • folding a cardboard box template 11, which carries side panels 46 around to form the open-end wrapper 47; • sealing side (edge) panels 46 together, using tab 19; • bend upper tabs 56, 42, 48 and seal in place; • insert the bag 12 into the cardboard box 11 through the open cardboard box bottom:. { in practice, a cardboard box collar would descend on an inflated bag} • attaching the collar 14 to the bag 12 through the opening of the cardboard box 43; • close the lower tabs 57, 58 and seal in place. Optionally, a pre-fabricated handle can also be fitted on the carton, as shown in Figure 9G.

Alternatively, an integrated handle or collar top plate could be adjusted, as shown in Figure 9H.

Construction of Cardboard Box Around Inflated / Full Bag Figure 10 shows an alternative pre-inflation / bag BIB assembly of bag 12 and carton 11 constructed around it.

Sub-Assembly Construction Figures 11A to 11C show sub-assembly of a bag roll 91 and individual carton template elements 41. Each successive individual bag 51 is overlapped with a respective cardboard box template 41. The box of cardboard 41 is then folded in half around the bag 51 until the side panels 46 lie adjacent to one another. The cardboard box tongue 19 is then glued or otherwise secured adjacent the side panel edge 46. Finally, the collar 14 is attached to the bag 51 and carton 41 to secure these elements together. Figure 12 shows iple individual BIB sub-assemblies 20.

Securing Sleeve Insertion Figures 13A through 13C illustrate securing sleeve insert 16 in carton 41. Securing sleeve 16 can be hardened or corrugated cardboard material as detailed in Figure 13C. The securing sleeve is preferably profiled to be nested within a carton body 41 and provides extra strength to the edges and corners, as illustrated in Figure 13B.

Corrugated Cardboard Box The complete cardboard box body 72 can be constructed of corrugated material, as such in Figures 14A and 14B. This may negate the need for an additional securing sleeve in applications where the case volume is of primary consideration. Corrugated cardboard boxes 72 may also be useful in applications where the carton does not require to be waterproof.

Collar Release Valve Figures 15A and 15B illustrate how collar gap 14 can act as a safe release valve when the BIB descends. While a cardboard box crashes from below, the inner bag 51 is forced up. This forces the hollow panel 73 which in turn pushes the attached collar 14 with the onboard bag collar 52. As can be seen from Figure 15B, the bag 51 then has more space in which to move away from the flattened carton under. This may mean that the bag 51 can remain intact despite the crushing of the carton 41.

Cushion pad A cushion pad 74 can be accommodated within the carton 41 as shown in Figure 16. This cushion pad 74 can be filled with air and placed on top of the bag 51, adjacent to the underside of the bag. hollow panel 73. While the air or gas is more easily compressed than the liquid, this cushion pad 74 may collide before the liquid contents of the bag 51.

Integrated Bag and Collar A bag can be integrated with a collar 82. This can then be inserted into a carton 83 as shown in Figure 17. The carton 83 is provided with an opening 84 in which the bag 82 is fed until the united collar seals the opening 84.

Collar and Bag Limitation Collar 14 and onboard bag collar 52 are limited from rotational movement by the cardboard box hollow profile 41. Thus, while applying a screw carton 62, the resulting torque the collar 14 or bag 51 does not rotate inside the carton 41, as illustrated in Figure 18.

Molded Plastic Cardboard Box Figures 19A and 19B show a variant cardboard box 93 configured of a molded plastic sheet. The collar 14 of that shape is integrated in the form of a cardboard box 93, which denies the need for joining an additional collar element 14. Other features can also be molded into a plastic cardboard box template. Figures 20A and 20B show a variant of the above with a cut of plastic handle incorporated in a cardboard box 94.

Characteristics of "Mix and Match" Generally, in the modalities, where it is feasible and appropriate, the characteristics can be selectively "mixed and matched" to appropriate circumstances, although it is not feasible to describe each of such combination of characteristics.

List of Components 11 box / carton 12 bag 13 handle 14 collar 15 cushion floor 16 securing sleeve 17 stacking plate 18 joining band 19 side tongue 20 sub-assembly 30 final assembly 40 cassette storage 41 carton box 42 top tab 43 neck opening 44 handle opening 45 side edge 6 end tabs 7 wrap 8 top closure tab 9 upper tab corner edge fold 50 cassette storage 51 bag element 52 bag neck 55 pouch band 56 top closure side tabs 57 bottom side tabs 58 bottom end tabs 60 cassette storage 61 collar opening 62 lid 70 cassette storage 71 sub-assembly band 72 corrugated cardboard box 73 hollow panel 74 cushion pad 80 conveyor belt 81 conveyor guides 82 integrated bag and collar 83 cardboard box 84 opening 90 handle station 91 bag roll 92 cardboard box roll 93 molded cardboard box 94 cardboard box molded with handle 100 sub-assembly line 110 inflation test station 111 valve cover 112 supply pipe 113 air pressure supply 114 rotary connector valve (rotating) 120 conveyor 130 end tab closure station 140 content filling station 150 BIB erected

Claims (38)

1. CLAIMS 1. - A BIB carton assembly method comprising the steps of: wrapping a carton member (41) around a bag member (51) and securing these together, with a location retention collar (14) ), to create a sub-assembly (20), capable of being packed flat for efficient transport or storage. 2. A method of assembling a BIB cardboard box according to claim 1, further comprising the step of: securing a handle (13) to the sub-assembly (20). 3. A method of assembling a BIB cardboard box according to claim 1, wherein the location retaining collar (14) is integrated with a handle element (13). 4. A method of assembling a BIB cardboard box according to claim 1, further comprising the steps of: inflating and / or filling the sub-assembly (20), by the support collar (14), to allow bag inflation (51) and / or filling and configuration of the surrounding surrounding cardboard box (41); and termination by closing and sealing upper carton tabs (56, 42, 48) and lower (57, 58). 5. A method of assembling a BIB cardboard box according to claim 4, further comprising the step of: injecting air into the bag (51), to act as an escape test, before filling contents. 6. A method of assembling a BIB cardboard box according to claim 1, further comprising the step of: erecting the sub-assembly (20) in a complete package after transfer to a remote filling line. 7. A method of assembling a BIB cardboard box according to claim 1, further comprising the step of: erecting the sub-assembly (20) in a complete package to a local filling line. 8. A method of assembling a BIB cardboard box according to claim 1, further comprising the step of: erecting the sub-assembly (20) in a complete package preparatory to filling. 9. A method of assembling a BIB cardboard box according to claim 1, further comprising the steps of: erecting the sub-assembly (20), by hand and selective doubling of cardboard box tabs (41); sealing upper cardboard box tabs (56, 42, 48) and lower (57, 58); and inflate and / or fill bag (51). 10. A BIB carton assembly procedure, substantially as described herein above, with reference to, and as shown in, the accompanying drawings. 11.- A BIB cardboard box assembly machine, with wrapping means for wrapping a cardboard box element (41) around a bag element (51) and securing these together, with a location retaining collar (14), to create a sub-assembly (20). 12. A BIB cardboard box assembly machine according to claim 11, with securing means for securing a handle (13) in the sub-assembly (20). 13. A BIB cardboard box assembly machine according to claim 11, with collar adjusting means for adjusting an integrated location retaining collar (14), and a handle member (13). 14. A BIB cardboard box assembly machine according to claim 11, with other means for inflating and / or filling the sub-assembly (20), by supporting the collar (14), and allowing inflation and / or filling the bag and configuring the surrounding cardboard box (41); and means for closing and sealing the upper carton tabs (56, 42, 48) and lower (57, 58). 15. A BIB cardboard box assembly machine according to claim 14, with other means for injecting air into the bag (51), to act as an escape test, before filling contents. 16. A BIB cardboard box produced by the method or machinery of any preceding claim. 17. A BIB cardboard box according to claim 16, with elements of cardboard box (11) and bag (12) mutually juxtaposed and shipped preparatory to the filling of bag contents (12). 18. A BIB cardboard box according to claim 16 comprising a pre-fabricated handle. 19. A BIB cardboard box according to claim 16, further comprising a deformable cushion floor capable of withstanding shock, collapse and failure after falling. 20. A BIB cardboard box according to claim 16, further comprising a securing liner or sleeve. 21. A BIB cardboard box according to claim 16, further comprising the upper and lower end stacking plates. 22. A BIB cardboard box according to claim 16, further comprising an air cushion bag. 23. - A BIB cardboard box according to claim 16, further comprising a cardboard box collar gap for facilitating a pressure release valve effect after the cardboard box falls. 24.- A BIB cardboard box according to claim 16, comprising an integrated neck collar and handle mold. 25. A BIB cardboard box according to claim 16, wherein the cardboard box is constructed of plastic sheet material. 26.- A BIB cardboard box according to claim 25, with integrated molded collar section. 27. A method of assembling a BIB cardboard box comprising the steps of: erecting a cardboard box element with a profiled opening, inserting a collar element with a bag element attached to said opening, so that the bag is dispose inside the cardboard box and the collar secures the bag and carton elements together. 28. A method of assembling a BIB cardboard box according to claim 27, wherein the collar is integrated with the bag. 29. A method of assembling a BIB cardboard box according to claim 27, wherein the bag and collar elements are joined in a pre-assembly step. 30.- A BIB cardboard box according to claim 22, wherein the air cushion bag is attached to the contents bag element. 31.- A BIB cardboard box according to claim 22, wherein the air cushion bag is inflated prior to insertion into the carton. 32.- A BIB assembly procedure comprising the steps of inserting a collapsed or collapsed bag through an opening in a wall of the carton of a substantially pre-assembled carton and inflating the bag when It is inside it. 33.- A BIB assembly procedure that includes the steps of pre-assembling a cardboard box, presenting a collapsed bag with a mounting collar on a bag collar in juxtaposition with a cardboard box wall opening, inserting the bag complete in the enclosure of the cardboard box, except for a protuberance or neck of retractable bag that fits the collar, by location of action of adjustment and capture, with the peripheral edge of the opening. 34.- A BIB cardboard box with a capture assembly releasable by impact between the bag neck and the cardboard box opening, configured to free the confines bag from the cardboard box by impact of the outer carton , to allow dissipation or release of impact energy by re-exit of the opening without rupture of bag or release of contents. 35.- A BIB assembly for a BIB cardboard box with a contents bag and impact cushion bag juxtaposed with a contents bag inside a cardboard box and filled with a compressible fluid for energy dissipation, bypass or relief on impact of cardboard box. 36.- A BIB assembly for a B1B cardboard box with a plurality of mixed bags, some for content filling, others pre-filled with cushion fluid, in a co-operative juxtaposition. 37.- A BIB assembly of multiple bags grouped in a common cardboard box, with respective or shared bag collars that protrude through individual openings or shared in a cardboard box wall and captured by discrete or shared mounting collars operative between the bag neck and the cardboard box wall. 38.- A BIB assembly machine with means for inserting a collapsed bag into an opening in a pre-formed cardboard box and adjusting a collar onboard by location of action of adjustment and capture, with the peripheral edge of the opening.