WO2007057677A1

WO2007057677A1 - Bag in box assembly and method for assembling a bag in box assembly

Info

Publication number: WO2007057677A1
Application number: PCT/GB2006/004284
Authority: WO
Inventors: John Stephenson
Original assignee: John Stephenson
Priority date: 2005-11-15
Filing date: 2006-11-15
Publication date: 2007-05-24
Also published as: BRPI0620476A2

Abstract

A bag in box assembly and method of assembling a bag in box assembly The method includes the steps of forming an outer carton, and subsequently inserting a cartridge into the opening, wherein the cartridge includes a bag having a spout coupled to a collar, wherein the bag is positioned within the outer carton and access is provided by the spout outside of the outer carton. The bag in box assembly includes a first carton component and a second carton component, wherein the first carton component is inserted into the second carton component. The cartridge is coupled to an aperture of the carton components.

Description

BAG IN BOX ASSEMBLY AND METHOD FOR ASSEMBLING

A BAG IN BOX ASSEMBLY

CROSS-REFERENCE TO RELATED APPLICATION [0001] The present application claims priority from UK. patent application number

0523232.7 entitled "Multiple (Double) Sleeve (Hybrid) Box or Carton for Bag-in-Box (BIB) Container" filed November 15, 2005, and UK patent application number 0524286.2, entitled "BIB Assembly + Erection Machine" filed on November 29, 2005. The entire specification of each of the foregoing are incorporated in their entirety by reference herein.

BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention

[0003] The invention relates in general to bag in box containers, and more particularly, to a bag in box assembly having a cartridge having a bag coupled thereto. The invention likewise discloses a double sleeve outer carton. Moreover, a number of methods of assembling such a bag in box assembly are disclosed. [0004] 2. Background Art

[0005] The use of bag in box assemblies is well known in the art. Typically, a bag filled with a flowable material is positioned within a rigid outer carton. While such containers have been quite well received, there have nevertheless been deficiencies related to filling, transport and dispensing of same.

[0006] Certain solutions have been developed to overcome these deficiencies.

Amongst other solutions has been the introduction of a bag in box container which includes a

bag that is coupled to a collar which is then coupled to the outer carton. Such bag in box containers and assembly methods are disclosed in each of PCT/GB04/002609 entitled Bag in

Box, PCT7GB05/00570 entitled Automatic Bag in Box Assembly and Contents Fill,

PCT/GB2005/004313 entitled Bag Cartridge + Anti Torque all of which share a common

inventor with the instant application. Each of the foregoing applications, as well as the underlying priority applications are incorporated herein by reference in their entirety.

[0007] It would be advantageous to provide another method by which to assemble the bag in box containers. Additionally, it would be advantageous to provide a substitute outer carton which provides enhancements over conventional outer carton configurations. [0008] It is an object of the present invention to provide a method of assembling a bag in box assembly.

[0009] It is another obj ect of the present invention to provide a method of assembling multiple bag in box assemblies.

[0010] It is another obj ect of the invention to provide a double sleeve outer carton for use in association with a bag in box assembly.

[0011] These objects as well as other objects of the present invention will become apparent in light of the present specification, claims, and drawings.

SUMMARY OF THE INVENTION

[0012] In one aspect of the invention, the invention is directed to a method of

assembling a bag in box assembly. The bag in box assembly method comprises the steps of

forming an outer carton having a plurality of walls, at least one of the walls having an aperture extending therethrough; and subsequently inserting a cartridge into the opening, wherein the cartridge includes a bag having a spout coupled to a collar, wherein the bag is positioned within the outer carton and access is provided the spout outside of the outer

carton. [0013] In a preferred embodiment, the step of forming an outer carton comprises the steps of (a) providing a collapsed outer carton, the outer carton having a plurality of walls, a plurality of top end flaps and a plurality of bottom end flaps, a cartridge aperture is disposed in the plurality of top end flaps; (b) articulating the walls of the outer container into a deployed position defining a substantially rectangular cubic configuration; (c) placing the bottom end flaps into a closed position; (d) securing the bottom end flaps in the closed position; (e) articulating the top end flaps into a closed position; and (f) securing the top end flaps in the closed position.

[0014] In one embodiment, the step of securing the bottom end flaps further

comprises the step of gluing the bottom end flaps to each other, and the step of securing the

top end flaps further comprises the step of gluing the top end flaps to each other. [0015] In another embodiment, the step of forming an outer carton comprises the

steps of (a) providing a first carton component having a front panel, a back panel, a first side panel and a second side panel; (b) providing a second carton component having atop panel, a

bottom panel, an outer front panel and an inner front panel; and (c) inserting the first carton into the second carton so that the outer front panel overlays the front panel and the outer rear

panel overlies the rear panel.

[0016] In one such preferred embodiment, the method further comprises the step of

securing the first carton component to the second carton component. In one embodiment, the method further comprises the steps of (a) injecting air into the spout of the cartridge; and (b)

inflating the bag toward a volume of the outer carton. In another embodiment, the step of inflating comprises the step of inflating with air at a pressure lower than a pressure of air during the step of injecting. [0017] In yet another embodiment, the step of inserting further comprises the steps of: (a) releasably grasping a cartridge from a plurality of cartridges with a robotic arm; (b) moving the robotic arm having the cartridge away from the plurality of cartridges; (c) positioning the cartridge proximate the aperture; (d) directing the cartridge into the aperture until the cartridges is restrained through cooperation with the aperture; and (e) releasing the cartridge from the robotic arm.

[0018] In another aspect of the invention, the invention comprises a method of assembling a plurality of bag in box assembly. The method comprises the steps of (a) forming at least two outer cartons, each outer carton having a plurality of walls, at least one of the walls having an aperture extending therethrough; (b) releasably grasping at least two cartridge in a spaced apart orientation from a plurality of cartridges with a robotic arm, wherein the

cartridge includes a bag having a spout coupled to a collar and wherein the bag is positioned

within the outer carton and access is provided the spout outside of the outer carton; (c) moving the robotic arm having the cartridge away from the plurality of cartridges; (d) optionally adjusting the spacing of the at least two cartridges so as to position each cartridge proximate a respective aperture of a respective one of the at least two outer cartons; (e)

directing each of the at least two cartridges into the aperture until each cartridge is restrained

through cooperation with the aperture; and (f) releasing each of the at least two cartridges

from the robotic arm. [0019] In one such embodiment, the step of directing each of the at least two cartridges further comprises the step of simultaneously directing each of the at least two cartridges.

[0020] In another such preferred embodiment, the step of adjusting the space of the at least two cartridges further comprises the step of laterally moving the at least two cartridges one of toward each other and away from each other.

[0021] In another aspect of the invention, the invention comprises a system for assembling a bag in box assembly. The system comprises an outer carton assembler and a cartridge insertion assembler. The outer carton assembler is configured for forming an outer carton having an aperture through at least one wall. The cartridge insertion assembler is positioned downstream of the outer carton assembler. The cartridge insertion assembler is configured for inserting a cartridge into the aperture. The cartridge includes a collar with a

rim, a bag having a bag body and a spout. The spout is attached to the collar. A retaining wrap retains the bag body in a collapsed position below the collar.

[0022] In one embodiment, the outer carton includes a plurality of walls, a plurality of upper end flaps and a plurality of lower end flaps. In such an embodiment, the outer carton

assembler comprises a bag gripping and expanding assembly, a flap folding assembly and a sealing assembly. The bag gripping and expanding assembly includes grippers structurally configured to grasp opposing walls of a box carton. The flap folding assembly is structurally configured for folding the upper and lower end flaps of the outer container into a closed

position. The sealing assembly seals the upper flaps in a closed position and sealing the lower

flaps in a closed position.

[0023] In another preferred embodiment the outer carton includes a first carton

component and a second carton component. In such an embodiment, the outer carton assembler comprises means for inserting the first carton component into the second carton component to form a substantially rectangular cubic configuration including a top wall, a bottom wall, opposing side walls, a front wall and a back wall.

[0024] In another embodiment, the system further includes means for attaching the first carton component to the second carton component upon insertion.

[0025] In another embodiment, the cartridge insertion assembler further comprises a robotic arm assembly and a cartridge storage assembly. The robotic arm assembly has a grip head and means for grasping a cartridge. The robotic arm has at least three degrees of movement. The cartridge storage assembly is associated with the robotic arm assembly. The cartridge storage assembly is configured for releasably maintaining a plurality of cartridges for sequential grasping thereof by the grasping means.

[0026] In yet another aspect of the invention, the invention comprises a double sleeve outer carton for use in association with a bag in box assembly. The double sleeve outer carton

comprises a first carton component, a second carton component and an aperture. The first carton component has a front panel, a back panel, a first side panel and a second side panel. The second carton component has a top panel, a bottom panel, an outer front panel and an

outer back panel. The aperture extends through at least one of the first carton and the second

carton. The aperture is sized to accept a cartridge. The first carton component is positionable within the second carton component such that the front panel and the outer front panel are

positioned in an overlying orientation. Additionally, the back panel and the outer back panel are positioned in an overlying orientation. In turn, this forms a substantially rectangular cubic

configuration having six walls. [0027] In one embodiment, the aperture comprises a cartridge aperture and a cartridge

slot. The cartridge aperture is positioned on the second carton component. The cartridge

aperture has a front portion on the outer front panel and a top portion on the top panel. The cartridge slot is positioned on the front panel of the first carton component. The cartridge slot substantially corresponds to the front portion of the cartridge aperture when the carton is in the articulated configuration.

[0028] In another preferred embodiment, the outer carton further comprises means for coupling the first carton component to the second carton component. [0029] In one such embodiment, the coupling means comprises at least one tab extending from a side edge of one of the panels of the second carton component, and means for attaching the at least one tab to the first carton component.

[0030] In another preferred embodiment, the coupling means comprises at least one tab positioned on a lower edge of one of the first side panel and second side panel, at least one slot correspondingly positioned on a respective side edge of a respective top and bottom

panel. The at least one tab communicates with the at least one slot.

[0031 ] In one embodiment, the double sleeve outer carton includes a handle aperture

positioned in the back panel of the first carton component, and a handle aperture positioned in the outer back panel. The handle aperture of the back panel corresponds to the handle aperture of the outer back panel. [0032] In another preferred embodiment, the handle aperture further includes a handle

insert extending at least partially about a circumference of each of the handle aperture of the

back panel and the handle aperture of the outer back panel.

[0033] In another preferred embodiment, the handle aperture of the outer back panel

further includes a flap foldable through the handle aperture of the back panel and securable to an inside surface of the back panel.

[0034] In yet another embodiment, the material from which the first carton component is formed is different from the material from which the second carton component is formed. [0035] In yet another aspect of the invention, the invention comprises a bag in box assembly comprising a double sleeve outer carton and a cartridge. The outer carton comprises a first carton component, a second carton component and an aperture. The first carton component includes a front panel, a back panel, a first side panel and a second side panel. The second carton component includes a top panel, a bottom panel, an outer front panel and an outer back panel. The aperture extends through at least one of the first carton and the second carton. The aperture is sized to accept a cartridge. The first carton component is positionable within the second carton component such that the front panel and the outer front panel are positioned in an overlying orientation and such that the back panel and the outer

back panel are positioned in an overlying orientation, to in turn form a substantially rectangular cubic configuration having six walls. The cartridge is coupled to the outer carton

and positioned in the aperture thereof. The cartridge includes a collar engaging the aperture, a bag having a body and a spout, the spout being coupled to the collar. The bag is positioned

within the carton and the spout is engageable from outside of the carton. [0036] In one such embodiment, the body of the bag is collapsed so as to have a

footprint substantially corresponding to the collar. The cartridge further comprises a retaining

wrap extending about at least a portion of the bag to maintain the collapsed configuration.

[0037] In another such embodiment, the bag is folded into a substantially flat collapsed configuration.

[0038] In another such embodiment, the collar further includes a rim which engages the cartridge aperture precluding further insertion thereof into the double sleeve outer carton.

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The invention will now be described with reference to the drawings wherein:

[0040] Figure 1 of the drawings is a perspective view of a bag in box container of the

present invention; [0041] Figure 2 of the drawings is an exploded perspective assembly view of the collar, the bag and the retaining member, showing, in particular, the folding sequence of same

to form a cartridge;

[0042] Figure 3A through 3F of the drawings are a series of perspective views showing sequential erection of the box carton, wherein, [0043] Figure 3A of the drawings is a perspective view of the initial supply of box cartons in a collapsed configuration, from, for example a pile or a cartridge;

[0044] Figure 3 B of the drawings is a perspective view of the initial supply of box cartons showing the grasping of one wall of the box carton;

[0045] Figure 3C of the drawings is a perspective view of the box carton showing the grasping or another wall of the box carton;

[0046] Figure 3D of the drawings is a perspective view of the box carton showing the formation and placement of the walls thereof;

[0047] Figure 3E of the drawings is a perspective view of the box carton showing the initial folding of the first and second side flaps of the bottom end flaps; [0048] Figure 3F of the drawings is a perspective view of the box carton showing the folding of the front and rear flaps of the bottom end flaps;

[0049] Figures 4 A through 4C are a series of perspective views showing sequential folding of the top end flaps of the box carton, wherein, [0050] Figure 4A of the drawings is a perspective view of the assembly procedure

showing, in particular, the initial folding of the first and second side flaps of the top end

flaps, as well as the sealing of the bottom flaps;

[0051] Figure 4B of the drawings is a perspective view of the assembly procedure

showing, in particular, the initial folding of the front and rear flaps of the top end flaps;

[0052] Figure 4C of the drawings is a perspective view of the assembly procedure

showing, in particular, the sealing of the top flaps and the complete box carton upon completion of the assembly procedure;

[0053] Figure 5A of the drawings is a perspective view of the assembly of the cartridge and the box carton to form the Bag in Box assembly;

[0054] Figure 5B of the drawings is a front plan view of an alternate embodiment of the cartridge insertion assembler;

[0055] Figures 6 A through 6D of the drawings are a series of perspective views showing sequential folding of the box carton from a blank prior to erection thereof wherein, [0056] Figure 6A of the drawings is a perspective view of the blank wherein two separate wall portions thereof have been grasped;

[0057] Figure 6B of the drawings is a perspective view of the blank wherein pairs of

walls have been folded about the mid-section of the blank so as to overlie each other;

[0058] Figure 6C of the drawings is a perspective view of the blank wherein the opposing ends are coupled to each other to form a collapsed box carton;

[0059] Figure 6D of the drawings is a perspective view of a completed but collapsed

box carton;

[0060] Figure 7 A of the drawings is a top plan view of a blank of a first component of a double sleeve box carton;

[0061] Figure 7B of the drawings is a bottom plan view of a blank of a second

component of the double sleeve box carton;

[0062] Figures 8A through 8D of the drawings are a series of perspective views

showing sequential assembly of a double sleeve box carton from the blanks of Figures 7 A

and 7B₅ wherein,

[0063] Figure 8A of the drawings is a perspective view of an articulated first component of a double sleeve box carton and an articulated second component of a double sleeve box carton;

[0064] Figure 8B of the drawings is a perspective view of a partial assembly of the first component and the second component of the double sleeve box carton;

[0065] Figure 8C of the drawings is a perspective view of an assembled double sleeve box carton, and the attachment thereto of a cartridge;

[0066] Figure 8D of the drawings is a perspective view of a fully assembled bag in box container;

[0067] Figure 9 of the drawings is an enlarged view of the portion 9 of Figure 8A, showing, in particular, the corrugations of the cross-sectional configuration of wall of the second component;

[0068] Figures 1OA through 1OC of the drawings are a series of perspective views showing an alternate sequential assembly of a double sleeve box carton, wherein,

[0069] Figure 1 OA of the drawings is a perspective view of the assembly of a first component and a second component of a double sleeve box carton;

[0070] Figure 1OB of the drawings is a perspective view of a partially assembled double box carton which has been placed in a collapsed configuration for shipment and

storage;

[0071] Figure 1 OC of the drawings is a perspective view of a partially assembled box

carton which has been erected from the collapsed configuration of 1 OB showing the final assembly and articulation thereof;

[0072] Figure 11 of the drawings is a perspective view of a partially assembled box carton wherein the box carton has been partially assembled by placing the respective front

panels in an abutting relationship prior to final assembly;

[0073] Figure 12A of the drawings is a perspective view of a partially assembled box carton wherein the box carton has been partially assembled by placing the respective front panels in an abutting relationship prior to final assembly, and, additionally, providing for a handle and a handle insert to facilitate handling of the container;

[0074] Figure 12B of the drawings is a perspective view of a fully articulated box carton of Figure 12 A;

[0075] Figure 13 of the drawings is a perspective view of an alternate embodiment of the double walled box carton, showing the incorporation of a handle therewith;

[0076] Figure 14 of the drawings is a perspective view of another embodiment of the double walled box carton, showing the incorporation of an alternate form of the handle;

[0077] Figure 15A of the drawings is a top plan view of a blank of a first component of a double sleeve box carton;

[0078] Figure 15B of the drawings is a bottom plan view of a blank of a second component of the double sleeve box carton;

[0079] Figures 16A through 16C of the drawings are a series of perspective views showing sequential assembly of a double sleeve box carton from the blanks of Figures 15A

and 15B, wherein,

[0080] Figure 16A of the drawings is a perspective view of an articulated first

component of a double sleeve box carton and an articulated second component of a double

sleeve box carton;

[0081] Figure 16B of the drawings is a perspective view of a partial assembly of the first component and the second component of the double sleeve box carton;

[0082] Figure 16C of the drawings is a perspective view of a fully assembled bag in box container;

[0083] Figure 17 of the drawings is a schematic representation of two alternate methods of assembly of a double sleeve box carton of the present invention;

[0084] Figures 18A through 18F of the drawings are a series of perspective views showing sequential assembly of a double sleeve box carton of an alternate embodiment, wherein,

[0085] Figure 18A of the drawings is a perspective view of the double sleeve box carton prior to assembly of the two components, but after attachment of the cartridge to the first component;

[0086] Figure 18B of the drawings is a perspective view of the double sleeve box carton upon attachment of the first and second components, while the second component is collapsed, and the first component is a blank;

[0087] Figure 18C of the drawings is a perspective view of the double sleeve box carton upon partial articulation of the first component;

[0088] Figure 18D of the drawings is a perspective view of the double sleeve box carton upon articulation of the second component and formation of the first component

around the second component;

[0089] Figure 18E of the drawings is a perspective view of the double sleeve box carton upon final formation of the first component around the second component;

[0090] Figure 18F of the drawings is a perspective view of the double sleeve box

carton upon completion of the formation thereof;

[0091] Figure 19 of the drawings is a schematic representation of an alternate method of assembly of a double sleeve box carton of the present invention; and

[0092] Figures 20A through 2OC of the drawings are a series of perspective views showing sequential assembly of a double sleeve box carton, wherein,

[0093] Figure 2OA comprises a perspective view of the first and second box carton components positioned within cassettes;

[0094] Figure 2OB comprises a perspective view of the first and second box carton components as said cartons exit from within the respective cassettes; and [0095] Figure 2OC comprises a perspective view of the first and second box carton components as said cartons are joined together.

DETAILED DESCRIPTION OF THE INVENTION

[0096] While this invention is susceptible of embodiment in many different forms,

there is shown in the drawings and described herein in detail a specific embodiment with the understanding that the present disclosure is to be considered as an exemplification of the

principles of the invention and is not intended to limit the invention to the embodiment

illustrated.

[0097] It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of the invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.

[0098] Referring now to the drawings and in particular to Figure 1 , a completed bag in box assembly 10 is shown. The bag in box assembly is typically used for storage, transport and dispensing of flowable materials (which may include, but not be limited to, any one of solids, liquids, gels, suspensions or combinations thereof). The particular bag in box

assembly of the present invention is shown in various embodiments in one or more of PCT/GB04/002609 entitled Bag in Box, PCT/GB05/00570 entitled Automatic Bag in Box Assembly and Contents Fill, PCT/GB2005/004313 entitled Bag Cartridge + Anti Torque all of which share common inventorship with the instant application. Each of the foregoing applications, as well as the underlying priority applications are incorporated herein by reference in their entirety.

[0099] The bag in box assembly includes outer carton 20 and cartridge 22. In the

embodiment shown in Figure 1, and with reference to Figures 3 A through 4C, the outer carton includes walls 24, top end flaps 26, bottom-end flaps 28 and means 29 for coupling the flaps. More specifically, the top end flaps 26 includes front flap 30, rear flap 32, first side flap

34 and second side flap 36. The various components of the top end flaps are structured such

that, upon articulation, the flaps define cartridge aperture 48. The cartridge aperture is sized

to receive cartridge 22 (Figure 2) and to engage rim 55 (Figure 2) thereof.

[0100] Referring again to Figures 3 A through 4C, the bottom end flaps include front flap 40, rear flap 42, first side flap 44 and second side flap 46. Typically, the outer carton can be formed from any number of different paperboard or plastic components. One common

form of the outer carton is a corrugated construction, such as the structure shown in Figure 9. Of course, the material from which the outer carton is formed, is not limited to any particular material, but, may comprise, corrugated paperboard, solid paperboard, coated and laminated boards, plastic shee and corrugated plastic sheet, among others.

[0101] Coupling means 29 may comprise any number of different members which facilitate the attachment of different flaps and walls to form an integrated outer carton. For example, the coupling means may comprise hot melt glues and adhesives, cold applied glues and adhesives. In other embodiments, the coupling means may comprise tapes strips, m other embodiments, the coupling means may comprise staples or clamps. Indeed, a number of different coupling means are contemplated.

[0102] Cartridge 22 is shown in Figure 2 as comprising collar 50, bag 52 and

retaining wrap 54. The collar comprises a rim 55 and an aperture 56. The bag includes body 57 and spout/neck 58. The spout 58 extends through aperture 56 and is secured thereto. In certain embodiments, the bag body is folded so as to be positioned below the collar, and retaining wrap 54 is extended therearound to maintain the folded configuration. In certain embodiments, such as the embodiment shown in Figure 19, the retaining wrap is not utilized;

rather the bag remains in an unfolded condition. In other embodiments, the retaining wrap

comprises a tape member which is adhered to multiple regions of the bag. The

aforementioned incorporated applications include further description of the cartridge and/or

the collar and the bag components.

[0103] Inasmuch as the cartridge can be coupled to the outer carton after the articulation and complete formation of the outer carton, assembly equipment can be configured to advantageously assemble same. The assembly equipment is shown in Figures 3 A through 5B as including outer carton assembler 102 and cartridge insertion assembler 104. Such assembly equipment can be positioned prior to filling equipment (not shown), such that immediately after formation and articulation (or shortly thereafter), the bag in box assembly can be filled with contents as desired.

[0104] Referring now to Figures 3 A through 4C, the outer carton assembler includes box gripping and expanding assembly 106, flap folding assemblies 108 and sealing assembly

110. With reference to Figures 3 A through 3F, the box gripping and expanding assemblies 106 include first suction grippers 112 and second suction grippers 114. The first and second

suction grippers are positioned on opposing sides of each other and cooperate to articulate the walls of the outer carton. The flap folding assembly, shown in detail relative to the folding of

the top end flaps, includes swing arm 118, deflection guide plate 120 and fold bars 122. To

insure that the box carton is directed through the flap folding assembly, a conveyor, such as conveyor 116 is provided.

[0105] Sealing assembly 110 is shown in Figures 4A and 4C as comprising tapers 123 and 125 which are configured to place a strip of tape at strategic locations to insure that the flaps remain positioned. In other embodiments, the sealing assembly 110 may comprise

dispensers of hot melt glue or other glues and adhesives. Advantageously, inasmuch as the

cartridge is inserted after formation of the outer carton, hot melt glue poses little risk of

melting the bag body or otherwise compromising the inner bag body.

[0106] Cartridge insertion assembler 104 is shown in Figure 5 A as comprising cartridge storage assembly 124 and robotic arm assembly 126. The cartridge storage assembly

124 comprises matrix storage member 128 which is configured to include multiple stacks of cartridges, such as, for example, in 3x3, 4x3, 4x4, etc. stacks. Each stack may include any number of cartridges. [0107] The robotic arm assembly 126 includes grip head 130, suction means 132 and arm member 134. The grip head is positioned at the end of the arm member. The suction means 132 includes regulator valve 136 and pneumatic reservoir 138. The grip head and the suction means cooperate to, through suction, releasably retain the cartridge at the grip head. The arm member comprises a multi-axis robotic arm capable of moving the cartridge from the cartridge storage assembly to the proper position on an outer carton. In the embodiment shown in Figure 5A, a single cartridge is grasped, moved and inserted.

[0108] In another embodiment, as is shown in Figure 5B, multiple grip heads 13 Oa,

130b may be associated with a single arm member. Specifically, the grip heads are mounted at the end of the arm member, and are capable of moving laterally relative to each other. As such, they are able to grasp multiple cartridges from the matrix 128 then properly insert the cartridges on adjoining or spaced apart outer cartons. While two grip heads are shown, it is

contemplated that a greater number of heads may be utilized. Advantageously, the same robot

arm assembly can be utilized and can be adjusted for differently sized outer cartons and for differently configured cartridges, inasmuch as the lateral spacing is adjustable.

[0109] In operation of such an embodiment is shown in Figures 3 A through 3F,

Figures 4 A through 4C and Figure 5. As is shown in Figure 3A₃ the first suction grippers 112

grasp a first outer carton. With reference to Figures 3B and 3 C, the carton is located such that

the second suction grippers 114 grasp another wall of the outer carton, spaced apart from (or on opposing sides of) the first suction grippers. In other embodiments, this grasping by the

first and second suction grippers can be simultaneous.

[0110] Once grasped, as is shown in Figure 3D, the gripper arms are manipulated so that the walls 24 become articulated into a fully deployed position. Once deployed, a flap folding assembly is employed to first articulate the first and second side flaps 44, 46 of the bottom end flaps, then, the front and rear flaps, 40, 42, respectively. At such time, five of the six walls have been articulated. A sealing assembly 110 is then employed to insure that the bottom end flaps are properly fixed in the articulated position. In the embodiment shown in Figure 4A, a taper member is employed. In other embodiments, a glue or adhesive can be applied to the inner or outer surfaces of the various flaps to glue/adhere the panels to each other.

[0111] With reference to Figures 4 A through 4C, to assemble the top end flaps 26, the

partially articulated container is placed on a conveyor. The outer carton approaches a swing arm 118 which folds the second side flap 34. Next, the deflector guide plate 120 folds the

second side flap 36. Subsequently, as is shown in Figure 4B, the fold bars 122 fold the front and rear flaps 30, 32, respectively. Once all of the top end flaps 26 have been positioned in

the fully articulated/deployed configuration, the taper is employed to fix the flaps in such an

orientation. In other embodiments, glue or adhesive or fasteners can be utilized during or after the articulation process to maintain the flaps in a deployed orientation.

[0112] With reference as the outer cartons leave the conveyor 116, the units are fully

formed and the cartridge is ready for insertion into the cartridge aperture 48. Even where a glue or an adhesive is utilized, the glue or adhesive is typically cooled or dried prior to the

inflation or articulation of the bag body within the outer carton.

[0113] Once the outer carton is formed, with reference to Figure 5 A, the outer carton

is directed to the cartridge insertion assembler 104. In particular, the robotic arm assembly is activated to retrieve a cartridge from the cartridge storage assembly. Specifically, grip head 130, through suction (or other grasping means, adhesion, magnetic couplings, physical gripping, etc .) grasps a cartridge from matrix 128. The arm member then moves from the area proximate the matrix to a position wherein the cartridge overlies the cartridge aperture 48. The cartridge is then inserted into the cartridge aperture, and the rim 55 engages the carton to limit further movement. Typically, the cartridge includes means for maintaining the inserted orientation so that removal requires greater effort than insertion. [0114] Once formed, any number of different methods, identified in the incorporated references can be utilized to initiate filling and use of the formed bag in box assembly. In one particular embodiment, deployment of the cartridge and filling thereof can be undertaken through a two step process. In particular, an initial short injection of high pressure air can be used to break the retaining wrap. Once broken, a second movement of air (typically of a

lower pressure) is utilized to deploy the bag so as to effectively increase the bag volume

toward that of the outer carton. Typically, the bag is not pressurized, so as to minimize the possibility of damaging the bag. The container assembly can then be positioned upon a

conventional bottle filling apparatus. In other embodiments, the filling process can be utilized to expand the bag instead of a volume of air.

[0115] In another embodiment of the bag in box assembly, a specially configured

double sleeve outer carton 200 has been provided. Such a container can be utilized in

association with the foregoing cartridge insertion assembler and is configured for use in

association with the cartridge of Figure 2. Such an embodiment is shown in Figures 7A through 2OC.

[0116] More specifically, and with reference to Figure 8 A, the double sleeve outer carton 200 is formed from first carton component 202 and second carton component 204. These carton components are shown in Figure 7A and 7B, as blanks 201, 203, respectively. The first carton component includes front panel 210, back panel 212, first side panel 214 and second side panel 216. These panels are articulated to form a generally rectangular configuration defining inner surface 217 and outer surface 218. Typically, the front panel 210 includes cartridge slot 219. Preferably, the materials from which the outer carton 200 is formed is similar to that of outer carton 20. It will be understood that the carton components are not required to be made from the same materials and a first material may be utilized for the first carton component whereas a second material may be utilized for the second carton component.

[0117] Second carton component 204 is shown in Figure 8 A as comprising top panel

220, bottom panel 222, outer front panel 224 and outer back panel 226. The panels are sized

such that the second carton component can be articulated into a generally rectangular configuration defining inner surface 227 and outer surface 228. Additionally, cartridge aperture 230 is defined in the top panel 220 and the outer front panel 224. The cartridge

aperture includes front portion 232 and top portion 234. The front portion 232 substantially matches the cartridge slot 219 in configuration.

[0118] The first and second components are sized such that nested insertion of one

component relative to the other facilitates the formation of the double sleeve outer carton 200. In particular, and with reference to Figures 8 A through 8D, to assemble the outer carton,

and, in turn, the bag in box assembly, the user first articulates each of the first and second

components 202, 204 from the respective blanks 201 and 203, respectively. Once articulated into generally rectangular components, as is shown in Figure 8B, first carton component 202 is slid into second carton component 204 such that the outer front panel 224 overlies front panel 210 and such that outer back panel 226 overlies back panel 212. At such time the cartridge slot 219 substantially corresponds to front portion 232 of cartridge aperture 230. [0119] Once the two components have been substantially interfaced, a coupling means 206 can be employed to maintain the articulated and interfaced position of the two carton components. In the embodiment shown in Figure 8A, tabs 236 can be attached (through adhesive, glue, staples, Velcro, etc) to the opposing first and second side panels 214, 216. In another embodiment, such as is shown in Figure 11, tabs 236 can be coupled to the outer front panel 224 and/or outer back panel 226. In other embodiments, such as the embodiment of Figures 15 A, 15B and 16 A through 16C, an edge tab 240 can be provided on one of the two carton components and a edge slot 242 can be provided on the other of the two

carton components. These two components cooperate to releasably restrain the second carton component relative to the first carton component in a predetermined articulated and

interfaced position. In other embodiments, reliance can be placed on the interface between the cartridge slot 219 and the cartridge aperture 230 to maintain the two carton components in

relative position. In yet other embodiments, the carton components can be attached together at the overlying walls themselves.

[0120] In still other embodiments, handle apertures 213, 223 can be positioned

through and defined by each of the back panel 212 and outer back panel 226, respectively.

Additionally, to increase the strength of any such handle, handle insert 246 can be provided. Typically, the handle insert comprises a separate component which matingly engages the apertures and is formed from a polymer component. In another embodiment, the outer back panel 226 may include a tuck-in flap 223 which can be extended through the aperture 213 and attached to the inner surface of the back panel 212.

[0121] Finally, and with reference to Figure 8C and 8D, cartridge 22 is inserted into cartridge aperture 230 which is defined by cartridge aperture 230 and cartridge slot 219. [0122] In the embodiment of Figures 1 OA through 1 OC, the first component can be inserted into the second component in a partially collapsed configuration. Whereupon insertion, the second component is likewise collapsed. In turn, the partially interfaced carton components can be shipped in a substantially flat orientation. Once delivered to the location of final assembly, the user can articulate each of the components and complete the final assembly. In the embodiment shown in Figures 1OA through 1OC, the back panel 212 and the outer back panel 226 are initially placed in an abutting and interfaced position prior to collapsing each of the carton components. With the embodiment of Figure 11 , the front panel

210 and the outer front panel 224 are so interfaced prior to collapsing of each of the two carton components. Schematic representations of such an assembly procedure is shown in Figure 17.

[0123] Still another embodiment of a double sleeve outer carton is shown in Figures

18 A through 18F. In these embodiments, the first carton component is formed, but collapsed. The second carton component initially is mated with a cartridge, but left in the configuration

of blank 203. Subsequently, this configuration can be shipped wherein, at the destination, the

user can articulate the first component, then form the second component around the first

component. Inasmuch as the cartridge is provided, upon formation of the second component,

the container assembly is fully formed.

[0124] In yet another configuration, the bag and the collar can be assembled during the articulation of the double sleeve outer carton. Specifically, and as is shown schematically in Figure 19, a bag 52 may be properly positioned within a collapsed first carton component 202. Once the bag is positioned, the first component can be inserted into the second component. The spout of the bag corresponds to the cartridge aperture 230. At such time, the first and second components can be collapsed. Inasmuch as the spout 58 extends through the aperture 230, the collar 50 can be attached when in this collapsed configuration, as is shown. Finally, the entire assembly is collapsed for shipment. The collapsed configuration can be articulated at the destination prior to filling.

[0125] In a final embodiment, as is shown in Figure 20, a cartridge system similar to that which is disclosed in PCT/GB05/004369 entitled Rotary Drum Dispenser for BIB, invented by the inventor of the instant application. The entire specification of this application

is incorporated in its entirety by reference. In such an embodiment, each cassette 300, 302

includes one of the carton components. The components are sequentially dispensed by the cassettes in such an orientation that they can be articulated and merely translated into the proper configured and attached configuration.

[0126] The foregoing description merely explains and illustrates the invention and the

invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications

without departing from the scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. A method of assembling a bag in box assembly comprising:

- forming an outer carton having a plurality of walls, at least one of the walls having

an aperture extending therethrough; and

- subsequently inserting a cartridge into the opening, wherein the cartridge includes a bag having a spout coupled to a collar, wherein the bag is positioned within the outer carton and access is provided the spout outside of the outer carton.

2. The method of claim 1 wherein the step of forming an outer carton comprises the steps of:

- providing a collapsed outer carton, the outer carton having a plurality of walls, a plurality of top end flaps and a plurality of bottom end flaps, a cartridge aperture is disposed in the plurality of top end flaps;

- articulating the walls of the outer container into a deployed position defining a substantially rectangular cubic configuration;

- placing the bottom end flaps into a closed position;

- securing the bottom end flaps in the closed position;

- articulating the top end flaps into a closed position; and

.- securing the top end flaps in the closed position.

3. The method of claim 2 wherein the step of securing the bottom end flaps further

top end flaps further comprises the step of gluing the top end flaps to each other.

4. The method of claim 1 wherein the step of forming an outer carton comprises the steps of:

- providing a first carton component having a front panel, a back panel, a first side panel and a second side panel;

- providing a second carton component having a top panel, a bottom panel, an outer

front panel and an inner front panel; and

- inserting the first carton into the second carton so that the outer front panel overlays the front panel and the outer rear panel overlies the rear panel.

5. The method of claim 4 further comprising the step of securing the first carton

component to the second carton component.

6. The method of claim 1 wherein the step of inserting further comprises the steps of:

- releasably grasping a cartridge from a plurality of cartridges with a robotic arm;

- moving the robotic arm having the cartridge away from the plurality of cartridges;

- positioning the cartridge proximate the aperture; - directing the cartridge into the aperture until the cartridge is restrained through

cooperation with the aperture; and

- releasing the cartridge from the robotic arm.

7. The method of claim 1 further comprising the steps of: - injecting air into the spout of the cartridge; and

- inflating the bag toward a volume of the outer carton.

8. The method of claim 7 wherein the step of inflating comprises the step of inflating with air at a pressure lower than a pressure of air during the step of injecting.

9. A method of assembling a plurality of bag in box assembly comprising:

- forming at least two outer cartons, each outer carton having a plurality of walls, at

least one of the walls having an aperture extending therethrough;

- releasably grasping at least two cartridges in a spaced apart orientation from a plurality of cartridges with a robotic arm, wherein the cartridge includes a bag having a spout

coupled to a collar and wherein the bag is positioned within the outer carton and access is provided the spout outside of the outer carton;

- moving the robotic arm having the cartridge away from the plurality of cartridges; - optionally adjusting the spacing ofthe at least two cartridges so as to position each cartridge proximate a respective aperture of a respective one ofthe at least two outer cartons;

- directing each ofthe at least two cartridges into the aperture until each cartridge is

restrained through cooperation with the aperture; and

- releasing each ofthe at least two cartridges from the robotic arm.

10. The method of claim 9 wherein the step of directing each of the at least two cartridges further comprises the step of simultaneously directing each ofthe at least two cartridges.

11. The method of claim 9 wherein the step of adjusting the space of the at least two cartridges further comprises the step of laterally moving the at least two cartridges one of toward each other and away from each other.

12. A system for assembling a bag in box assembly comprising:

- an outer carton assembler for forming an outer carton having an aperture through at

least one wall; and

- a cartridge insertion assembler positioned downstream of the outer carton assembler,

the cartridge insertion assembler for inserting a cartridge into the aperture, the cartridge including a collar with a rim, a bag having a bag body and a spout, wherein the spout is

attached to the collar, and a retaining wrap retaining the bag body in a collapsed position below the collar.

13. The system of claim 12 wherein the outer carton includes a plurality of walls, a plurality of upper end flaps and a plurality of lower end flaps, the outer carton assembler comprises:

- a bag gripping and expanding assembly having grippers structurally configured to grasp opposing walls of a box carton;

- a flap folding assembly structurally configured for folding the upper and lower end flaps of the of the outer container into a closed position;

- a sealing assembly sealing the upper flaps in a closed position and sealing the lower flaps in a closed position.

14. The system of claim 12 wherein the outer carton includes a first carton component

and a second carton component, the outer carton assembler comprises:

- means for inserting the first carton component into the second carton component to

form a substantially rectangular cubic configuration including a top wall, a bottom wall,

opposing side walls, a front wall and a back wall.

15. The system of claim 14 further comprising means for attaching the first carton component to the second carton component upon insertion.

16. The system of claim 12 wherein the cartridge insertion assembler further comprises :

- a robotic arm assembly having a grip head and means for grasping a cartridge, the robotic arm having at least three degrees of movement;

- a cartridge storage assembly associated with the robotic arm assembly, the cartridge storage assembly configured for releasably maintaining a plurality of cartridges for sequential grasping thereof by the grasping means.

17. A double sleeve outer carton for use in association with a bag in box assembly:

- a first carton component having a front panel, a back panel, a first side panel and a

second side panel;

- a second carton component having a top panel, a bottom panel, an outer front panel

and an outer back panel; and

- an aperture extending through at least one of the first carton and the second carton, the aperture sized to accept a cartridge,

- wherein the first carton component is positionable within the second carton component such that the front panel and the outer front panel are positioned in an overlying orientation and such that the back panel and the outer back panel are positioned in an overlying orientation, to in turn form a substantially rectangular cubic configuration having six walls.

18. The double sleeve outer carton of claim 17 wherein the aperture comprises: - a cartridge aperture positioned on the second carton component, the cartridge aperture having a front portion on the outer front panel and a top portion on the top panel, and

- a cartridge slot positioned on the front panel of the first carton component,

- wherein the cartridge slot substantially corresponds to the front portion of the

cartridge aperture when the carton is in the articulated configuration.

19. The double sleeve outer carton of claim 17 further comprising means for coupling the first carton component to the second carton component.

20. The double sleeve outer carton claim 19 wherein the coupling means comprises at

least one tab extending from a side edge of one of the panels of the second carton component,

and means for attaching the at least one tab to the first carton component.

21. The double sleeve outer carton of claim 19 wherein the coupling means comprises:

- at least one tab positioned on a lower edge of one of the first side panel and second side panel;

- at least one slot correspondingly positioned on a respective side edge of a respective top and bottom panel, - wherein the at least one tab communicates with the at least one slot.

22. The double sleeve outer carton of claim 17 further comprising:

- a handle aperture positioned in the back panel of the first carton component;

- a handle aperture positioned in the outer back panel, wherein the handle aperture of the back panel corresponds to the handle aperture of the outer back panel.

23. The double sleeve outer carton of claim 22 wherein the handle aperture further includes a handle insert extending at least partially about a circumference of each of the handle apertures of the back panel and the handle aperture of the outer back panel.

24. The double sleeve outer carton of claim 17 wherein the handle aperture of the outer

back panel further includes a flap foldable through the handle aperture of the back panel and securable to an inside surface of the back panel.

25. The double sleeve outer carton of claim 17 wherein the material from which the first

carton component is formed is different from the material from which the second carton

component is formed.

26. A bag in box assembly comprising:

- a double sleeve outer carton comprising:

- a first carton component having a front panel, a back panel, a first side panel and a second side panel; - a second carton component having a top panel, a bottom panel, an outer front panel and an outer back panel,

- wherein the first carton component is positionable within the second carton component such that the front panel and the outer front panel are positioned in an overlying orientation and such that the back panel and the outer back panel are positioned in an

overlying orientation, to in turn form a substantially rectangular cubic configuration having six walls; and

- a cartridge coupled to the outer carton and positioned in the aperture thereof, the cartridge including a collar engaging the aperture, a bag having a body and a spout, the spout being coupled to the collar, the bag being positioned within the carton and the spout being engageable from outside of the carton.

27. The bag in box assembly of claim 26 wherein the body of the bag is collapsed so as to

have a footprint substantially corresponding to the collar, the cartridge further comprising a

retaining wrap extending about at least a portion of the bag to maintain the collapsed

configuration.

28. The bag in box assembly of claim 27 wherein the bag is folded into a substantially flat collapsed configuration.

29. The bag in box assembly of claim 26 wherein the collar further includes a rim which

engages the cartridge aperture precluding further insertion thereof into the double sleeve outer carton.