Recoverable transport package and method and apparatus for forming transport package of loosely filled products

Abstract

A container blank (1) sized and shaped to form a transport package having a front wall (2) and a rear wall (3) to which side wall portions (11, 12, 16, 17) are attached along respective fold lines (2a, 2b, 3a), each side wall portion being foldable such that the front and rear walls are juxtaposed in alignment with an open inner pocket (30) adhered to the inner surfaces of the front and rear walls. When a transport package is erected from the container blank, the folded inner pouch (30) is unfolded to align with the inner volume of the erected package so as to provide an open container having an open inner pouch to be filled and subsequently sealed for dispensing. The transport package may be configured in a folded flat stackable form with in-situ inner pouches for storage or dispensing, and in use is easy to machine assemble or manually form into an open transport package.

Description

Technical Field

[0001] The present invention relates to container blanks, foldable transport packages formed from container blanks having expandable inner bags mounted therein, and methods and apparatus for forming transport packages for packaging articles, particularly a plurality of small articles (including individually wrapped small articles), and most particularly for packaging loose-fill products such as cereals, seeds, grains, dehydrated foods (including pet food), pet litter, and the like.

[0002] The transport packages formed from the container blanks are suitable for storage or transport in bulk as folded packages for easy assembly at the filling and dispensing site. The present invention also relates to methods and apparatus for forming transport packages from the container blanks, and most particularly to the use of recycled, recyclable and compostable materials.

[0003] The present invention is particularly directed to a container blank made of cardstock and paperboard or similar material, which is modified to include an inner bag therein to facilitate packaging of loose fill materials and small items of fixed volume in a preformed folded shipping package that is easy to assemble. In addition, the present invention is directed to a system that first manipulates the blank to form a folded shipping package, then forms an open package to receive the material, and then seals the package for distribution (shipping) or storage. The present invention is described below with reference to loose fill products and multiple items (such as the items exemplified above), however it should be understood that there is no such limitation.

[0004] The skilled person will appreciate that the present invention, while directed to the packaging of loose-fill products and multiple smaller items (e.g., irregularly shaped pre-packaged items), can be applied to any three-dimensional object that can be positioned within a container. The present invention can also be used to package and transport stacks of flat items (such as books and DVDs). In addition, the present invention can be adapted for storage, transportation and distribution of other products, including pastes, jams, nut butters, jellies, wet foods (e.g., meat nuggets, dog or cat food), and fluids.

[0005] As mentioned above, the term "loose fill" is not intended to be limiting, however, it is an ideal product to which the primary purpose of the present invention is directed. Examples of loose fill products include primary commercial products such as seeds, grains, foods, or detergents, and can range from powdered and granular products; including instant coffee, sugar, laundry detergent, and corn meal; flaked goods such as oatmeal and dry dog ​​food; and a plurality of loose, unwrapped items such as biscuits (including dog biscuits), and wrapped items such as chocolate candies.

[0006] The term "container blank" refers to a cut, pre-formed profile of a unitary raw material to which is adhered or otherwise attached an adhesive and additional material having the same or substantially similar recycling characteristics as the raw material from which the blank is formed.

[0007] The present invention furthermore particularly relates to a method and apparatus for forming a folded shipping package and a system for erecting, filling and sealing a shipping package, which package ideally can be mechanically formed on an automated production line in a distribution center or warehouse. Background Art

[0008] More and more consumers are avoiding time-consuming daily travel and instead purchase their shopping and / or personal and business necessities. Purchases are now commonly made by mail order, by telephone, and via the Internet and email. As a result, there is a significant increase in the use of postal and courier services to deliver purchases for goods to be received.

[0009] With the increasing popularity of Internet shopping and the distribution of ordered items through the postal system, the demand for packaging has increased exponentially. TM and eBay TM The popularity of websites has increased postal volumes for books, CDs, CDROMs and DVDs etc. As these markets and the public's familiarity with online shopping develop, the speed with which deliveries are made and the acceptability of distributing staple products, everyday "consumables" (industrial, commercial and household goods), food and other perishables has also increased. In the home environment, this has increased the bulk purchase of certain materials that were typically purchased in branded packaging at retail outlets such as supermarkets.

[0010] One perceived disadvantage of buying products in bulk is that plastic wrap is often used to wrap individual items or weighted portions, which are then loose-filled in RSC (Regular Slotted Carton) type packages with an integrated plastic shrink-wrap liner to prevent movement of the package contents. It is important to note that such liners do not prevent the ingress of moisture or the emission of odors. Therefore, the contents are often placed in a plastic bag, or flow-wrap techniques are utilized to create a "pillow" of sealed product.

[0011] Containers formed from blanks made of cardstock and paperboard and other materials suitable for distribution by postal services are well known in the prior art. Typically, the container is formed from a relatively simple blank having a plurality of cuts to define the blank, the blank having side walls separated by fold lines and one or more bases and lids connected to one or more side walls by corresponding fold lines. Typically, to construct the container, the end tabs of one side wall are secured to the edge portions of the other side wall, and the base or bases are folded and secured to form an open container. When the article or articles to be distributed have been placed in the container, the lid or lids are folded and secured. The means for securing the parts to form the container are typically selected from gluing, stapling or applying tape.

[0012] It should be understood that unless the container is designed to receive the specific item(s) to be dispensed, additional packaging material will be required to prevent the item(s) from moving around within the container. In the packaging industry, there are often measures to avoid extraneous packaging materials, and in some countries there are regulations and legislation to prevent wasteful packaging practices.

[0013] In an attempt to avoid some of the disadvantages highlighted above, solutions proposed in the prior art have been to utilize a web of lining material to enclose or secure the items within the container to prevent damage due to movement within the container during transport to its destination.

[0014] French patent application publication No. FR 2 853 885 to SMURFIT SOCAR discloses a preformed carton having a pair of sheets attached to opposing inner side walls and adapted to be overlaid on and secured to each other so that the double-sided adhesive tapes are aligned to hold the object in place within the box. This avoids the step of heating the sheets of heat-shrinkable plastic material and provides a substantially recyclable transport package.

[0015] UK Patent Application Gazette No. GB ​​832,372 to HENSING and KOHRIG discloses a folding carton type package having a foil, paper or plastic material liner formed as a tube within an open and base-open container so as to facilitate simultaneous closure and sealing of the liner and container at each of the base and top of the container. The main object of the invention is to avoid the necessity of closing the liner and carton separately and to highlight the difficulties to be avoided in the case of the liner being fixed to the closing flaps of the carton. A particular feature of the invention is the provision of a fastening triangle in the form of an isosceles triangle, which is fastened to the opposite side walls of the carton by tape or the like.

[0016] U.S. Patent No. 9,340,317 issued to SMART KARTON WORLDWIDE, Inc. discloses a RSC type container blank to which a web of material is attached to hold items within a container formed from a lined blank. The web of material is recyclable and coated with an adhesive film so that tension can be applied to one or more items within the container by covering the adhesive portion and tensioning the web over the items.

[0017] In various disclosures of exemplary prior art, a container blank is provided with a web liner of material attached to a plurality of container blank panels. When the blank is erected, the liner is folded in a manner dictated by attachment points or glue lines. None of these disclosures feature a sealed liner or a liner having a preformed base region sealed opposite an opening presented for filling prior to sealing.

[0018] As described above, prior art liners do not prevent the ingress of moisture or the emission of odors, and the presence of odors increasingly attracts rodents and insects, which presents additional disadvantages that are neither recognized nor addressed in the exemplary art. It is known that sealable bags and expandable bladders, typically comprising metallized polyethylene terephthalate (PET) foil, are used in conjunction with cardstock and paperboard boxes, including for non-carbonated beverages, such as juices and wines. One disadvantage of such bladder or bag-in-box arrangements is that typically a significant volume of the primary container is not used.

[0019] There is a growing awareness of the need for packaging to be easily recyclable, and despite increasing public involvement in the separation of recyclable and non-recyclable waste, in cases where separation of materials is required, it is considered simpler to simply discard the entire packaging as non-recyclable waste for disposal. More recently, packaging legislation has pushed packaging manufacturers towards simpler and less conspicuous packaging uses in order to reduce the volume of packaging material used for a single container.

[0020] One particular use of the present invention relates to the packaging and storage of animal feed, particularly dry dog ​​food. Conventional packaging comprises a paperboard container (sometimes incorporating a spout with a foldable lid or tear strip) in which no liner or inner bag is disposed. Glue lines are used in the formation and sealing of the container, however, no tape seal is provided on any exposed edges of the paperboard material or at the ends of the package.

[0021] At the request of the applicant, a test was conducted at the Grain and Animal Health Research Center in the Agricultural Research Service (ARS) of the United States Department of Agriculture (USDA) to compare the packaging integrity of commonly available dry dog ​​food products in industry-accepted packaging and packaging exemplified by the present invention. Details of the test are provided in the detailed description below.

[0022] The object of the present invention is to alleviate the above-mentioned disadvantages and to provide a transport package which is fully recyclable and has holding means therein which can be deployed to utilize substantially all of the packaging volume.

[0023] Another object of the present invention is to provide a shipping package comprising a container blank and an inner bag, the container blank and the inner bag each being composed entirely of recycled, recyclable or compostable materials.

[0024] Another object of the present invention is to provide a transport package for food and similar products, which are known to attract insects and rodents when stored, which has a reduced risk of attracting rodents or being infested by insects.

[0025] It is another object of the present invention to provide a method and apparatus for forming a folded shipping package that is stackable for distribution or storage.

[0026] It is a further object of the present invention to provide a transport package having an inner bag that is deployable from a folded configuration to an open configuration.

[0027] It is yet another object of the present invention to provide a system for erecting, filling and sealing an open shipping package. Summary of the invention

[0028] In a first aspect, the present invention provides a container blank sized and shaped to form a folded, erectable transport package, the blank having a front wall and a rear wall, side wall portions attached to the front wall and the rear wall along respective folding lines, the side wall portions being foldable so that when the blank is in a folded or storage configuration, the front wall and the rear wall remain aligned juxtaposed, the front wall and the rear wall being suitable for securing the corresponding rear wall and the front wall of a folded inner bag therebetween, the inner bag having a sealed base and a sealable opening so that when the container blank is erected from the folded configuration, the inner bag unfolds to an open configuration, in which the bag substantially presents the interior volume of the transport package thus formed.

[0029] In an exemplary embodiment thereof, the blank has: a first main fold line, about which a selected one of the front and rear walls of the blank is folded to be aligned with the other of the walls, to which one surface of the inner bag is adhered, the folded blank wall being aligned with and adhered to the exposed surface of the inner bag; and a second main fold line, about which the side wall portion is folded to be aligned with the end closure tab adhered thereto to form a folded transport package, in which the inner bag is fixed to the inner surfaces of the front and rear walls of the container blank by its rear and front surfaces, respectively.

[0030] The skilled person will appreciate that the bag may be adhered to the inner surface of the front wall and the rear wall subsequently folded about the first main fold line, or vice versa, to align with and adhere to the exposed surface of the inner bag.

[0031] The container blank is provided as a pre-cut profile with fold lines integrated into the profile to ensure quick and accurate folding during manual or mechanical folding. The main fold lines used to form the folded transport package provide sufficient rigidity in a manner well known in the art to prevent the profile from collapsing under its own weight while facilitating a smooth inward folding action as desired.

[0032] Ideally, the blanks are provided in a silo stack for machine feeding to an apparatus for forming a folded transport package. A cold seal pressure activated adhesive may be applied to the outer surface of the end closure tab and / or the inner surface of the free side wall element so as to eliminate the glue application step when forming the folded transport package. The skilled person will appreciate that a tacky adhesive will ensure minimal snagging between blanks and a more secure bond between the end closure tab and the side wall element.

[0033] In the erected, open configuration, the base-forming elements of the blank are folded about their respective fold lines to abut and support the sealed base of the inner bag so that the package can be filled with product for shipping and storage.

[0034] In a second aspect, the present invention provides a transport package comprising: a container blank sized and shaped to form a folded shipping package, the blank having a front wall and a rear wall to which side wall portions are attached along respective fold lines, the side wall portions each being foldable so that the front wall and the rear wall are maintained in juxtaposed alignment to define a folded configuration; and A foldable open-mouth bag having a front surface and a rear surface adhered between the front wall and the rear wall of the blank, Wherein, when the container blank is erected from the folded configuration, the folded inner bag unfolds to align with the inner volume of the erected blank to provide an open shipping package with an open inner bag to be filled and subsequently sealed for dispensing.

[0035] The transport package of the present invention comprises a preformed container blank profile and an inner bag provided in a folded configuration.

[0036] Conveniently, the inner bag is arranged in a folded configuration in which the side walls and base of the inner bag are folded along corresponding centrally arranged longitudinal fold lines so as to present only the rear surface and the front surface as major surfaces to be adhered to the inner surfaces of the front wall and the rear wall of the container blank respectively.

[0037] It should be understood that alternative folding configurations of the bag may be used without departing from the spirit of the invention, and the side walls of the bag may be folded outwardly and may include areas or points where they may be adhered to the inner surface of the side walls of the blank in the folded shipping package configuration. The inward folding of the base of the inner bag along a longitudinal and ideally central fold line provides enhanced utility to the inner bag.

[0038] Preferably, the coating is applied to at least the inner surface of the inner bag. Resistance to moisture and / or odor penetration provides additional benefits to the shipping package, both in preventing product deterioration during shipment and in preventing transfer of odor-carrying components from one shipped product to another. The loss of volatile oils from certain products can result in significant reduction in their value and potential contamination of other products.

[0039] In an enhanced configuration, additional fold lines are formed around the opening of the inner bag to guide a user in manually forming a sealable closure configuration in one arrangement, or to facilitate machine folding and / or closing of the filled inner bag in another arrangement.

[0040] In other arrangements, the inner bag has an adhesive portion, an adhesive is applied near the opening, and the adhesive portion is bonded by folding and / or closing, either manually or by machine, so that pressure can be applied to activate the adhesive bond, thereby sealing the bag.

[0041] Optionally, spray the sticky portion with a cold seal adhesive.

[0042] Alternatively, use water-activated tape to seal the opening of the inner bag.

[0043] In a preferred configuration, the transport package includes: a container blank having a series of six segments, each segment defining a wall portion to which the base element and the lid element are attached along respective fold lines, the segments being joined to at least one other segment by a side wall fold line; and an inner bag having wall sections corresponding to the individual sections in the blank, base elements attached to the wall sections along respective fold lines, the base element being folded along a central longitudinal fold line in the storage or transport configuration and forming a flat base area perpendicular to the individual bag sections in its erected configuration; Therein, the inner bag in the erected configuration expands to conform to the interior volume of the erected container blank, thereby forming an open shipping package for receiving an article or product to be sealed in the shipping package for distribution.

[0044] Conveniently, the inner bag is sized and shaped to fit within the peripheral contour of the container blank, thereby minimizing snagging and facilitating increased throughput. Additionally, edge damage to the bag is minimized during storage or transportation.

[0045] Although the transport package can be delivered, stored or distributed in an open configuration, it is ideally folded so that the inner bag is not potentially exposed to hooking or tearing before being folded into a storage or transport configuration, in which the bag is completely protected by the blank. As described above, the inner bag is protected by folding the container blank around the first main fold line. The blank is sealed around the bag to form a flat, stackable transport package by adhering the end closure tabs to the free side wall elements to provide enhanced protection and practicality. Thereafter, when the transport package is needed for its intended purpose, pressure applied manually or mechanically to the peripherally arranged main fold lines causes the package to present a substantially tubular configuration, wherein the bag is unfolded within the tube. The base of the blank is then folded to support the base of the bag, and the transport package presents its open configuration.

[0046] In a third aspect of the invention there is provided a method of forming a transport package from a container blank of the type described, the container blank having a front wall and a rear wall, to which are attached a deployable open inner bag, the inner bag being adapted to deploy from a folded configuration to align with and conform to the interior volume of a stand-up package formed from the blank, the method comprising: forming a folded shipping package by adhering a major surface of a folded bag to an inner surface of one of the front and rear walls of the container blank and folding the other of the front and rear walls about a major fold line therebetween into alignment with the adhered bag and the selected wall; and The free wall edge of the container blank is folded about the second main fold line and the end closure tab is adhered thereto to secure the transport package in a storage or shipping configuration with the bag secured therein.

[0047] The method also includes: erecting the folded transport package into an open configuration by applying sidewall pressure, thereby unfolding the inner bag into a corresponding open configuration; Gathering and securing the bases of the front and rear walls and the base elements of the side walls to form a transport package base adjacent to and supporting the base of the inner bag; Placing one or more articles or products into an open bag within a stand-up shipping package; Seal the opening of the inner bag; Gathering and securing the cover portions of the front and rear walls and the cover elements of the side walls to form a transport package cover over the sealed opening of the inner bag; a sealing cover; and Deliver closed transport packaging for distribution or storage.

[0048] Advantageously, an additional fold line is formed around the opening of the inner bag to facilitate manual closing or machine folding of the sealable closure arrangement.

[0049] Advantageously, the step of closing the inner bag opening comprises gathering the adhesive portions arranged around the inner bag opening to which the adhesive has been applied, whereby the adhesive bonds together to seal the bag.

[0050] Optionally, the opening of the inner bag is closed and the cover is secured using water activated tape.

[0051] In a further aspect of the invention, there is provided an apparatus for forming a transport package from a container blank of the type described, to which is attached an expandable open inner bag adapted to be expanded from a folded configuration to align with and conform to the interior volume of a stand-up package formed from the blank, the apparatus comprising: A storage bin from which container blanks are supplied; Adhesive application station; a magazine from which folded bags are fed onto a selected inner surface of the first major surface of the container blank; Conveying device; a folding station in which the blank is folded about the primary fold line so that the inner surface of the second major surface is aligned with the first surface, the folded pocket is disposed therebetween, and the end closure tab is adjacent the second primary fold line; folding means adapted to fold the free side wall element about said second main folding line to cover the closure tab; and A forming station in which pressure is applied to the main surfaces and the side wall elements to ensure sufficient adhesion to hold the folded transport package thus formed in its storage or transport configuration.

[0052] It will be appreciated that the inner bag may initially be adhered to either of the major surfaces (front and rear walls) prior to being folded about the first major fold line.

[0053] The first apparatus of the present invention implements a method of forming a folded transport package from container blanks and inner bags, which can then be conveyed individually to additional erecting, filling and sealing equipment, or stacked for storage or for transport to a point of sale or distribution facility.

[0054] The invention also provides an apparatus for erecting, filling and sealing an open transport package, the transport package being formed by a folded transport package having a folded open inner bag of the type defined herein, the apparatus comprising: means for erecting the folded transport package into an open configuration by applying sidewall pressure, thereby unfolding the inner bag into a corresponding open configuration; means for gathering and securing the bases of the front and rear walls and base elements of said side walls to form a transport package base adjacent to and supporting the base of the inner bag; a filling station having means for placing one or more articles in an open bag within a stand-up transport package or for pouring a product into an open bag; a device for closing the opening of the inner bag; means for gathering and securing the cover portions of the front and rear walls and the cover elements of the side walls to form a transport package cover over the sealing opening of the inner bag; a sealing device for closing the cover; and A conveying device for conveying a closed transport package for distribution or storage.

[0055] While it will be appreciated that the folded shipping package of the present invention may be erected, filled and / or sealed manually, it may also be adapted for rapid automation by machine.

[0056] When filled, an arrangement may be employed that utilizes additional fold lines formed around the opening of the inner bag to form a sealable closed configuration.

[0057] In one arrangement, the inner bag has a sticky portion, an adhesive is applied adjacent the opening, and the apparatus includes means for bringing the sticky portion together under applied pressure so that the adhesive bonds to seal the bag.

[0058] Optionally, the apparatus comprises a dispenser for applying the water activated tape to the opening and the lid of the inner bag.

[0059] Handle apertures may optionally be provided in the front and rear walls, however, it has been noted that the high density of products within the inner pocket may make it difficult or uncomfortable for the user to grip. The same experience has been noted with aligned handle apertures provided in the lid. An alternative is to adhere a cardstock material handle that can be pulled through the aligned handle apertures.

[0060] A further improvement to the transport package includes forming a tear strip adjacent to the cover in the blank corresponding to the upper periphery of the erected transport package. This facilitates rapid exposure of the folded and / or sealed inner bag for the convenience of the end user. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] The invention will now be described in more detail with reference to the accompanying drawings, which show, by way of example only, one embodiment of a transport package comprising a container blank and an inner bag. Reference is also made to a method and apparatus for forming a transport package from a container blank and a method and apparatus for erecting, filling and sealing a transport package according to the invention. In the drawings: Figure 1 is a schematic perspective elevational view of a container blank to which a first set of glue lines are applied; Figure 2 a to Figure 2 c is a perspective view of the inner bag in an unfolded configuration and in a folded configuration, respectively; Figure 3 yes Figure 1 A schematic perspective elevation view of a container blank of Figure 2 c, the folded bag having been adhered to the inner surface of the rear wall of the blank by means of an applied glue line; Figure 4 is a perspective view of a folding step in which the front face inner surface is folded about a first main fold line to adhere to the exposed surface of the folded inner bag using a line of glue applied to the front face inner surface; Figure 5 is a perspective view of a folded transport package in which the free side wall element has been folded on a second main fold line to adhere to an end closure tab; Figure 6 Is Figure 5 A perspective elevation view of an open transport package formed from a folded transport package for receiving articles or loose fill products for subsequent sealing and storage or distribution; Figure 7 is a schematic perspective view of a production line for forming transport packages from container blanks and expandable open inner bags, wherein stations (vii) to (xiv) are respectively Figures 8 to 14 Example in; Figure 8 is a schematic perspective view of a first station (viii) comprising a magazine into which the container blanks are loaded and from which they are fed via a second station (ix); Figure 8 is a schematic perspective view of a first station (viii) comprising a magazine into which the container blanks are loaded and from which they are fed via a second station (ix); Fig. 9 is a schematic perspective view of a second station (ix) comprising a door and a feed roller mechanism to hand over container blanks to a third station (x); Fig.10 is a schematic perspective view of a third station (x) comprising a glue application station, wherein a line of glue is applied to the container blank before the inner bag is adhered to the inner surface of the container blank at a fourth station (xi); Fig.11 is a schematic perspective view of a fourth station (xi) comprising an inner bag placement station, wherein a single inner bag is fed from a magazine onto a selected inner surface of a blank; Fig.12 is a schematic perspective view of a fifth station (xii) in which pressure is applied to the exposed surface of the inner bag to ensure bonding of the adhesive between the inner surface of the blank and the inner bag disposed thereon; Fig.13is a schematic perspective view of a sixth station (xiii) in which the container blank is folded about a first main fold line P1 so that the free inner surface of the container blank is aligned with and adhered to the exposed surface of the inner bag, and then the free edge of the blank is folded about a second main fold line P2 and secured to the end closure tab; and Fig.14 is a schematic perspective view of the seventh station (xiv) in which transparent individual file folder shipping packages are stacked for subsequent use in a silo or bundled for storage or transport. DETAILED DESCRIPTION

[0062] Referring to the attached drawings, first refer to Figure 1 , there is provided a container blank 1 cut from kraft card, paperboard or another recycled or recyclable and ideally compostable material, and preferably die cut corrugated paperboard.

[0063] The blank comprises first and second wall portions defining major surfaces hereinafter identified as rear wall 2 and front wall 3, respectively. Each wall portion has a lid forming portion 4, 5 attached thereto along a respective fold line 4a, 5a. Each wall portion also has a base forming portion 6, 7 attached thereto along a respective fold line 6a, 7a arranged opposite to said lid portion 4, 5.

[0064] Between said front and rear walls 2, 3 is arranged a first side wall portion comprising a pair of side elements 11, 12, each having an identical cover element 14 and a base element 15 attached to the cover element along respective folding lines 14a, 15a. The side wall portion elements 11, 12 are connected to each other along a first main folding line P1 which also defines a folding line between the respective cover element 14 and base element 15. Secondary folding lines 2a, 3a connect the first side wall portion to the rear wall portion 2 and the front wall portion 3, respectively.

[0065] Connected to the opposite side of the rear wall 2 along the secondary fold line 2b is a second side wall portion comprising a pair of side elements 16, 17, each of which also has a corresponding cover element 18 and base element 19. The cover element 18 and base element 19 are attached to the side elements 16, 17 along respective fold lines 18a, 19a. As previously described, the side wall portion elements 16, 17 are connected to each other along a second main fold line P2, which also defines a fold line between each cover element 18 and each base element 19.

[0066] An end closure tab 20 is connected to the free side of the front wall 3 along the secondary fold line 3b, which tab is adapted to engage and be secured to the free side wall element 17 to form the folded transport package of the present invention for storage or transport to a distribution center, such as Fig.14 For example, or alternatively, fastened to an open transport package, such as Figure 6A series of glue lines 2g are applied to the inner surface of the rear wall 2 (or alternatively glue lines 3g are applied to the inner surface of the front wall 3), and will again be referred to Figure 3 and Fig.10 .

[0067] like Figure 2 a to Figure 2 c exemplifies, a flexible and foldable bag 30 has an unfolded configuration and a folded configuration, in which its side walls and base are hidden. Ideally, the bag 30 comprises standard light kraft paper having flat front and rear surfaces 31, 32, which are connected to the side walls 34 along respective fold lines 31a, 32a, and are connected to the base 36 along respective fold lines 31b, 32b. Each side wall 34 has a centrally arranged longitudinal fold line 34a. The base 36 also includes a longitudinal fold line 36a, which allows the base and each side wall 34 to be folded into a geometric shape defined by the front surface 31 and the rear surface 32. Thus, when folded, the fold lines 31b, 32b between the surfaces 31, 32 and the base 36 define the lower periphery of the folded bag 30.

[0068] The bag 30 is supplied in a folded configuration so that it can be supplied from a storage bin, as will be described in detail below. Fig.11 Described in more detail.

[0069] Ideally, the bag is formed from a single sheet of material that can be coated on one surface to provide moisture and odor impermeability. Different substrates can be applied to either side of the material forming the bag, however, it is preferred that the recyclability of the bag is not compromised. As mentioned above, the focus of the present invention is on dry loose fill materials, however, it should be understood that other products made of pastes, jams, nut butters, jellies, wet foods (e.g., meat nuggets dog or cat food) and fluids can be packaged and stored in the transport package of the present invention by appropriate coating and sealing of the inner bag. This is particularly advantageous for foods and materials that need to be dispensed from a relatively wide caliber feeder, because the opening profile of the inner bag can adapt to most requirements.

[0070] It will also be appreciated that whilst the focus of the present invention is primarily on a fully recyclable product and preferably there should be no need to separate the outer box and inner bag, this is not entirely necessary and there are completely waterproof inner bag materials available which are themselves recyclable.

[0071] Reference now Figure 3, the folded bag 30 is positioned on the inner surface of the rear wall 2 and is held thereto by the glue line 2g. As described above, the fold lines 31b, 32b adjacent to the base 36 define the lower periphery of the bag 30 and are aligned with the base fold line 6a at the lower edge of the rear wall 2 of the container blank 1. The additional glue line 3g on the front wall 3 can be applied simultaneously with the glue line on the rear wall 2, or as part of a separate method step.

[0072] Although the glue line 2g is illustrated on the inside of the rear wall 2, the bag 30 can be secured by applying glue to the bag when the bag 30 is fed into position relative to the blank. In either case, pressure is applied equally across the engaging surface of the bag (i.e., its surface overlying the inner surface of the rear wall 2). The glue line 3g illustrated on the inner surface of the front wall 3 can be avoided by spraying the adhesive onto the main engaging surface 31 of the bag. Many adhesives require pressure to activate, however, certain spray contact adhesives will achieve the desired goal as long as the glue line is accurately applied.

[0073] although Figures 3 to 5 The exemplary arrangement of illustrates the placement of the inner bag 30 on the rear wall 2, but the alternative of the inner bag 30 being adhered to the front wall 3 via the glue line 3g is entirely feasible and is described in reference to Figures 7 to 14 An exemplary shipping package forming method is illustrated in FIG.

[0074] Figure 4 A method of forming a folded transport package from a blank 1 and an inner bag 30 is illustrated. With the bag 30 secured to the inner wall 2, the front wall 3 is folded on a first main fold line P1 (defined between the first side wall elements 11, 12) so that the inner surface of the front wall is aligned with the rear wall 2, with the bag 30 held therebetween. The free end wall element 17 (together with its lid element 18 and base element 19) is folded on a second main fold line P2 so that the end closure tab 20 is thereby engaged and secured thereto by a glue line 20g on the outer surface of said tab 20.

[0075] Figure 5 A folded transport package with an integrated bag is illustrated in . The folded packages can be stacked in a storage bin for subsequent immediate use, or bundled for storage or transportation.

[0076] To assemble the transport package of the invention, the folded transport package is erected by applying inward pressure to the respective main fold lines P1, P2 at or near the side wall elements, forming (manually or mechanically) the transport package as shown. Figure 6 When the inner bag 30 is adhered to the respective inner surfaces of the front wall 3 and the rear wall 2 of the container blank, the bag 30 unfolds from its folded configuration as the front and rear walls are moved apart by the unfolding of the side wall portions 11, 12; 18, 19.

[0077] A further improvement to the transport package includes forming a tear strip 38 adjacent to the cover portion in the blank corresponding to the upper periphery of the erected transport package, such as Figure 6 This facilitates quick exposure of the folded and / or sealed inner bag for the convenience of the end user.

[0078] The skilled person will appreciate that the use of a preformed folded inner bag of kraft card or kraft paper provides a major advantage of the present invention in that the transport packaging is fully recyclable without the additional costs incurred in packaging taxes and recycling costs which are major for packaging using multiple material types or materials that cannot be recycled at the same time or in the same process.

[0079] As mentioned in the preamble, the transport package of the present invention has particular utility in transporting food products in the 3 kg to 30 kg range. The opening of the inner bag presents an advantage when transferring loose-filled products from a large hopper-fed storage device to a container filling line. An example of such a use is the provision of boxed animal and pet food, of which dry dog ​​food is the most familiar.

[0080] Unfortunately, traditional boxed solutions don’t offer adequate protection against moisture damage, insect infestation, or rodent attack.

[0081] In an attempt to evaluate the vulnerability of packaging to insect infestation, the USDA-ARS test conducted at the Grain and Animal Health Research Center was developed to evaluate package integrity against a number of different insects known to infest stored products.

[0082] The insects selected were from colonies maintained at USDA-ARS facilities and include: 1- to 2-week-old adults of Red Castanea castanea (RFB).

[0083] One to two-week-old adults of Sawtooth Beetle (STGB).

[0084] Indian meal moth (IMM) 3rd instar (11 days from egg introduction).

[0085] Small / medium larvae of Dermestidae (WB) The test box with waterproof and dustproof cover is equipped with a series of air holes covered with fine mesh and a small limited food supply to prevent starvation but not enough to sustain development. One hundred adults of Tribolium castaneum and Saw-toothed castaneum and fifty larvae of each of Dermestrum floridulus and Indian meal borer are added to the box to compare the conventional box container (control) with the box container of the present invention (test).

[0086] Observations were conducted for two weeks in an environmental chamber followed by one week in a refrigerator. Each box was checked for insect counts both outside and inside the box (as well as the inner bag of the test box). Observations of the test boxes were further broken down into the number of insects between the box and the bag and in the tape inside the bag. The contents of the control and test boxes were sieved to detect any insects inside the box.

[0087] The observations are briefly summarized as follows: The control (conventional) packaging did not prevent any infestation by insect species, and numerous larvae, pupae and adults were found in the boxes (and therefore in the food contents).

[0088] The test package streamlined exceptionally well, with significantly lower numbers of larvae, pupae, and adults found between the box and inner bag, primarily due to the superior tape seal at the base and exposed panel edges. The tape adhesive also acted as a barrier. Of the insects found to have reached the top of the inner bag, all insects were prevented from accessing the food contents by sealing the inner bag.

[0089] The basic conclusion of the test is that even though the conventional box-only packaging sealed with tape is not adequate to protect the contents from intrusion, a completely sealed inner bag within a properly taped box provides much superior protection against intrusion.

[0090] The present invention also provides a method and apparatus for forming a transport package from a container blank. A person familiar with packaging machinery will appreciate that there are many ways to implement a method for forming a transport package from a shaped blank, and the exemplary method and apparatus described below is one of many variations depending on specific size and throughput requirements.

[0091] Although no detailed examples are given, Figure 7 The schematically illustrated device actually comprises: Conveying device; a storage bin from which preformed container blanks 1 are fed onto said conveying device so as to present the inner surfaces of their front and rear walls; Adhesive application station; a magazine from which the folded bags 30 are fed onto the inner surface of a selected one of the front wall and the rear wall of the container blank 1; a folding station in which the blank is folded about a main folding line P1 so that the inner surface of the remaining wall is aligned with the selected wall (between which the folded pocket 30 is arranged) and a second main folding line P2 is adjacent to the end closure tab 20; folding means adapted to fold the free side wall element 17 about the second main folding line P2 so as to cover the closure tab 20; and A forming station in which pressure is applied to the main surfaces and the side wall elements to ensure sufficient adhesion to hold the folded transport package thus formed in its storage or transport configuration.

[0092] The various stages of this method are respectively about Figures 8 to 14 Stations (viii) to (xiv) of the device illustrated in FIG. 1 are described.

[0093] At the first station (viii), the cardboard blanks 1 are loaded into a bottom feed bin 40 where they are gripped by a vacuum belt (not shown). The second station comprises a door which, when raised, allows the vacuum gripped blanks to be fed to a pair of rollers which present the container blanks for processing. Fig.10 The illustrated third station comprises a glue application station where a glue gun (or series thereof) applies a predetermined pattern of adhesive to the inner surface of the front wall 3, ideally in the form of glue lines 3g, and optionally also applies glue lines 2g to the rear wall 2. The additional glue lines 2g on the rear wall may be applied to the inner surface of the rear wall as it passes through the adhesive application station, or may be applied separately. This alternative method is similar to Figures 3 to 5 The exemplary method illustrated in is contrasted.

[0094] Additionally, at the glue application station, a handle 48 is glued to the inner surface of the cover portion, which features an aperture 49 adapted to align with a corresponding aperture on another of the cover portions so that when the cover is formed, the handle can be pulled through the aperture to facilitate lifting the filled shipping package.

[0095] An additional line of glue 17 g may be applied to the free side wall element 17 for subsequent adhesion to the closure tab 20 .

[0096] exist Fig.11 In the fourth station (xi), the second storage bin 50 contains a batch of folded bags 30, from which individual bags are extracted in a manner similar to the container blank supply to be placed in alignment with the periphery of the front wall 3 under process-controlled registration so that the peripheral ends of the bags (the corresponding folding lines 31b, 32b of the surfaces 31, 32) are aligned with the base folding line 7a and so that its opening does not extend beyond the periphery of the cover 5.

[0097] A vacuum plate or similar bag transport device carries and places the bag 30 in place and optionally applies glue activation pressure thereto to ensure that the adhesive in the glue line 3g is bonded to the rear surface 32 of the bag 30. However, ideally, the inner bag 30 is precisely positioned relative to the container blank 1. Fig.12 The illustrated fifth station (xii) applies pressure, such as by nip rollers or contact plates, to ensure that the glue in the glue line 3g adheres to the bag's rear surface 32. In the case of a cold seal adhesive, pressure applied to the bag's front surface 31 activates the adhesive in the glue line 3g.

[0098] Fig.13The actions performed at the sixth station (xiii) are illustrated, at which the container blank 1 is folded about its first main folding line P1 so that the rear surface 2 of the inner bag is aligned with the exposed front surface 31. The line of glue 2g applied to the rear surface 2 of the blank 1 engages and adheres (where necessary, by additional applied pressure) to the front surface of the inner bag 30. The free end wall element 17 (together with its lid element 18 and base element 19) is folded on the second main folding line P2 so that the end closure tab is adhered thereto by the line of glue 17g applied to the free end wall element 17 as described above and / or the line of glue 20g applied to the outer surface of the tab 20. Pressure may again be applied to the outer surface of the folded transport package thus formed to ensure the desired adhesion of the front surface 31 and rear surface 32 of the inner bag 30 to the main inner surfaces 2, 3 of the container blank 1.

[0099] Fig.14 A seventh station (xiv) is illustrated, at which the successively folded transport packages are stacked. The stacks may be fed to a storage silo for immediate use, or they may be bundled for storage or transport.

[0100] The first apparatus of the present invention implements a method of forming a folded transport package from container blanks and inner bags, which can then be conveyed individually to additional erecting, filling and sealing equipment, or stacked for storage or for transport to a point of sale or distribution facility.

[0101] To form the base of the transport package, the base elements 15, 19 are deflected inwardly about their respective fold lines 15a, 19a, and the respective base forming parts 6, 7 are then folded about their respective fold lines 6a, 7a to align the respective base parts. Where the free edges of the base forming parts 6, 7 meet, they are secured by applying a strip of tape. The previously folded transport package is now in an open configuration to receive articles or loose-filled products as required.

[0102] In a non-illustrated embodiment, there is provided an apparatus for erecting, filling and sealing an open transport package formed by a folded transport package of the type defined herein with a folded open inner bag 30. Ideally, the apparatus comprises means for erecting the folded transport package into an open configuration by applying side wall pressure on or near the main fold lines P1, P2 so as to unfold the inner bag 30 into a corresponding open configuration. The bases 6, 7 of the front and rear walls 2, 3 and the base elements 15, 19 of the respective side walls 11, 12; 16, 17 are gathered and fixed to form a transport package base adjacent to and supporting the base 36 of the inner bag 30.

[0103] The apparatus also comprises a filling station having means for placing one or more articles in an open bag within the erected transport package or for pouring the product into the open bag and means for subsequently closing the opening of the inner bag. In case the inner bag is provided with additional fold lines formed around its opening, these fold lines can be used to form a sealable closed configuration.

[0104] In one arrangement, the inner bag has a sticky portion, an adhesive is applied adjacent the opening, and the apparatus includes means for bringing the sticky portion together under applied pressure so that the adhesive bonds to seal the bag.

[0105] Finally, the device is provided with a device for gathering and fixing the cover parts 4, 5 of the front wall 2 and the rear wall 3 and the cover elements 14, 18 of the side walls 11, 12; 16, 17 to form a transport package cover on the closed or sealed mouth of the inner bag, and the cover thus formed is sealed, after which the conveying device sends the closed transport package for distribution or storage.

[0106] Optionally, the device includes a dispenser for applying the water activated tape to the opening and lid of the inner bag.

[0107] It should be understood, of course, that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and variations are possible within the scope of the appended claims.

Claims

1. A container blank sized and shaped to form a folded, standable transport package, the blank having a front wall and a rear wall, side wall portions attached to the front wall and the rear wall along respective fold lines, each side wall portion being foldable so that the front wall and the rear wall remain in juxtaposed alignment when the blank is in a storage or folded configuration, the front wall and the rear wall being adapted to secure therebetween the corresponding rear wall and the front wall of a folded inner bag, the inner bag having a sealed base and a sealable opening, Such that when the container blank is erected from said folded configuration, the inner bag unfolds to an open configuration in which the bag substantially assumes the inner volume of the transport package thus formed.

2. The container blank according to claim 1, wherein: the blank having: a first major fold line, a selected one of the front wall and the back wall of the blank being folded about the first major fold line to be aligned with the other of the walls, a surface of the bag being attached to the other of the walls, the folded wall being aligned with and adhered to an exposed surface of the inner bag; and a second main fold line about which the side wall portion is folded to align with the end closure tab adhered thereto to form a folded shipping package within which the inner bag is secured by its rear and front surfaces to the inner surfaces of the front and rear walls of the container blank, respectively.

3. The container blank according to claim 1 or 2, wherein: In the erected, open configuration, the base-forming elements of the blank are folded about their respective fold lines to abut and support the sealed base of the inner bag so that the package can be filled with product for shipping and storage.

4. A transport package, comprising: a container blank sized and shaped to form a folded shipping package, the blank having a front wall and a rear wall, side wall portions attached to the front wall and the rear wall along respective fold lines, the side wall portions each being foldable so that the front wall and the rear wall remain in juxtaposed alignment to define a folded configuration; as well as A foldable open bag having a front surface and a rear surface adhered between the front wall and the rear wall of the blank, Wherein, when the container blank is capable of being erected from the folded configuration, the folded inner bag unfolds to align with the inner volume of the erected blank to provide an open transport package with an open inner bag to be filled and subsequently sealed for distribution.

5. The transport package according to claim 4, wherein: The container blank has a first main fold line about which the front wall is folded to align with and adhere to the front surface of the inner bag, and a second main fold line about which the side wall portion is folded to align with the end closure tab adhered thereto to form a folded storage or shipping configuration, presenting a flat, foldable shipping package with an inner bag.

6. The transport package according to claim 5 or 6, wherein: The inner bag is arranged in a folded configuration, wherein the side walls and base of the inner bag are folded along respective centrally arranged longitudinal fold lines so as to present only the rear and front surfaces as major surfaces to be adhered to the inner surfaces of the rear and front walls of the container blank, respectively.

7. The transport package according to any one of claims 4 to 6, wherein: The coating is applied to at least the inner surface of the inner bag.

8. The transport package according to any one of claims 4 to 7, wherein: Additional fold lines are formed around the opening of the inner bag to guide the user to manually form a sealable closed configuration.

9. The transport package according to any one of claims 4 to 8, wherein: The inner bag has a sticky portion, and an adhesive is applied near the opening, and the sticky portion is bonded so that the adhesive bonds to seal the bag.

10. The transport package according to claim 9, wherein: The sticky portion was sprayed with a cold seal adhesive.

11. The transport package according to any one of claims 4 to 8, wherein: The opening of the inner bag is sealed using water-activated tape.

12. The transport package according to any one of claims 4 to 11, wherein: The package includes: a container blank having a series of six segments, each segment defining a wall portion to which the base element and the lid element are attached along respective fold lines, the segments being connected to at least one other segment by a side wall fold line; and an inner bag having wall segments corresponding to the respective segments in the blank, base elements attached to the wall segments along respective fold lines, the base element being folded along a central longitudinal fold line in the storage or transport configuration and forming a flat base region perpendicular to each bag segment in its erected configuration; Therein, the inner bag in its erected configuration expands to conform to the interior volume of the erected container blank to form an open shipping package for receiving an article or product to be sealed in the shipping package for distribution.

13. The transport package according to any one of claims 4 to 12, wherein: The inner bag is sized and shaped to fit within the peripheral contour of the container blank, thereby minimizing snagging and facilitating increased throughput.

14. A method of forming a transport package from a container blank of the type having a front wall and a rear wall to which are attached an expandable open inner bag adapted to expand from a folded configuration to align with and conform to the interior volume of a stand-up package formed from the blank, the method comprising: forming a folded shipping package by adhering a major surface of a folded bag to an inner surface of one of the front or rear walls of a container blank and folding the other of the front and rear walls about a major fold line therebetween into alignment with the adhered bag and the selected wall; as well as The free wall edge of the container blank is folded about the second main fold line and the end closure tab is adhered thereto to secure the transport package in a storage or shipping configuration with the bag secured therein.

15. The method of forming a shipping package according to claim 14, further comprising: erecting the folded transport package into an open configuration by applying sidewall pressure, thereby unfolding the inner bag into a corresponding open configuration; Gathering and securing the bases of the front and rear walls and the base elements of the side walls to form a transport package base adjacent to and supporting the base of the inner bag; Placing one or more articles or products into an open bag within a stand-up shipping package; Seal the opening of the inner bag; Gathering and securing the cover portions of the front and rear walls and the cover elements of the side walls to form a transport package cover over the sealed opening of the inner bag; Sealing cover; as well as Deliver closed transport packaging for distribution or storage.

16. The method of forming a shipping package according to claim 15, wherein: Additional fold lines are formed around the opening of the inner bag to facilitate a sealable closed configuration.

17. A method of forming a transport package according to claim 15 or 16, wherein: The inner bag has a sticky portion, and an adhesive is applied near the opening, and the sticky portion is bonded so that the adhesive bonds to seal the bag.

18. A method of forming a transport package according to any one of claims 14 to 16, wherein: The opening of the inner bag was closed and the cover was secured using water activated tape.

19. An apparatus for forming a transport package from a container blank of the type having an expandable open inner bag attached thereto, the open inner bag being adapted to expand from a folded configuration to align with and conform to the interior volume of a stand-up package formed from the blank, the apparatus comprising: a storage bin from which the container blanks are supplied; Adhesive application station; a magazine from which folded bags are fed onto a selected inner surface of the first major surface of the container blank; Conveying device; a folding station at which the blank is folded about the primary fold line so that the inner surface of the second major surface is aligned with the first surface, the folded pocket is disposed therebetween, and the end closure tab is adjacent the second primary fold line; folding means adapted to fold the free side wall element about said second main folding line to cover the closure tab; as well as A forming station, at which pressure is applied to the main surfaces and the side wall elements to ensure sufficient adhesion to hold the folded transport package thus formed in its storage or transport configuration.

20. An apparatus for erecting, filling and sealing an open transport package, the transport package being formed by a folding transport package of the type having a folded open inner bag, the apparatus comprising: means for erecting the folded transport package into an open configuration by applying sidewall pressure to thereby unfold the inner bag into a corresponding open configuration; means for gathering and securing the base of the front and rear walls and base elements of said side walls to form a transport package base adjacent to and supporting the base of the inner bag; a filling station having means for placing one or more articles in an open bag within a stand-up transport package or for pouring a product into an open bag; means for closing the opening of the inner bag; means for gathering and securing the cover portions of the front and rear walls and the cover elements of the side walls to form a transport package cover over the sealing opening of the inner bag; a sealing device for closing the cover; as well as A conveying device for conveying a closed transport package for distribution or storage.

21. Apparatus for erecting, filling and sealing an open transport package according to claim 20, wherein: An additional fold line is formed around the opening of the inner bag to facilitate closing the opening of the inner bag to form a sealable closed configuration.

22. Apparatus for erecting, filling and sealing an open transport package according to claim 20 or 21, wherein: The inner bag has a sticky portion with an adhesive applied adjacent the opening, and the apparatus includes means for gathering the sticky portion under applied pressure so that the adhesive bonds to seal the bag.

23. The apparatus for erecting, filling and sealing an open transport package according to claim 20, wherein: The apparatus includes a dispenser for applying a water activated tape to the opening and lid of the inner bag.

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