System and method for combination box blank and liner packaging

Abstract

A blank and liner combination for forming a box, the combination including: a blank having a plurality of foldably connected panels, an inner surface, an outer surface, and at least one dispensing opening disposed in at least one of the panels; and at least one liner connected to the inner surface of the blank. A system for forming a box with an integrated liner, the system including at least one blank feeder, at least one conveyor belt, at least one liner applicator, at least one folding and forming machine, and at least one filling machine. A method for forming a box with an integrated liner, the method including: a) providing a blank; b) providing at least one liner; c) connecting the liner to the blank to form a blank and liner combination; and d) sealing, folding, and forming the blank and liner combination to form a box.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 395,062, entitled "System and Method for Combination Box Blank and Liner Packaging," filed August 4, 2022, the contents of which are incorporated herein by reference in their entirety. [Background technology]

[0002] High speed manufacturing and filling of cereal boxes and other types of boxes that require liners to encase the contents is limited by the speed at which the filling machine can load filled bags of product into the formed box. Additionally, this traditional forming and filling method is not applicable to boxes with dispensing openings.

[0003] More specifically, known liners and boxes must be formed separately, either on different production lines or at different times on the same production line. However, in either case, because the liner is flexible and the blank from which the box is formed is rigid, their different configurations require different machines to form the box, and they are not formed simultaneously. Then, when it comes time to place the filled liner into the formed box, a typical production line will have multiple machines running simultaneously to place the filled liner into the formed box in order to keep production speed as fast as possible.

[0004] Therefore, there is a need for a) a liner and blank combination that can be simultaneously formed and filled, b) a single system for forming and filling the liner and blank combination, which allows for faster forming, filling, and sealing of cereal boxes and the like, and c) a method for using same, particularly for boxes with a side / top dispensing opening that does not require opening the top of the box and tearing the liner bag to access the contents. Summary of the Invention

[0005] The present invention fulfills this need. In a first embodiment, the present invention relates to a combination of a blank and a liner for forming a dispensing box. The combination includes the blank and at least one liner connected or configured to connect to the blank.

[0006] The blank has a plurality of foldably connected panels, an inner surface, an outer surface, and at least one dispensing opening disposed in at least one of the panels.

[0007] Optionally, the liner has at least one perforation zone configured to align with at least one dispensing opening in the blank.

[0008] Optionally, the blank is made from paperboard.

[0009] Optionally, the blank includes a first panel, a second panel foldably connected to the first panel, the second panel having a small top flap foldably connected thereto, a third panel foldably connected to the second panel, the third panel having a first dispensing opening disposed therein, a large top flap foldably connected thereto, and a large bottom flap foldably connected thereto, a fourth panel foldably connected to the third panel, the fourth panel having a small top flap foldably connected thereto and a small bottom flap foldably connected thereto, a fifth panel foldably connected to the fourth panel, the fifth panel having a large top flap foldably connected thereto and a large bottom flap foldably connected thereto, a sixth panel foldably connected to the fifth panel, the sixth panel having a small bottom flap foldably connected thereto, a seventh panel foldably connected to the sixth panel, and an eighth panel foldably connected to the seventh panel.

[0010] Optionally, the top major flap of the fifth panel is foldably connected to a dispensing flap, the dispensing flap having at least one second dispensing opening.

[0011] In a second embodiment, the present invention relates to a system for forming boxes with integrated liners, the system including at least one blank feeder, at least one conveyor belt, at least one liner applicator, at least one folder and former, and at least one filler.

[0012] Optionally, the at least one liner applicator includes at least one rolled liner, at least one glue supply system, and at least one application loop.

[0013] In a third embodiment, the present invention relates to a method of forming a box with an integral liner, the method comprising the steps of:

[0014] A) providing a blank, the blank having a plurality of foldably connected panels, an inner surface, an outer surface, and at least one dispensing opening disposed in at least one of the panels.

[0015] B) providing at least one liner configured to connect to an inner surface of the blank, the liner having at least one perforation zone configured to align with at least one dispensing opening in the blank;

[0016] C) connecting at least one liner to the inner surface of the blank, aligning at least one perforation zone of the liner with at least one dispensing opening of the blank to form a blank-liner combination;

[0017] D) Sealing, folding and forming the blank and liner combination to form a box. [Brief explanation of the drawings]

[0018] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings. [Figure 1] 1 is a perspective view of a box and liner combination system and method having features of the present invention; FIG. [Figure 2] FIG. 1 is a top view of a box and liner combination. [Figure 3] FIG. 2 is a perspective view of a first step of the system and method of FIG. 1. [Figure 4] FIG. 2 is a perspective view of a second step of the system and method of FIG. 1. [Figure 5] FIG. 2 is a perspective view of a third step of the system and method of FIG. 1. [Figure 6] FIG. 2 is a perspective view of a fourth step of the system and method of FIG. 1. [Figure 7] 7 is a perspective view of the folding step performed in FIG. 6. FIG. [Figure 8A] FIG. 7 is a partial perspective view of an additional folding step performed in FIG. 6. [Figure 8B] FIG. 7 is a partial perspective view of an additional folding step performed in FIG. 6. [Figure 9] FIG. 2 is a perspective view of a fifth step of the system and method of FIG. 1. DETAILED DESCRIPTION OF THE INVENTION

[0019] As used herein, the following terms and variations thereof have the meanings given below, unless a different meaning is clearly intended by the context in which the term is used.

[0020] As used herein, "a," "an," and similar reference words such as "the" are to be construed as covering the singular and the plural, unless the usage in context indicates otherwise.

[0021] When used in this disclosure, the words "comprise" and variations such as "comprising" and "comprises" are not intended to exclude other additives, ingredients, integer components or steps.

[0022] All dimensions specified in this disclosure are for illustrative purposes only and are not intended to be limiting. Additionally, the proportions shown in these figures are not necessarily to scale. As will be understood by those of ordinary skill in the art with reference to this disclosure, the actual dimensions and proportions of any system, any device / component or portion of a device disclosed herein, and / or any additional devices as needed, will be determined by its intended use.

[0023] 1, there is shown a system 100 and method for assembling the blank and liner combination 200 shown in FIG. 2 to form a box 904 with a liner therein. The system 100 includes five main components: a blank feeder 102, a conveyor belt 104, a liner applicator 106, a folder and former 108, and a filler 110.

[0024] 2, a blank and liner combination 200 is shown. The combination 200 includes a blank 202 and a liner 204 adhesively connected thereto by at least one adhesive patch / strip 206. Any number of adhesive patches / strips 206 can be used, and the patches / strips 206 can be in any configuration along the blank 202. The liner 204 can be any shape and configuration, but preferably, the liner 204 covers a substantial portion of the corresponding blank 202 so as to adequately function as a liner for the resulting box 904. The liner 204 can be made from a food-grade or food-compatible plastic or biodegradable material typically used as a liner for boxes containing food products.

[0025] In the embodiment shown in FIG. 2 , the blank 202 includes eight longitudinally connected panels 212, 214, 216, 218, 220, 222, 224, and 226. The second panel 214 has a foldably connected top minor flap 228. The third panel 216 has a first dispensing opening 208A disposed therein and a foldably connected top major flap 230 and a foldably connected bottom major flap 232. The fourth panel 218 has a foldably connected top minor flap 234 and a foldably connected bottom minor flap 236. The fifth panel 220 has a foldably connected top major flap 238 and a foldably connected bottom major flap 240. The sixth panel 222 has a foldably connected bottom minor flap 242. The fourth and fifth panels 218, 220 may share at least one cut-out window 250 that allows a user to view the contents of the box 904 without opening the box 904. However, it should be noted that the at least one cut-out window 250 may be located anywhere along the blank 202, and the placement of the windows 250 is not limited to that shown in the figures.

[0026] An upper large flap 238 foldably connected to the fifth panel 220 has two additional panel portions 244, 246 foldably connected thereto, the panel portion 246 having a second dispensing opening 208B disposed therein.

[0027] When folded onto the box 904, the third panel 216 forms the front panel of the box 904, and the fifth panel 220 forms the back panel of the box 904. The panel portions 244, 246 fold within the box 904 to form a dispensing flap 248 that blocks and opens the first dispensing opening 208A, thereby allowing the second dispensing opening 208B to be aligned and disaligned with the first opening 208A. When the first and second openings 208A, 208B are aligned, the contents of the box 904 can be dispensed from the box 904. When the openings 208A, 208B are not aligned, the contents of the box 904 cannot be dispensed from the box 904.

[0028] 2, the blanks 202 are shown as having a particular shape / configuration and a particular number of panels, it should be understood that the blanks 202 used as part of the combination 200 may be of any shape and are not limited to the particular configuration shown in the figure. Preferably, however, each blank 202 has at least one dispensing opening 208 therein.

[0029] 3, the system 100 begins with the automatic blank feeder 102. The blank feeder 102 is a standard blank feeder configured to feed paperboard blanks 202, typically one at a time, although it can also be configured to feed multiple blanks 202 simultaneously. The blank feeder 102 can utilize a tray feeder or one or more mechanical / robotic arms that pick up and place the blanks 202 onto the conveyor belt 104. As mentioned above, the paperboard blank 202 can have at least one dispensing opening 208 therein for dispensing or pouring product from a fully formed box 904.

[0030] Optionally, the conveyor belt 104 is disposed around at least one roller 300 and may be porous with a plurality of holes 302. One or more vacuum zones (supplied by at least one vacuum system) may be utilized to apply vacuum / suction pressure 304 to the underside of the belt 104 to draw the blanks 202 onto the belt 104 and hold the blanks 202 in place as they are transported by the belt 104.

[0031] Optionally, the belt 104 may utilize speed i-sensors calibrated along the belt 104 to ensure that the liners 204 and blanks 202 are properly positioned and timed.

[0032] 4 and 5, once the blank 202 is placed on the conveyor belt 104, the conveyor belt 104 moves the blank 202 into position beneath the liner applicator 106. The liner applicator 106 is primarily comprised of three parts: one or more rolls of liner / film 400, at least one adhesive application system 402, and an application loop 404.

[0033] The roll of liner / film 400 is an industry standard roll. However, the roll 400 may optionally include perforations 406 to distinguish and facilitate the separation of each box liner 204 from the next as it is applied to its respective blank 202. Optionally, the roll of liner 400 is die-cut to the shape of the blank 202 to which it will be applied, and also includes a dispensing opening 208 in the blank 202.

[0034] The adhesive application system 402 includes one or more rollers 408 with an appropriate adhesive pattern (pattern glue) 410, which applies the appropriate adhesive pattern 206 to each liner sheet 204 as the liner 204 leaves the liner roll 406 and passes over the rollers 408 of the adhesive system 402. It is important that the adhesive pattern 206 applied to each liner 204 does not interfere with the fold lines of the blank 202 and / or the dispensing openings 208 in the blank 202. Each liner 204 may have one or more perforation zones 210 corresponding to one or more dispensing openings 208 in the blank 202. Typically, the adhesive pattern 206 includes applying adhesive to each liner 204 around each perforation zone 210, and on at least one side, and preferably both sides, of the perforation zone 210. This maintains each perforation zone 210 aligned with the corresponding dispensing opening 208 in the blank 202. Additionally, there should be at least one adhesive line or glue 206 on the "side panel" of the liner 204 (at this point, there are no technically any side panels, as the liner 204 is simply a sheet of liner attached to the flat, unrolled blank 202). Ensure that each side of the liner 204 adheres to each side panel of the blank 202 and to the resulting box 904. If food is to be placed within the box 904, it is desirable that the adhesive / glue 206 used be food-grade.

[0035] The liner 202, with the adhesive pattern 206 applied, then continues down along the application loop 404, allowing the adhesive pattern 206 to be applied to the blank 202 as it passes under the loop 404. This is best shown in Figure 5. Because the adhesive pattern 206 is on the outer surface of the liner 204, it can press against and connect to the inner surface of the blank 202 (which is oriented upward to receive the liner 204) as it passes under the loop 404.

[0036] After the loops 404, at least one additional roller or wheel (crushing roller) 500 may be positioned along the belt 104 over the blank 202 to apply pressure to the liner 204 and ensure proper adhesion of the liner 204 to the blank 202. Optionally, the orientation of the liner loops 404 and blank 202 may not necessarily be on top of each other, and the blank 202 may not pass under the loops 404, but may be in another direction / orientation that allows the liner 204 to be applied to the blank 202.

[0037] The blank 202 with the bonded liner 204 then travels along the conveyor belt 104 to the folding and forming machine 108 and finally to the filling, sealing and bonding machine 110. Although not shown in the figures, the folding and forming machine 108 and the filling, sealing and bonding machine 110 can be the same machine or can be housed in the same housing (as opposed to two different machines / stations as shown in the figures).

[0038] 6, the folding and forming machine 108 is shown in basic detail. The folding and forming machine 108 folds and forms the blank and liner combination 200 into an open-top box / liner combination 600.

[0039] 7-8, the basic folding steps required to achieve open-top box / liner combination 600 are shown. More specifically, flat, unfolded, blank and liner combination 200 is folded to form a partially folded combination, with the side panels folded over to form an open top 700 and an open bottom 702. FIG. 7 illustrates this folding step. Next, the bottom of liner 204 is sealed, and then the bottom of blank 202 is folded and glued 800 to form a closed bottom 800 of combination 200. This is shown in FIGS. 8A and 8B. This results in open-top box / liner combination 600, as shown in FIG. 6. In this case, the tops of both the partially folded blank 202 and liner 204 are open and unsealed, while the bottoms 800 of liner 204 and blank 202 are closed and sealed.

[0040] 9, once the open-top box / liner combination 600 is formed, a conveyor belt 104 moves it to a filling, sealing, and gluing machine 110. In this machine 110, the open-top box / liner combination 600 is positioned upright with the open top 700 facing upward. The machine 110 can then pour contents 900 into the box / liner combination 600 through the opening in the box / liner top 700. Once the contents 900 enter the box / liner combination 600, the top of the liner is heat sealed, after which the box top can be folded, formed, and sealed / glued in a conventional manner.

[0041] Multiple sensors and / or cameras may be used throughout the system 100 to ensure proper placement, positioning, and application of the blanks 202 and / or liners 204.

[0042] The present invention has many advantages. First, the standard method of packaging a box with contents requiring a liner requires that the liner be pre-filled and sealed to form a loose, flimsy bag / pouch. The act of sliding a soft material bag into a rigid box requires the filling machine to operate at a much slower pace than the box former. Therefore, the production rate of products requiring a liner is limited by the rate at which the filling machine can feed the soft material bag into a pre-formed box.

[0043] The present invention addresses this problem by creating a blank / liner combination that can be folded into a box with a pre-installed liner. This pre-installed liner box can be filled much faster than standard filling methods that involve filling an unfolded liner. This is because pouring or dumping loose material into an open-top, box-installed liner combination is faster than inserting loose material into a rigid box. Therefore, the present invention allows for faster filling speeds and increased product yields, resulting in significant cost savings.

[0044] Furthermore, while a typical configuration involves one forming and folding machine and multiple liner filling machines, the significantly faster filling speed of the present invention allows the forming and folding machine and the filling machine to operate at a similar speed, further reducing manufacturing costs.

[0045] An added benefit is that a standard pre-filled liner / bag is much smaller than the box, and the box is always finished leaving a large amount of empty space to accommodate the filled liner bag, which wastes a large amount of paper / paperboard.

[0046] The present invention reduces wasted packaging material.

[0047] Although the present invention has been described in considerable detail with reference to certain preferred embodiments, other embodiments are possible. For example, the steps disclosed for the present methods are not intended to be limiting, nor are they intended to indicate that each step is necessarily essential to the method, but are instead exemplary steps only. Therefore, the scope of the appended claims should not be limited to the description of the preferred embodiments contained in this disclosure. All documents cited herein are incorporated by reference.

Claims

1. A combination of a blank and a liner to form a box, comprising: a) The following: i) a plurality of foldably connected panels; ii) inner surface; iii) outer surface; iv) at least one dispensing opening disposed in at least one of the panels; and b) at least one liner connected to the inner surface of the blank; Combinations including:

2. The combination of claim 1 , wherein the liner has at least one perforated zone configured to align with at least one dispensing opening in the blank.

3. 10. The combination of claim 1, wherein the blank is formed from paperboard.

4. The blanks are: a) a first panel; b) a second panel foldably connected to the first panel, the second panel comprising: i) a small upper flap foldably connected thereto; c) a third panel foldably connected to the second panel, the third panel comprising: i) a first dispensing opening disposed therein; ii) a large upper flap foldably connected thereto; and iii) a large bottom flap foldably connected thereto; d) a fourth panel foldably connected to the third panel, the fourth panel comprising: i) a small upper flap foldably connected thereto; and ii) a small bottom flap foldably connected thereto; e) a fifth panel foldably connected to the fourth panel, the fifth panel comprising: i) a large upper flap foldably connected thereto; and ii) a bottom major flap foldably connected thereto; f) a sixth panel foldably connected to the fifth panel, the sixth panel comprising: i) a small bottom flap foldably connected thereto; g) a seventh panel foldably connected to the sixth panel; and h) an eighth panel foldably connected to the seventh panel; 2. The combination of claim 1 comprising:

5. 5. The combination of claim 4, wherein the upper major flap of the fifth panel is foldably connected to a dispensing flap, the dispensing flap having at least one second dispensing opening.

6. A combination of a blank and a liner to form a box, comprising: a) The following: i) a plurality of foldably connected panels; ii) inner surface; iii) outer surface; iv) at least one dispensing opening disposed in the at least one panel; a blank having b) at least one liner configured to adhesively connect to an inner surface of the blank; Combinations including:

7. The combination of claim 6 , wherein the liner has at least one perforated zone configured to align with at least one dispensing opening in the blank.

8. 7. The combination of claim 6, wherein the blank is formed from paperboard.

9. The blanks include: a) a first panel; b) a second panel foldably connected to the first panel, the second panel comprising: i) a small upper flap foldably connected thereto; c) a third panel foldably connected to the second panel, the third panel comprising: i) a first dispensing opening disposed therein; ii) a large upper flap foldably connected thereto; and iii) a large bottom flap foldably connected thereto; d) a fourth panel foldably connected to the third panel, the fourth panel comprising: i) a small upper flap foldably connected thereto; and ii) a small bottom flap foldably connected thereto; e) a fifth panel foldably connected to the fourth panel, the fifth panel comprising: i) a large upper flap foldably connected thereto; and ii) a bottom major flap foldably connected thereto; f) a sixth panel foldably connected to the fifth panel, the sixth panel comprising: i) a small bottom flap foldably connected thereto; g) a seventh panel foldably connected to the sixth panel; and h) an eighth panel foldably connected to the seventh panel; 7. The combination of claim 6, comprising:

10. 10. The combination of claim 9, wherein the top major flap of the fifth panel is foldably connected to a dispensing flap, the dispensing flap having at least one second dispensing opening therein.

11. 1. A system for forming a box with an integrated liner, comprising: a) at least one blank feeder; b) at least one conveyor belt; c) at least one liner applicator; d) at least one folding and forming machine; and e) at least one filling machine; A system including:

12. The at least one liner applicator comprises: a) at least one roll of rolled liner; b) at least one adhesive dispensing system; and c) at least one application loop; The system of claim 11 , comprising:

13. 1. A method for forming a box with an integrated liner, comprising: a) providing a blank, the blank comprising: i) a plurality of foldably connected panels; ii) inner surface; iii) outer surface; iv) at least one dispensing opening disposed in at least one of the panels; b) providing at least one liner configured to connect to an inner surface of the blank, the liner having at least one perforation zone configured to align with at least one dispensing opening in the blank; c) connecting at least one liner to an inner surface of the blank, wherein at least one perforation zone of the liner is aligned with at least one dispensing opening of the blank to form a blank-liner combination; and d) sealing, folding and forming the combination of blank and liner to form a box; A method comprising:

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