Bag-in-box with collapsed head-space

Abstract

The present invention is directed to a bag-in-box package having a flowable product contained in a thermoplastic bag which is inserted in or encased within an outer relatively rigid box or carton is provided. The box or carton may be constructed from a rigid or semi-rigid plastic or paperboard and has (i) a flat bottom panel, an opposing top panel, and a self-supporting, upstanding wall connecting the bottom and top panels, and (ii) an access port through the box for inserting a rigid implement, such as a drinking straw or other spout/tap therethrough to puncture the bag and withdraw the flowable product from inside the bag. The flowable product occupies less than 100% of the available volume of the bag and the remaining available head-space volume above the product is evacuated or collapsed in order to prevent spillage or leakage of product from the straw or spout when the bag is punctured.

What is claimed is: 
     
         1 . A retail bag-in-box package comprising:
 a flowable product, a bag, and a box; said product contained in said bag which is contained in said box; wherein   (a) said box has (i) a bottom panel, an opposing top panel, and a self-supporting upstanding wall connecting said bottom and top panels, (ii) an access port through said box;   (b) said bag is made from a flexible thermoplastic film, hermetically sealed to itself, and attached to an interior surface of said box proximate said access port;   (c) said product occupies at most 87% of the available volume of said bag to create a head-space above said product comprising the remaining available volume of said bag; and   (d) said head-space is collapsed and void of said product.   
     
     
         2 . A retail bag-in-box package, as defined in  claim 1 , wherein said product occupies between 50% and 83% of the available volume of said bag. 
     
     
         3 . A retail bag-in-box package according to  claim 1 , wherein said bag has a WVTR of less than 0.5 g/100 in 2 /24 hours at 100° F. (38° C.), 90% Relative humidity (R.H.), and 1 atmosphere. 
     
     
         4 . A retail bag-in-box package according to  claim 1 , wherein said bag has a WVTR of less than 0.1 g/100 inches 2  per 24 hours at 100° F. (38° C.), 90% Relative humidity (R.H.), and 1 atmosphere. 
     
     
         5 . A retail bag-in-box package according to  claim 1 , wherein said bag has a puncture resistance of between 4.4 N (1 lb-force) and 22.2 N (5 lb-force). 
     
     
         6 . A retail bag-in-box package according to  claim 1 , wherein said bag has a total internal capacity of less than or equal to 1000 mL (33.8 oz). 
     
     
         7 . A retail bag-in-box package according to  claim 1 , wherein said bag has a total internal capacity of between 118 mL (4 oz) and 946 mL (32 oz). 
     
     
         8 . A retail bag-in-box package according to  claim 1 , wherein said bag has a total internal capacity of about 354.9 mL (12 oz). 
     
     
         9 . A retail bag-in-box package according to  claim 1 , wherein said bag comprises at least five layers including a heat sealable layer, and a layer of EVOH. 
     
     
         10 . A retail bag-in-box package according to  claim 1 , wherein said bag has an O 2 TR value of less than or equal to 10 cm 3 /100 in 2 /24 hours at 1 atmosphere, 23° C. and 0% RH. 
     
     
         11 . A retail bag-in-box package according to  claim 1 , wherein said bag has an Elmendorf tear strength value of at least 100 grams in at least one of the machine and transverse directions. 
     
     
         12 . A retail bag-in-box package according to  claim 1 , wherein said bag film has a Gurley stiffness of less than 50 grams. 
     
     
         13 . A retail bag-in-box package according to  claim 1 , wherein said product comprises a liquid. 
     
     
         14 . A retail bag-in-box package according to  claim 1 , wherein said box comprises paperboard. 
     
     
         15 . A retail bag-in-box package according to  claim 1 , wherein said box comprises amorphous polyethylene terephthalate (APET). 
     
     
         16 . A retail bag-in-box package according to  claim 1 , wherein said box wall has a Gurley stiffness of at least 1000 grams. 
     
     
         17 . A retail bag-in-box package according to  claim 1 , wherein said package further comprises a rigid straw, a pump, a tap, a valve, a sprayer, a twist screw cap, or a dispensing cap. 
     
     
         18 . A retail bag-in-box package according to  claim 1 , wherein said bag is transparent. 
     
     
         19 . A retail bag-in-box package according to  claim 1 , wherein both said bag and said box are each transparent. 
     
     
         20 . A retail bag-in-box package according to  claim 1 , wherein said bag is transparent and said box is formed from paper board and has at least one window.