Boxes, blanks, and systems for bag-in-box dispensed products

Abstract

Corrugated boxes, box blanks, and systems for individually shipping a bag of liquid stored therein and converting into a bag-in-box dispenser are provided. An example system comprises a box with walls defining an opening. A perforation feature is defined on a front wall with a bottom thereof being spaced apart from the box bottom. The perforation feature is removable to enable a dispensing tap of the stored bag to be accessed and positioned to extend past/through the front wall. An insert is designed to be positioned within the box and includes a top surface that is positioned proximate the bottom of the perforation feature to support the stored bag. The box is configured to store a bag of liquid ranging from 2 to 10 liters and is designed to pass individual box shipping test standards, such as ISTA and SIOC test standards. Methods of forming the box are also provided.

1 . A system for shipping a bag of liquid in a corrugated box and converting the box into a bag-in-box dispenser thereafter, the system including:
 the box for shipping the bag of liquid stored therein and converting into the bag-in-box dispenser, the box comprising:
 a plurality of walls defining an opening configured to receive the bag of liquid; and 
 a bottom, wherein the bottom is formed from at least one bottom flap being folded with respect to one of the plurality of walls; 
 wherein the box defines:
 a perforation feature defined on a first wall of the plurality of walls such that a bottom of the perforation feature is spaced apart a first vertical distance from the bottom of the box, wherein the perforation feature is defined by at least one series of perforations and is removable or movable with respect to the first wall to enable a dispensing tap of the bag stored in the box to be positioned into a dispensing position such that the dispensing tap extends at least partially through or past the front wall; and 
 
   an insert that is formed of corrugated web product and sized to fit within the opening of the box and rest on the bottom of the box, wherein the insert has a top surface and a height, wherein the height corresponds to the first vertical distance such that, when the insert is positioned within the box and resting on the bottom of the box, the top surface of the insert is positioned within a second vertical distance from the bottom of the perforation feature, wherein the first vertical distance is greater than the second vertical distance, and wherein the top surface is configured to provide a support surface of the bag stored in the box.   
     
     
         2 . The system of  claim 1 , wherein the perforation feature comprises a first portion and a second portion, wherein each of the first portion and the second portion is defined by at least one series of perforations, wherein the first portion is removable from a remainder of the first wall, and wherein the second portion is at least partially separable from the first wall and configured to pivot with respect to the first wall. 
     
     
         3 . The system of  claim 2 , wherein the first portion defines a shape that corresponds to a portion of the dispensing tap such that a hole in the first wall formed by removal of the first portion holds the dispensing tap in position when the box is converted into the bag-in-box dispenser. 
     
     
         4 . The system of  claim 3 , wherein the second portion, after separation of the corresponding at least one series of perforations, defines a cantilever structure that can be pivoted to enable a user to reach inside the box to access the dispensing tap and reposition the dispensing tap into the dispensing position. 
     
     
         5 . The system of  claim 1 , wherein the second vertical distance is 2 inches such that the top surface of the insert is within 2 inches of the bottom of the perforation feature. 
     
     
         6 . The system of  claim 1 , wherein the top surface of the insert is positioned at a vertical point such that, when the dispensing tap is in the dispensing position, the dispensing tap is aligned with the bottom of the bag to facilitate removal of contents of the bag with the aid of gravity. 
     
     
         7 . The system of  claim 1 , wherein the top surface of the insert is angled toward a first flap of the insert, and wherein the insert is designed to be positioned within the box such that the first flap is adjacent to the first wall of the box. 
     
     
         8 . The system of  claim 1 , wherein the insert includes a plurality of flaps that are folded down from the top surface to cause the insert to define the height. 
     
     
         9 . The system of  claim 1 , wherein the top surface of the insert includes one or more openings that are each shaped to receive a finger of a user or a portion of a machine so as to enable the user or the machine to position the insert within the opening of the box. 
     
     
         10 . The system of  claim 1 , wherein the box defines a side flap that is attached to an outside surface of one of the plurality of walls so to form the opening of the box, wherein the side flap is attached to the outside surface of the one of the plurality of walls so as to be separated from the stored bag within the box to avoid damage to the stored bag during shipping. 
     
     
         11 . The system of  claim 1 , wherein the box is configured to store the bag of liquid with volume ranging from 2 liters to 10 liters and keep the bag from damage or leaking during individual box shipping. 
     
     
         12 . The system of  claim 11 , wherein the box is designed to store the bag and pass individual box shipping test standards, including at least the 2018 International Safe Transit Association (ISTA) Series 6-Amazon.com-Ship In Own Container (SIOC) test protocol for Type A. 
     
     
         13 . The system of  claim 1  further comprising the bag of liquid including the dispensing tap. 
     
     
         14 . The system of  claim 1 , wherein the box is designed to survive individual box shipping such that the perforation feature is intact and the bag is free of damage or leaking so as to enable conversion of the box into the bag-in-box dispenser thereafter. 
     
     
         15 . A box blank for a system for shipping a bag of liquid in a corrugated box and converting the box into a bag-in-box dispenser thereafter, wherein the box blank is formed of corrugate and comprises:
 a box portion that can be formed into a box for shipping the bag of liquid stored therein and converting into the bag-in-box dispenser, the box portion comprising:
 a plurality of panels, wherein, when the box is formed, the plurality of panels define a plurality of walls that define an opening configured to receive the bag of liquid; and 
 at least one bottom flap, wherein, when folded with respect to one of the plurality of walls, the at least one bottom flap defines a bottom of the box; 
 wherein the box portion defines:
 a perforation feature defined on a first panel of the plurality of panels such that a bottom of the perforation feature is spaced apart a first vertical distance from the bottom of the box when the box is formed, wherein the first panel is a first wall when the box is formed, wherein the perforation feature is defined by at least one series of perforations and is removable or movable with respect to the first wall to enable a dispensing tap of the bag stored in the box, when formed, to be positioned into a dispensing position such that the dispensing tap extends at least partially through or past the first wall; and 
 
   an insert that is sized to fit within the opening of the box and rest on the bottom of the box when the box is formed, wherein the insert has a top surface and a height, wherein the height corresponds to the first vertical distance such that, when the insert is positioned within the box and resting on the bottom of the box, the top surface of the insert is positioned within a second vertical distance from the bottom of the perforation feature, wherein the first vertical distance is greater than the second vertical distance, and wherein the top surface is configured to provide a support surface of the bag stored in the box.   
     
     
         16 . The box blank of  claim 15 , wherein the perforation feature comprises a first portion and a second portion, wherein each of the first portion and the second portion is defined by at least one series of perforations, wherein the first portion is removable from a remainder of the first wall, and wherein the second portion is at least partially separable from the first wall and configured to pivot with respect to the first wall. 
     
     
         17 . The box blank of  claim 16 , wherein the first portion defines a shape that corresponds to a portion of the dispensing tap such that a hole in the first wall formed by removal of the first portion holds the dispensing tap in position when the box is converted into the bag-in-box dispenser. 
     
     
         18 . The box blank of  claim 16 , wherein the second portion, after separation of the corresponding at least one series of perforations, defines a cantilever structure that can be pivoted to enable a user to reach inside the box to access the dispensing tap and reposition the dispensing tap into the dispensing position. 
     
     
         19 . The box blank of  claim 15 , wherein the insert defines a plurality of flaps that are configured to fold down from the top surface to cause the insert to define the height. 
     
     
         20 . The box blank of  claim 19 , wherein the plurality of flaps comprises at least a front flap and a back flap, wherein the back flap defines a length that is greater than the length of the front flap such that, when formed, the top surface of the insert is angled toward the front flap. 
     
     
         21 . The box blank of  claim 15 , wherein the top surface of the insert defines one or more openings that are each shaped to receive a finger of a user or a portion of a machine so as to enable the user or the machine to position the insert within the opening of the box. 
     
     
         22 . The box blank of  claim 15 , wherein the box, when formed, is configured to store the bag of liquid with volume ranging from 2 liters to 10 liters and keep the bag from damage or leaking during individual box shipping. 
     
     
         23 . The box blank of  claim 22 , wherein the box, when formed, is designed to store the bag and pass individual box shipping test standards, including at least the 2018 International Safe Transit Association (ISTA) Series 6-Amazon.com-Ship In Own Container (SIOC) test protocol for Type A. 
     
     
         24 . The box blank of  claim 15 , wherein the box, when formed, is designed to survive individual box shipping such that the perforation feature is intact and the bag is free of damage or leaking so as to enable conversion of the box into the bag-in-box dispenser thereafter. 
     
     
         25 . A method of manufacturing a box blank for a system for shipping a bag of liquid in a corrugated box and converting the box into a bag-in-box dispenser thereafter, the method comprising:
 forming corrugated web product;   cutting out a box portion of the box blank from the corrugated web product, wherein the box portion can be formed into a box for shipping the bag of liquid stored therein and converting into the bag-in-box dispenser, the box portion comprising:
 a plurality of panels, wherein, when the box is formed, the plurality of panels define a plurality of walls that define an opening configured to receive the bag of liquid; and 
 at least one bottom flap, wherein, when folded with respect to one of the plurality of walls, the at least one bottom flap defines a bottom of the box; 
 wherein the box portion defines:
 a perforation feature defined on a first panel of the plurality of panels such that a bottom of the perforation feature is spaced apart a first vertical distance from the bottom of the box when the box is formed, wherein the first panel is a first wall when the box is formed, wherein the perforation feature is defined by at least one series of perforations and is removable or movable with respect to the first wall to enable a dispensing tap of the bag stored in the box, when formed, to be positioned into a dispensing position such that the dispensing tap extends at least partially through or past the first wall; and 
 
   cutting out an insert of the box blank from the corrugated web product, wherein the insert is sized to fit within the opening of the box and rest on the bottom of the box when the box is formed, wherein the insert has a top surface and a height, wherein the height corresponds to the first vertical distance such that, when the insert is positioned within the box and resting on the bottom of the box, the top surface of the insert is positioned within a second vertical distance from the bottom of the perforation feature, wherein the first vertical distance is greater than the second vertical distance, and wherein the top surface is configured to provide a support surface of the bag stored in the box.   
     
     
         26 . The method of  claim 25  further comprising:
 erecting the box with an open top from the box blank; 
 forming the insert from the box blank; and 
 positioning the insert within the opening of the box when formed. 
 
     
     
         27 . The method of  claim 26  further comprising:
 inserting the bag of liquid into the opening of the box to rest on the top surface of the insert; and 
 sealing the top of the box with the bag stored therein.