Telescoping boxes, blanks, and systems for pour-style 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 box comprises a top portion with a removable perforation feature defined on a front wall. A bottom portion is sized to fit within an opening of the top portion and includes a cut-out feature in a front wall that aligns with the perforation feature of the top portion when the box is formed. The removed perforation feature and the cut-out feature enable a dispensing valve of a stored bag to extend past/through both front walls when the box is converted into the bag-in-box dispenser. 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 corrugated box for shipping a bag of liquid stored therein and converting into a bag-in-box dispenser, the box comprising:
 a top portion comprising a plurality of walls, wherein the top portion defines an opening, wherein the top portion includes:
 a perforation feature defined on a first wall of the plurality of walls, wherein the perforation feature is defined by a series of perforations and is removable from a remainder of the first wall, wherein the perforation feature is configured to enable a dispensing valve of the bag to extend past or through the first wall of the top portion when the box is converted into the bag-in-box dispenser and the perforation feature is removed; and 
   a bottom portion comprising a plurality of walls, wherein the bottom portion defines an opening configured to receive the bag of liquid, wherein the bottom portion is sized to fit within the opening of the top portion, wherein the bottom portion defines:
 a cut-out feature that defines a portion of a first wall of the plurality of walls of the bottom portion that is at least one of pre-removed or capable of being removed from a remainder of the first wall of the bottom portion, wherein the cut-out feature is positioned on the first wall of the bottom portion to align with the perforation feature of the top portion when the bottom portion is received within the top portion, wherein the cut-out feature is configured to enable the dispensing valve to extend past or through the first wall of the bottom portion when the box is converted into the bag-in-box dispenser. 
   
     
     
         2 . The box of  claim 1 , wherein the first wall of the top portion defines a top edge, a bottom edge and a length therebetween, and wherein the perforation feature extends from a position at or above a center position along the length to the bottom edge. 
     
     
         3 . The box of  claim 2 , wherein the perforation feature defines an elongated shape that increases in width in a direction leading to the bottom edge of the first wall of the top portion. 
     
     
         4 . The box of  claim 2 , wherein a width of the perforation feature proximate the bottom edge of the first wall of the top portion is sized to receive one or more pieces of tape, wherein the tape is used to secure the top portion to the bottom portion. 
     
     
         5 . The box of  claim 4 , wherein removal of the perforation feature results in the removal of the one or more pieces of tape to enable movement of the top portion relative to the bottom portion. 
     
     
         6 . The box of  claim 1 , wherein the first wall of the top portion has a top edge, a bottom edge and a length therebetween, and wherein the perforation feature defines an elongated shape with a perforation feature length that extends from a position at or above a center position along the length toward the bottom edge, wherein the perforation feature length is greater than a corresponding length characteristic of the dispensing valve such that the top portion may be lifted upwardly from the bottom portion and a user can pull the dispensing valve through an opening formed in the first wall of the top portion by removal of the perforation feature. 
     
     
         7 . The box of  claim 1 , wherein the first wall of the top portion has a top edge, wherein the perforation feature is positioned on the first wall of the top portion such that it is spaced apart from the top edge. 
     
     
         8 . The box of  claim 1 , wherein the cut-out feature defines a shape that corresponds to a portion of the dispensing valve such that the cut-out feature holds the dispensing valve in position when the box is converted into the bag-in-box dispenser. 
     
     
         9 . The box of  claim 8 , wherein the cut-out feature is defined along a top edge of the first wall of the bottom portion. 
     
     
         10 . The box of  claim 1 , wherein the top portion further defines a finger access feature positioned adjacent to the perforation feature. 
     
     
         11 . The box of  claim 1 , wherein the perforation feature is a first perforation feature, wherein the top portion further includes a second perforation feature defined on a second wall of the plurality of walls of the top portion, wherein the second wall of the top portion is opposite the first wall of the top portion, wherein the second perforation feature is defined by a series of perforations and is removable from a remainder of the second wall, and wherein the bottom portion further comprises a handle feature that is defined on a second wall of the plurality of walls of the bottom portion, wherein the second wall of the bottom portion is opposite the first wall of the bottom portion, wherein the handle feature is defined by one or more perforations on the second wall of the bottom portion, wherein the handle feature is positioned on the second wall of the bottom portion to align with the second perforation feature of the top portion when the bottom portion is received within the top portion. 
     
     
         12 . The box of  claim 11 , wherein the second wall of the top portion has a top edge, a bottom edge and a length therebetween, and wherein the second perforation feature extends from a position at or above a center position along the length to the bottom edge. 
     
     
         13 . The box of  claim 1 , wherein the bottom portion 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 bottom portion, wherein the side flap is attached to the outside surface so as to be separated from the stored bag within the box to avoid damage to the stored bag during shipping. 
     
     
         14 . The box 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. 
     
     
         15 . The box of  claim 14 , 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. 
     
     
         16 . The box 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. 
     
     
         17 . A system including the box of  claim 1 , wherein the system further includes the bag of liquid including the dispensing valve, wherein the bag is stored within the opening of the bottom portion of the box. 
     
     
         18 . A box blank for a corrugated box for shipping a bag of liquid stored therein and converting the box into a bag-in-box dispenser, wherein the box blank is formed of corrugate and comprises:
 a top portion comprising a plurality of panels, wherein the top portion, when formed into a box top portion, defines an opening, wherein the top portion defines:
 a perforation feature defined on a first panel of the plurality of panels, wherein the perforation feature is defined by a series of perforations and is removable from a remainder of the first panel, wherein the perforation feature is configured to enable a dispensing valve of the bag to extend past or through the first panel when the box is converted into the bag-in-box dispenser and the perforation feature is removed; and 
   a bottom portion comprising a plurality of panels, wherein, when formed into a box bottom portion, the bottom portion defines an opening configured to receive the bag of liquid and the bottom portion is sized to fit within the opening of the top portion, wherein the bottom portion defines:
 a cut-out feature that defines a portion of a first panel of the plurality of panels of the bottom portion that is at least one of pre-removed or capable of being removed from a remainder of the first panel of the bottom portion, wherein the cut-out feature is positioned on the first panel of the bottom portion to align with the perforation feature of the top portion when the bottom portion is received within the top portion, wherein the cut-out feature is configured to enable the dispensing valve to extend past or through the first panel of the bottom portion when the box is converted into the bag-in-box dispenser. 
   
     
     
         19 . The box blank of  claim 18 , wherein the first panel of the top portion defines a top edge, a bottom edge and a length therebetween, and wherein the perforation feature extends from a position at or above a center position along the length to the bottom edge. 
     
     
         20 . The box blank of  claim 19 , wherein the perforation feature defines an elongated shape that increases in width in a direction leading to the bottom edge of the first panel of the top portion. 
     
     
         21 . The box blank of  claim 18 , wherein the first panel of the top portion defines a top edge, a bottom edge and a length therebetween, and wherein the perforation feature defines an elongated shape with a perforation feature length that extends from a position at or above a center position along the length toward the bottom edge, wherein the perforation feature length is greater than a corresponding length characteristic of the dispensing valve such that the formed box top portion may be lifted upwardly from the formed box bottom portion and a user can pull the dispensing valve through an opening formed in the first panel of the formed box top portion by removal of the perforation feature. 
     
     
         22 . The box blank of  claim 18 , wherein the first panel of the top portion defines a top edge, wherein the perforation feature is positioned on the first panel such that it is spaced apart from the top edge. 
     
     
         23 . The box blank of  claim 18 , wherein the cut-out feature defines a shape that corresponds to a portion of the dispensing valve such that the cut-out feature is configured to hold the dispensing valve in position when the box is converted into the bag-in-box dispenser. 
     
     
         24 . The box blank of  claim 18 , wherein the perforation feature is a first perforation feature, wherein the top portion further includes a second perforation feature defined on a second panel of the plurality of panels of the top portion, wherein the second panel of the top portion is opposite the first panel of the top portion, wherein the second perforation feature is defined by a series of perforations and is removable from a remainder of the second panel, and wherein the bottom portion further comprises a handle feature that is defined on a second panel of the plurality of panels of the bottom portion, wherein the second panel of the bottom portion is opposite the first panel of the bottom portion, wherein the handle feature is defined by one or more perforations on the second panel of the bottom portion, wherein the handle feature is positioned on the second panel of the bottom portion to align with the second perforation feature of the top portion when the box bottom portion is received within the box top portion. 
     
     
         25 . The box blank of  claim 18 , 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. 
     
     
         26 . The box blank of  claim 25 , 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. 
     
     
         27 . The box blank of  claim 18 , 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. 
     
     
         28 . A method of manufacturing a box blank for a corrugated box for shipping a bag of liquid stored therein and converting into a bag-in-box dispenser, the method comprising:
 forming corrugated web product;   cutting out a top portion of the box blank from the corrugated web product, wherein the top portion comprises a plurality of panels, wherein the top portion, when formed into a box top portion, defines an opening, wherein the top portion defines:
 a perforation feature defined on a first panel of the plurality of panels, wherein the perforation feature is defined by a series of perforations and is removable from a remainder of the first panel, wherein the perforation feature is configured to enable a dispensing valve of the bag to extend past or through the first panel when the box is converted into the bag-in-box dispenser and the perforation feature is removed; and 
   cutting out a bottom portion of the box blank from the corrugated web product, wherein the bottom portion comprises a plurality of panels, wherein, when formed into a box bottom portion, the bottom portion defines an opening configured to receive the bag of liquid and the bottom portion is sized to fit within the opening of the top portion, wherein the bottom portion defines:
 a cut-out feature that defines a portion of a first panel of the plurality of panels of the bottom portion that is at least one of pre-removed or capable of being removed from a remainder of the first panel of the bottom portion, wherein the cut-out feature is positioned on the first panel of the bottom portion to align with the perforation feature of the top portion when the bottom portion is received within the top portion, wherein the cut-out feature is configured to enable the dispensing valve to extend past or through the first panel of the bottom portion when the box is converted into the bag-in-box dispenser. 
   
     
     
         29 . The method of  claim 28  further comprising:
 erecting the box top portion; and 
 erecting the box bottom portion. 
 
     
     
         30 . The method of  claim 29  further comprising:
 inserting the bag of liquid into the opening of the box bottom portion; and 
 sliding the box top portion over the box bottom portion with the bag stored therein.