WO2009133359A1

WO2009133359A1 - Container

Info

Publication number: WO2009133359A1
Application number: PCT/GB2009/001076
Authority: WO
Inventors: Martin William Myerscough
Original assignee: Greenbottle Limited
Priority date: 2008-04-28
Filing date: 2009-04-28
Publication date: 2009-11-05

Abstract

A method of forming a container having an outer shell (10) and an inner bag (20) that extends through the dispensing aperture (14) of the shell and which is attached with respect to the shell. A hollow shell including a dispensing aperture and a bag having a body portion (22) and a neck (24) are provided. The bag is inserted into the hollow shell through the dispensing aperture, with at least the neck of the bag extending through the dispensing aperture. The neck of the bag is secured with respect to the hollow shell.

Description

CONTAINER

BACKGROUND OF THE INVENTION

The present invention relates generally to a container and a method for assembling a shell and a bag to form a container.

It is generally desirable to be able to produce a large number of containers quickly. It is therefore important to be able to assemble the bag and shell quickly.

There is a general environmental desire to reduce the amount of waste generated, and to re-use or recycle waste materials where possible. A particular concern is the amount of material used to create packaging, and the problems associated with the recycling of packaging materials.

Traditionally, many beverages such as wine, beer and milk have been supplied in glass bottles. The glass used to make these bottles may itself be recycled. However, the energy required to make the bottles is high. Also, the weight of the resulting packaging is high, increasing the amount of energy required to transport the products. Whilst the glass can be recycled, this does require that the bottles are separated from other waste, for example by users separating the glass bottles from other household waste for collection. Therefore, it is often the case that glass bottles are disposed of with other waste. In this case, the glass bottles may be disposed of in a landfill site. This is a problem since, unlike some other forms of waste, glass is not biodegradable. More recently, it has become common to use bottles made from plasties, such as PET or HDPE, for liquid such as milk and carbonated drinks. In this case, it is common for the bottles to be formed from virgin, i.e. non-recycled, material to ensure that the liquid contained within the bottle is not contaminated as could be the case if the containers were formed from recycled material. Whilst the material itself could be recycled if separated from other waste, as with glass bottles this frequently does not occur due to the need for the waste producer, such as a householder, to separate the containers from other waste material. Again, if the container is disposed of in a landfill site or the like, the bottle is not biodegradable. Also, bottles take up a volume larger than that of the material itself due to their hollow, rigid, structure, and therefore take up an excessive amount of space in a landfill site.

It has also been proposed to package liquid in laminated cardboard containers, for example in Tetra-Paks (Trade Mark). The cardboard is laminated with a waterproof coating. This both ensures that the container is able to hold liquid, and also acts as a barrier between the liquid and the cardboard which can prevent contamination of the liquid from the cardboard. A problem with such packages is that they are difficult to recycle, and the waterproof coating prevents them fully decomposing. If it were possible to separate the waterproof coating from the cardboard, the cardboard could be biodegradable, or at least recycled with other cardboard waste. However, this separation is difficult. The problem is exacerbated when a plastics dispensing nozzle or cap is formed as part of the package for dispensing the contents. This is another component that would need to be separated before the container can be recycled or parts of this be allowed to decompose.

In some countries, liquid such as milk is packaged in bags. However, these bags have little structural stability, and therefore are difficult to transport and to stack on shelves.

It is known to package wine in wine boxes. These comprise a box body, typically formed of laminated cardboard, which provides the structure for the package. A separate foil bag is provided within the box, the wine being contained within the bag. A dispensing tap is provided on the bag, and in use is arranged to protrude through an opening in the box. For the efficient disposal of such a container, it would be necessary to separate the parts made from different materials, namely the bag from the box, the dispensing tap from the bag, and the lamination from the cardboard forming the box. This separation of integrated components of the packaging is very difficult. Therefore, such packages cannot be disposed of or recycled efficiently.

US Patent No. 5,996,427 relates to a device for storing a liquid sample, for example a sample of wastewater, water from a river or stream or liquid effluent from a commercial or manufacturing enterprise. It is disclosed that a problem with known sample devices formed from glass or plastics material is that these must be thoroughly washed before they can be re-used to avoid contamination between samples. To overcome this problem, a liquid sample storage device is disclosed comprising a liner-holder formed from a plastics material in combination with a liner. The liner-holder is able to open, for example along a longitudinal hinge, to provide access to the interior of the liner-holder to allow a liner to be positioned within and later removed from the liner-holder. The liner extends through an inlet neck of the liner-holder, and is held in place by a retaining ring that is provided around the outside of the inlet neck of the liner-holder to claim the liner in place. The liner-holder is provided with vents on its top, bottom and sides to allow displacement of the air as the liner fills with liquid.

US Patent No. 3,255,932 also discloses a container comprising a re-usable, relatively rigid, outer container in combination with a disposable flexible bag contained within and supported by the outer container. According to the disclosure in this document, the bag is formed with ah integral spout that can pass through an opening in the upper portion of the outer container. The spout is engageable with the upper portion of the outer container to enable the spout to be closed and to support the bag within the outer container. It is described that the bag, containing milk or other liquid, can be placed in the outer container with the spout of the bag extending through the opening in the lid of the outer container before the end of the spout is removed to open the bag and allow the contents to be dispensed. A cap can be placed over the spout to seal this.

In our earlier International Patent Application No. WO 2007/066090, we disclose and claim a container comprising a hollow shell defining the container body and including a dispensing aperture, and a bag or liner provided within the shell, the open end of the bag extending through the dispensing aperture of the shell and being secured with respect to the outside of the shell. It is disclosed in our earlier application that the bag or liner may be attached to the outside of the shell by an adhesive, by tape, or by shrink wrapping where the bag or liner is heated to shrink this into contact with the outside of the shell around the dispensing opening. The bag or liner is made from a material suitable for containing the intended contents of the container, for example being formed from a moisture resistant or waterproof material where the container is intended to contain liquid. With the container described in our earlier application, the main part of the container, and in particular the part that provides structural stability and integrity, can be formed from materials that are recycled, recyclable and/or biodegradable, and which need not be normally suited for containing the intended contents of the container. The only part of the container that needs to be formed from material suited to containing the intended content of the container is the bag or liner. Accordingly, the container described in our earlier application requires less material that is suited for containing the intended content of the container, and is therefore more environmentally friendly than other containers. Further, as the shell and bag or liner can be separated and disposed of separately, the recycling or other processing of the used container is better than prior containers.

SUMMARY QF THE INVENTION

According to a first aspect of the present invention, a method of forming a container comprises the steps of: providing a hollow shell including a dispensing aperture; providing a bag having a body portion and a neck; inserting the bag into the hollow shell through an aperture in the hollow shell, with at least the neck of the bag extending through the dispensing aperture; and, securing the neck of the bag with respect to the hollow shell.

This method enables the easy assembly of a container having an outer shell and an inner bag that is able to hold the contents of the container whilst preventing these coming into contact with the hollow shell. The method allows easy automation of the assembly process, and allows consistent and reliable assembly of containers.

By providing the bag within the hollow body, the contents of the container will be stored within the bag and do not come into contact with the hollow shell. This means that the hollow shell, which can provide the strength of the container, can be formed from materials that would not normally be suitable for containing the contents. By extending the bag through the dispensing aperture, the contents of the container can be introduced and/or dispensed through the dispensing aperture without coming into contact with the inside of the shell. Securing the neck of the bag with respect to the shell ensures that the bag does not get drawn into the shell, for example due to the weight of the contents.

The aperture through which the bag is inserted into the hollow shell may be the dispensing aperture. This avoids the need to provide an additional aperture in the shell. However, the bag may be inserted through another aperture provided in the hollow shell, for example through an opening formed in the side or bottom of the hollow shell. In this case, the aperture may be closed after the bag has been inserted. For example, the opening may be formed with a flap in the wall of the hollow shell that can be opened to allow the bag to be inserted into the hollow shell, and closed subsequently. This can give structural integrity and/or stability to the container. The flaps or panels may be provided integrally with the shell, or may be provided as a separate element that is attached to the shell. In one example, the opening may be closed by a cup like component into which the hollow shell is received, or by a plug to close the opening.

In general, the aperture through which the bag is inserted into the hollow shell, especially where this is the dispensing aperture, will have a size smaller than the cross-sectional area of the hollow shell. The neck of the bag will generally be smaller than the body of the bag.

Preferably, the neck of the bag is secured to the outer surface of the shell, at least around the dispensing aperture. Alternatively or additionally, the neck of the bag could be attached to the inside of the hollow shell, for example using an adhesive.

Especially where the aperture through which the bag is inserted is relatively small, the body of the bag may need to be compressed to insert this into the aperture. The body of the bag will then need to be expanded after passing through the aperture. To assist the body of the bag to pass through the aperture, it is preferred that the bag is folded or rolled to reduce its dimensions. The bag may be retained in this folded or rolled condition by an adhesive, tape, band or clip. By folding or rolling the bag to reduce its dimensions, the bag can be easily and reliably expanded after insertion into the shell. This can be important when filling the container. If the bag has not been properly expanded, trapped volumes may be formed in regions of the bag. If the bag has not been properly expanded and contains trapped volumes, the intended volume of contents may not be introduced into the bag. Further, where the container is to be filled by a system that uses a pressure sensor to determine when the container is full, if there are trapped volumes in the bag, the pressure sensor may incorrectly determine when the bag had been filled with the appropriate volume of content. Folding or rolling the bag to reduce its dimension, will assist in ensuring that the bag is properly expanded, and reduces the possibility of trapped volumes occurring in the bag.

Where an adhesive, tape, band or clip is used to retain the bag in a folded or rolled condition, this may be ruptured or removed as part of the expansion of the bag.

Whether or not the bag is rolled or folded for introduction into the shell, the bag may be expanded by injecting a jet of fluid, for example air or an inert gas through the neck of the bag.

It is preferred that the body of the bag has a larger size and/or volume than the internal size and/or volume of the hollow shell. In this way, when the bag is filled with contents, the bag will abut against the interior wall of the body of the hollow shell, therefore ensuring that the hollow shell provides support for the weight of the contents.

To insert the bag into the shell, the bag is aligned with the dispensing aperture of the shell, and the bag and shell are moved with respect to each other. The bag can be moved towards the shell, the shell moved towards the bag, or the bag and shell moved towards each other.

In a preferred example, the bag may be hung or suspended over the aperture of the hollow shell. In this case, the hollow shell may be raised towards the bag. This may be especially advantageous when the bag is made of generally light flexible material as movement of the bag towards the shell could cause unwanted misalignment of the bag with respect to the shell, resulting in the bag being loaded into the shell at an incorrect position, or failing to be inserted into the shell. It is particularly desirable in this case to ensure that the distance between the aperture of the hollow shell and the opposite end of the hollow shell is a predetermined distance. This will ensure that each time a bag is loaded into the shell, the bag will be positioned within the shell at a predetermined desired position. This can be particularly advantageous in ensuring the produced container is consistent, especially when producing a large number of containers quickly.

Alternatively, the bag may be lowered towards the shell. This may be particularly advantageous when loading bags into shells of different volumes or heights where the height of the aperture for different shells may not be known or may vary. The bag may be supported by an extendible means that is extended to lower the bag into the shell.

Whilst moving the bag and shell with respect to each other to insert the bag into the shell, the bag and shell can be moved laterally whilst remaining in alignment with each other. This can enable the container to be assembled on a conveyor system. In this case, the relative movement of the bag and shell can be achieved by including an inclined surface along which the shell is moved to raise the shell with respect to the bag.

In one example, the bag is secured with respect to the shell by providing tape to bridge the outside of the hollow shell and the outside of the neck of the bag. The tape may be an adhesive tape that adheres to the shell and bag.

An advantage of providing tape to bridge the outside of the hollow shell and the outside of the neck of the bag is that the tape covers and protects the outside of the hollow shell around the dispensing aperture, and prevents anything, including the contents of the container as they are dispensed, passing between the outside of the bag and the shell and into the shell. In particular, providing a tape covering the shell around the dispensing aperture ensures that this vulnerable portion of the hollow shell does not come into contact with the contents of the container as these are dispensed or as the container is filled. This is particularly advantageous when the shell is made from a material which could be damaged or weaken by coming into contact with the contents of the container.

During dispensing of the contents of the container, it is possible that some of the contents will drip or run down the outside of the neck of the bag. Should the contents be allowed to pass between the outside of the neck of the bag and the inside of the shell, they would come into contact with the shell, and may damage this. Further, any such content could become contaminated by contact with the shell, and this contaminated content could be dispensed when further content is dispensed. Providing a tape that bridges the neck of the bag and the outside of the shell prevents any content passing between the bag and the shell and therefore avoids these problems. A tape is also easily removable to allow separation of the bag from the shell after use.

In one embodiment, a single strip of tape is provided around both sides of the dispensing aperture and both sides of the neck of the bag. Alternatively, multiple lengths of tape may be used, for example one on each side of the neck of the bag.

It is preferred that prior to applying a tape across the bridge between the outer surface of the hollow shell and the outside of the neck of the bag, the sides of the hollow shell around the dispensing aperture are at least partially flattened, for example by applying a clamping force to the opposed sides of the hollow shell around the dispensing aperture. This will assist the subsequent application of the tape to the hollow shell and the neck of the bag. It may be beneficial to at least partially flatten the sides of the hollow shell around the dispensing aperture prior to attaching the bag to the shell even where other securing mechanisms are used.

The width of the neck may be greater than the diameter of the dispensing aperture such that when the bag is loaded into the hollow shell, the neck of the bag sits above the dispensing aperture. In these cases, flattening the sides of the shell around the dispensing aperture increases the eccentricity of the dispensing aperture and allows the neck of the bag to drop further into the hollow shell. This can assist in ensuring that the neck of the bag is accurately located with respect to the hollow shell.

Other means can be used to secure the neck of the bag with respect to the shell. For example, the neck portion of the bag can be rolled or folded around the dispensing aperture and secured to the outer surface of the shell, for example by an adhesive, by tape or by shrink wrapping. This ensures that the outside of the hollow shell, around the dispensing aperture is covered and protected. Further still, the neck of the bag may be attached to the inside of the shell, for example by an adhesive.

The neck of the bag may include a seal for sealing the body of the bag. In one example the seal comprises a zip-seal.

The shell around the dispensing aperture may include a pair of opposed recesses. Protrusions in the neck of the bag, for example the opposed ends of a zip type seal where provided can be located in the recesses when the bag is positioned within the shell. The opposed recesses may be grooves or depressions in the shell, or may be notches formed in the shell. By locating the protrusions in the recesses, the bag is able to hang from the protrusions providing support for the bag to prevent this from being drawn into the container, for example through the weight of the contents.

In one example, a plurality of bags may be provided on a wicket. In this case, the bags may be connected together for ease of transport, and arranged such that one bag can be pulled from the remainder of the bags, for example by tearing a web or stop that connects the bags. In another example, the bags may be provided on a roll. In this case, the bags can be spaced apart on the roll. The bags may be provided with means that can hold the bags whilst allowing the bag to be inserted into the shell. In either case, this can assist automation of the assembly of containers.

The bag may be inserted into the shell using an elongate member. In this case, the elongate member may be used to push the body of the bag through the aperture. Alternatively, the bag can be supported by the elongate member which is then inserted into the hollow shell through the aperture to load the bag into the shell. Where the bag is supported by an elongate member, the elongate member may be a vacuum picker. This is a generally hollow member including apertures in the side wall. By applying a vacuum to the generally hollow interior, suction is created through the apertures in the side wall. Separate suction or vacuum lines may be connected to each of the openings, or to a number of the openings. This may be beneficial in ensuring that the bag is held on the vacuum picker, since if all openings are connected to the same vacuum line, a failure of the bag to seal any one of the openings may result in the vacuum or suction being lost. This can be used to hold the bag on the elongate member during loading. In this case, a positive pressure may be applied to the hollow interior of the elongate member when the bag is positioned within the hollow shell to release the bag from the loading member. The use of a vacuum picker enables a single bag to be picked from a stack or wicket of bags, as a vacuum picker is able to attract a single bag from a stack or wicket of bags for loading into the hollow shell.

Alternatively, where the bag is provided on an elongate member, the elongate member may attract and hold the bag by other means, for example using an adhesive or an electrical charge, or the bag may be clamped to the elongate member. A combination of means for holding the bag to the elongate member may be provided.

Where the bag is provided on an elongate member, the bag may be rolled or folded around the elongate member prior to loading into the hollow shell. This can be achieved by rotation of the elongate member about its longitudinal axis. This will assist in the loading of the bag into the shell through the dispensing aperture in the shell. In this case, it may be advantageous to provide a means for retaining the bag in the rolled condition, for example using an adhesive tape, band or the like. Where the bag is provided on an elongate member, it will be appreciated that the bag may be loaded onto the elongate member such that the elongate member is received within the interior of the bag. However, it is preferred that the elongate member supports the bag from the outside. This means that the elongate member will not come into contact with the interior of the bag which will contain the intended contents of the bag. This may be advantageous when seeking to avoid contamination of the bag prior to this being filled.

Where the bag is provided on an elongate member, the elongate member may be adjustable in length. In this way, prior to the introduction of the elongate member loaded with a bag into the interior of the hollow shell, the elongate member may have a reduced length. As or after the elongate member is introduced into the hollow shell, the length of the elongate member may be increased, positioning the bag within the hollow shell and extending through the dispensing aperture. This variation in the length of the elongate member may assist and speed up the loading of the bag into the hollow shell as the elongate member has less distance to move when it has a reduced length, and therefore can enter the hollow shell more quickly and easily in this form. Also, it is advantageous for the bag to be longer than the height of the shell to allow the bag to fill the interior of the shell. Adjustment of the length of the elongate member may be achieved by providing an elongate member with at least two portions telescopically connected together, such that the portions may slide with respect to each other to change the overall length of the elongate member. Alternatively, the elongate member could be formed in two parts that are moveable relative to each other to create a Z fold in the bag thereby shortening it.

Where the bag is provided on an elongate member, the elongate member may include a single elongate element, or a plurality of elongate elements arranged side-by-side. The elongate members may be in the form of a plate.

Where the bag is provided on an elongate member and a tape bridging the outer surface of the hollow shell and the outside of the neck of the bag is provided to secure the bag with respect to the shell, the tape may be provided before or after the elongate member is removed from the shell.

It is preferred that during formation of the hollow shell, a step is included to ensure the accurate position of the dispensing aperture of the shell with respect to at least one other part of the shell. In particular, it is advantageous to include a step to ensure that the distance between the dispensing aperture of the hollow shell and the opposite end of the hollow shell is a predetermined distance. This will ensure that the height of the dispensing aperture above the bottom of the hollow shell during subsequent operations is accurately known. It is preferred that this step comprises a cutting or slicing step to cut the spout at the dispensing aperture in a known location with respect to the opposite end of the hollow shell. By accurately cutting or slicing the spout to form the dispensing aperture, the position of the dispensing aperture can be more accurately formed than may be the case for a simple moulded shell. Where the hollow shell is moulded as an open shell, and is subsequently assembled to form the hollow shell, it is preferred that the cutting or slicing step takes place before the assembly of the open shell to form the hollow shell.

After the container has been assembled, the container can be filled and sealed.

The loading of the bag into the shell, the filling of the container, and the sealing of the container may be done on a single packaging line. Alternatively, the container may be formed and then transported to a separate location for filling.

According to a second aspect of the invention, there is provided a container formed in accordance with the first aspect of the invention.

SUMMARY OF THE DRAWINGS

The present invention will now be described with respect to the accompanying drawings, in which:

Figure 1 shows a perspective view of a hollow shell;

Figure 2 shows an end view of an open shell from which the hollow shell is formed;

Figure 3 shows a plan view of the open shell of Figure 2;

Figure 4 shows a sectional view of a bag;

Figure 5 shows a schematic view of the loading of a bag into a hollow shell;

Figure 6 shows the location of a bag in a spout;

Figures 7a to 7e show steps for loading a bag using an elongated member;

Figure 8 shows the extension of an elongated member;

Figure 9 shows a sectional view of a bag loaded into a shell using an elongated member; Figures 10a to 10c show the securing of the neck of a bag to a shell;

Figure 11 shows a plan view of a rotary turret;

Figure 12 shows a base along which a hollow shell is conveyed; and,

Figure 13 shows an alternative example of the loading of a bag into a shell.

DETAILED DESCRIPTION

In accordance with a preferred example for assembling a container, the first step is to form a hollow shell 10, such as shown in Figure 1. The hollow shell includes a spout with an open end defining a dispensing aperture 14. As shown in Figure 1 , the spout may be a short spout. It will be appreciated that the dispensing aperture, which is shown being smaller than the cross- sectional area of the shell, need not be defined by a spout, but may be a simple opening.

The hollow shell shown is moulded from pulp, such as wood or paper pulp. The pulp is diluted so that this can be a moulded. A mould is provided, typically in the form of a wire mesh, and the pulp is sucked onto the surface of the mould by applying a sucking force or vacuum. After moulding the component, the component is heated to evaporate the moisture, and solidify the shell. Where the shell is formed from paper pulp, rather than wood pulp, less dilution of the pulp is necessary, and therefore less energy is required to evaporate the moisture.

Both wood and paper pulp are biodegradable, and can themselves be recycled material. These are therefore preferred materials for forming a disposable container. However, other materials which need not be recycled or biodegradable, can be used.

As shown in Figures 2 and 3, the hollow shell 10 is moulded in an open condition. Figure 2 shows an end view of the open shell 10 from the spout end, and Figure 3 shows a plan view. As shown, the hollow shell 10 is formed with two half portions 12a, 12b formed side-by-side. At one end of each of the portions 12a, 12b, the end wall includes a depression 14a, 14b that each define a portion of a spout forming a dispensing aperture 14 when the hollow shell 10 is assembled.

It will be appreciated that a number of open shells can be nested together for storage and/or transportation.

Each of the portions 12a, 12b define part of the volume of the hollow shell 10. A flange 16a, 18a extends around portion 12a, and a corresponding flange 16b, 18b extends around portion 12b. The flanges are shown extending around the entire periphery of the respective portion of the shell other than at the depression 14a, 14b provided at the end to form the dispensing aperture. The flange 18a of portion 12a and the flange 18b of portion 12b are formed or joined together, defining a hinge 120. The hinge 120 is typically made thinner than the remainder of the flanges 18a, 18b to assist with the hinging of the portions 12a, 12b around the hinge 120. This may be achieved during moulding, or by a subsequent scoring step. By hinging the portions 12a, 12b about the hinge 120, the portions 12a, 12b are brought to face each other, defining an internal volume of the hollow shell 10 between the portions 12a, 12b. In this case, the hinge 120 extends along a longitudinal side of the hollow shell. The depressions 14a, 14b will also face each other, defining the dispensing aperture 14 formed by and between the walls of the depressions 14a, 14b. By providing a suitable adhesive on the flanges 16a, 16b, 18a, 18b, when the two portions 12a, 12b of the hollow shell 10 are hinged about the hinge 120 to face each other, the two portions 12a, 12b may be joined together by the adhesive adhering the flanges 16a, 16b, 18a, 18b to each other when the shell is closed. By using a pressure sensitive or contact adhesive in the flanges 16a, 16b, 18a, 18b, the adhesive may be applied to the flanges 16a, 16b, 18a, 18b while the hollow shell 10 is in an open condition, and the hollow shells 10 may be transported to another location before the open shells are folded to assemble the hollow shell 10. The flanges 16a, 16b, 18a, 18b can be joined by the application of pressure.

It will be appreciated that the flanges need not extend around the entire periphery of each portion of the hollow shell other than the dispensing aperture, but may extend only around part of the periphery. Also, it is understood that when an adhesive is used to join the two portions, this need not be applied along the entire length of the flanges. For example, the adhesive may be applied as discrete dots or patches on the flanges. Furthermore, some parts of the flanges may not have any adhesive. For example there may be no adhesive on the flanges 18a, 18b including the hinge 120.

Although the use of a pressure sensitive or contact adhesive has been described, it will be appreciated that other suitable adhesives may be used to join the flanges 18a, 18b and 16a, 16b of the shell. Alternatively or additionally, the flanges 18a, 18b and 16a, 16b may be attached by mechanical fasteners, such as pins or staples. In some embodiments, flanges may be omitted and the portions of the shell may be held with respect to each other to form the hollow shell by other means, for example by a band or film wrapped around the outside of the hollow shell 10. Although the hinge 120 is shown extending along one long side of the hollow shell 10, it will be appreciated that the hinge could be formed elsewhere, for example along the bottom of the shell or laterally along the side of the shell.

As will be described below, a bag is provided within the hollow shell 10 of the final container through the dispensing aperture, and the contents of the container will be held within the bag. Therefore, even when the container is to hold a fluid, it is not necessary for the join between the portions 12a, 12b of the hollow shell 10 to be fluid tight, since the contents are held within a bag provided within the hollow shell 10. Indeed, it is advantageous that the hollow shell 10 is not fluid tight so that air within the hollow shell 10 can be displaced through the hollow shell 10 as the bag is filled, and that air can pass through the walls of the hollow shell 10 to fill the volume as contents are dispensed from the bag. Allowing air to pass into the volume inside the hollow shell 10 as the contents are dispensed from the bag helps ensure smooth dispensing of the contents. The flow of air through the hollow shell 10 may be achieved using the porosity of the walls of the hollow shell 10, or by including a vent in the hollow shell 10. In the latter case, this is provided at a position where there is little risk of puncturing the bag.

By forming the hollow shell 10 from wood or paper pulp, the hollow shell 10 can easily be disposed of, since this is biodegradable, and therefore will decompose naturally. However, it will be appreciated that other materials may be used, and other formation techniques may be used. For example, it may be possible to mould the component as a single hollow component, without requiring the additional steps of folding and fixing as described above. It is not necessary that the hollow shell 10 is formed from biodegradable material, although this is clearly preferred. As an alternative, the shell may be formed from two or more components that are joined together to form the hollow shell. For example the portions 12a and 12b shown in Figures 2 and 3 may be formed as separate components, without the interconnecting hinge 120. In this case, rather than folding the portions with respect to each other to form the hollow shell, the portions are brought into alignment with each other.

In an alternative example, the hollow shell is not formed by moulding pulp. For example, the hollow shell may be formed by pressing material such as paper or cardboard, by folding a blank sheet to form the hollow shell, for example using a sheet of paper or cardboard, or by moulding from other materials.

In the example shown in Figure 1 , the hollow shell 10 is formed to include features such as a handle. A handle may assist a user in picking up the completed container, and in tilting the completed container to dispense its contents.

For the later assembly stages, and in particular for the connection of a bag with respect to the hollow shell 10, it is advantageous to ensure that the dimensions of the hollow shell 10, and in particular the height of the dispensing aperture 14 with respect to the opposite end of the container, is accurately known and is consistent for all containers. Where the hollow shell 10 is moulded as described above, the height of the dispensing aperture 14 with respect to the bottom of the shell may vary, for example depending upon the composition of the pulp, the drying characteristics etc. To ensure that the height of the dispensing aperture is accurate, the end of the spout forming the dispensing aperture 14 is cut off at a predetermined height above the base of the hollow shell 10. This ensures that even though other dimensions of the hollow shell 10 may vary, the distance and therefore position of the top of the dispensing aperture 14 from the opposite end of the hollow shell 10 is consistent and accurate.

After the hollow shell 10 has been formed and assembled, a bag is inserted into the hollow shell 10. The bag 20 may be formed from a suitable plasties material, such as polythene. It will be appreciated that where the container is to include food or beverage, the bag 20 should be made of a material that is of food standard. Suitable materials which are certified as being of food standard include the Starpol 2000, Starpol Blown Film and Polymer 2189/106 films available from Starpol RF Technologies Limited.

One example of a bag is shown in Figure 4. The bag 20 has a body 22 and a neck 24 which is open or openable. The body 22 of the bag 20 is sized and shaped to conform generally to the inner volume of the hollow shell 10, although advantageously has a slightly larger size and volume than the internal volume of the hollow shell 10. In this way, when the body 22 of the bag 20 is within the hollow shell 10 and is filled with the contents of the container, the body 22 of the bag 20 will be in contact with the inner wall of the hollow shell 10, thereby ensuring that the weight of the contents of the container is supported by the hollow shell 10 rather than by the bag itself. The neck 24 of the bag 20 is provided so that when the body 22 of the bag 20 is provided within the hollow shell 10, the neck 24 of the bag 20 extends through and beyond the dispensing aperture 14 of the hollow shell 10.

In one example, the neck 24 of the bag 20 includes a sealing means for closing and sealing the open neck 24 of the bag. One suitable sealing means is a ZIP seal as shown in Figure 4. In this case, one inner surface of the neck 24 of the bag 20 includes a male strip member 26. The opposed inner surface of the neck 24 of the bag 20 includes a female strip member 28 including two spaced elongate members that are able to receive and retain the male strip member 26. In other examples, the neck of the bag may be sealed by an adhesive material, for example wax, that temporarily joins the opposed surface of the neck of the bag, or by a more permanent seal such as by welding. In other examples, the neck of the bag may be left open.

The body 22 of the bag 20 will generally have a width greater than the maximum dimension of the dispensing aperture 14. Accordingly, in one example of the present invention, the body 22 of the bag 20 is rolled or folded such that it has a size able to pass through the dispensing aperture 14 of the hollow shell 10. The bag 20 may be held by tape, adhesive, clip or a band that is ruptured or removed when the body 22 of the bag 20 has been loaded into the hollow shell 10. In Figure 5 it can be seen that the side portions of the bag have been rolled or folded in so that the body of the bag is narrower than the neck. A band 23 is provided around the body 22 to hold this in its compacted condition. After the bag 20 has been loaded into the shell as described below, the body 22 can be expanded by injecting fluid into the bag 20. This can rupture the band 23, allowing the body 22 of the bag 20 to expand. The body 22 of the bag 20 is inserted through the dispensing aperture 14 and into the hollow shell 10, leaving the free end of the neck 24 of the bag 20 outside the hollow shell 10. As also shown in Figure 5, the folded bag 20 is held in alignment with the dispensing aperture 14 of the shell 10, and the bag 20 and shell 10 are moved with respect to each other. The bag 20 and shell 10 are moved towards each other until the body of the bag 22 is provided within the hollow shell and the neck portion of the bag 24 is extending through the dispensing aperture.

As illustrated in Figure 5, the bag can be hung or suspended from a suspension means (not shown) directly over the dispensing aperture of the hollow shell, and the bag and shell are moved towards each other, by raising the hollow shell. In one example, the bag may be inserted into the hollow shell on a conveyor system, for example on a rotary turret system. In such a system, the hollow shell is moved along a path with the bag being inserted into the hollow shell and secured with respect to the hollow shell as the hollow shell moves along the path. In a rotary turret system, this path is generally a circular path, the hollow shell engaging with a recess in a circular drive mechanism to cause the shell to move along the path.

Figure 11 shows a plan view of a rotary turret conveyor system. The system includes a star wheel 200 which is arranged to rotate about its axis as shown by arrow A. The star wheel includes openings 202 in its outer periphery, each of which are able to receive a hollow shell 10. As the star wheel 200 rotates, the hollow shells 10 are received within the openings 202 are conveyed around a path defined generally by the circumference of the star wheel 200. The openings 202 are slightly larger than the width of the hollow shells 10 allowing the hollow shells 10 to be raised and lowered whilst remaining within the openings 202.

As illustrated in Figure 11, a hollow shell 10a is fed into the opening 202a, for example from a feed conveyor (not shown). As the star wheel 200 is rotated, the hollow shell is moved around the circular path, as can be seen from a hollow shells 10b to 10e in openings 202b to 202e. As will be explained in more detail below, as the shell is moved around this path, it is loaded with a bag. The resulting container is then discharged from the star wheel 200, for example on a discharge conveyor (not shown) as can be seen from the illustrated container 10f discharged from opening 202f.

To load a bag 20 into a hollow shell 10, the bag 20 should be aligned with the dispensing aperture 14 of the shell 10. Where the hollow shell 10 is continually moved along a path, such as the circular path shown in Figure 11, the bag should also be moved along a similar path during the loading procedure so that there is no relative lateral movement between the bag 20 and the shell 10. In one example, this is achieved by suspending the bag from a support which rotates with the star wheel 200.

As described above with respect to Figure 5, one way to load a bag 20 into a hollow shell 10 is to move the hollow shell 10 towards the bag 20. With a conveyor arrangement, this can be achieved by including inclined portions along which the shell is conveyed. As shown in Figure 12, the support or base 250 along which the hollow shell 10 is conveyed includes an initial portion 252 as a first height where the hollow shell 10a is received in the opening 202a of the star wheel 200. The base 250 includes an inclined portion 254 to a second, higher, base portion 256. As the hollow shell 10 is conveyed along the base 250, and in particular along the inclined portion of 254, the shell 10 will rise. As described above, since the opening in the star wheel 200 is larger than the width of the hollow shell 10, the hollow shell 10 can continue to be conveyed whilst being raised. During this raising of the hollow shell 10, the main body 22 of the bag 20 will be received through the dispensing aperture 14 of the hollow shell.

Especially where the dispensing aperture 14 comprises a generally circular spout, the width of the neck 24 of the bag 20 will be greater than the diameter of the dispensing aperture 14. Accordingly, after the initial loading of the body 22 of the bag 20 into the dispensing aperture 14 of the shell 10, the opposed sides of the spout may be squeezed together, elongating the dispensing opening 14. This may be achieved by passing the dispensing aperture 14 between a pair of rollers. This will allow the neck 24 of the bag 20 past further into the dispensing aperture 14 of the hollow shell. To assist with this, the support base 250 may include a further inclined portion 258 and base 260 to further raise the hollow shell.

As described in more detail below, after the bag 20 has been loaded into the dispensing aperture 14 of the hollow shell 10, the neck 24 of the bag 20 may be secured with respect to the outside of the hollow shell 10, for example using a tape. This tape can be applied to bridge the outside of the hollow shell 10 and the neck of the bag 20 as the hollow shell is conveyed around the path by the star wheel 200.

Whilst it has been described that the hollow shells are conveyed around a generally circular path by a circular star wheel, it will be appreciated that the shells could be conveyed along a different path, for example a straight path. Alternatively, the bag and shell may remain in one position as the bag is introduced into the shell without conveying the bag and shell.

In another example, the hollow shell can be maintained at a constant height and the bag lowered into the shell.

Where the neck of the bag includes a zip seal, the hollow shell 10 may include grooves or notches 15a, 15b around the dispensing aperture 14 on the spout to receive the zip seal, and thereby locate the bag with respect to the shell as shown in Figure 6. This prevents the bag falling into the shell before it is attached to the shell. Where the bag does not contain a zip seal, the bag may be shaped to provide a portion receivable within the grooves or notches 15a, 15b to retain the bag in position. Where the hollow shell 10 includes grooves or notches 15a, 15b around the dispensing aperture 14 on the spout to receive a zip seal in the neck of the bag, the bag may be flattened to allow the neck of the bag to drop further into the hollow shell until the grooves or notches 15a, 15b communicate with the zip seal in the neck of the bag.

Rather than hanging or suspending the bag freely over the dispensing aperture, the bag may be supported on an elongate member that is inserted into the hollow shell to introduce the bag into the shell. This is illustrated in Figures 7a to 7e which show the picking of a bag 20 by an elongate support in the form of a vacuum picker 110 in preparation for the loading of the bag 20 into the hollow shell 10.

As shown in Figure 7, the bags 20 are provided in a stack of bags. The vacuum picker 101 is able to capture an individual bag 20 for loading into the hollow shell 10. In this case, the bags 20 may be connected together for ease of transport, and arranged such that the selected bag 20 can be pulled from the remainder of the bags 20, for example by tearing a web that connects the bags 20. In one example, the bags 20 may be wicketed, and held in place by a stop. The bags 20 can be held together by one or more pins 102.

As shown in Figure 7, the vacuum picker 101 is provided to select a bag 20 and remove this from the stack. The vacuum picker 101 comprises a generally hollow member having apertures in the side wall between the hollow interior and the outer surface. By applying a vacuum to the hollow interior of the vacuum picker 101 , a suction force is created through the apertures in the side wall. In this way, by bringing the vacuum picker 101 towards a bag 20 and applying the vacuum to the hollow interior of the vacuum picker 101 , the bag 20 will be sucked onto and held against the outer surface of the vacuum picker 101. By maintaining the vacuum within the interior of the vacuum picker 101, the bag 20 can be transported along with the vacuum picker 101 as required. As shown in Figure 7, after a bag 20 has been collected by the vacuum picker 101 , the vacuum picker 101 is rotated to remove the bag 20 from the stack. The vacuum picker 101 is then rotated about its axis to cause the bag 20 to be draped over the vacuum picker 101 (as shown in Figure 7) to provide additional holding and positioning of the bag 20 with respect to the vacuum picker 101. To assist with the loading the bag 20 into the hollow shell, the vacuum picker 101 may be further rotated about its longitudinal axis to roll the bag 20 around the outside of the vacuum picker 101 (as shown in Figure 7). Alternatively, the bag 20 could be folded or merely introduced into the hollow shell 10 whilst draped over the vacuum picker 101.

The overall length of the bag 20 should be longer than the length or height of the hollow shell 10 to ensure that there is sufficient length of bag 20 extending out of the dispensing aperture of the shell 10 to be secured with respect to the outside of the shell 10, and also to accommodate the volume required for the bag 20 when the container is filled. To assist with the rapid loading of the bag into the hollow shell, after the bag has been picked by the vacuum picker 101 , the vacuum picker 101 may be reduced in length, thereby contracting the overall length of the bag 20. As shown in Figure 8, this can be achieved by having a vacuum picker 101 comprising two or more parts 101a, 101b which are telescopically mounted with respect to each other, allowing these to contract. In this way, the vacuum picker 101 used to travel a shorter distance to fully load the bag 20 into the hollow shell 10 than would otherwise be the case.

Figure 9 shows the loading of the bag 20 into the hollow shell 10 of the container, through the dispensing aperture, using an elongate loading member. As shown, the vacuum picker 101 carrying a bag 20 wrapped around the vacuum picker 101 is inserted through the dispensing aperture 14 and into the inside of the shell. The vacuum picker 101 is then removed through the dispensing aperture, leaving the main body of the bag loaded in the hollow shell, with the neck portion of the bag extending through the dispensing aperture. The neck portion of the bag extending through the dispensing aperture of the shell can then be secured to the outside of the hollow shell as described in more detail below. Either before or after the neck of the bag is secured to the outside of the shell, the vacuum picker 101 can be retracted through the dispensing aperture of the hollow shell 10, leaving the bag 20 in place.

Although the elongate loading member has been described as a vacuum picker, it will be appreciated that other support members may be used, for example support members that are able to attract and hold a bag using an adhesive or electric charge.

Figure 13 shows an example of the loading of a bag 20 into the hollow shell 10 of the container - In this example, the hollow shell 10 includes an opening 105 provided generally opposite the dispensing opening 14. This opening 105 can be made larger than the dispensing opening 14 of the container, and is defined by two flaps 111 in the bottom of the shell 10. These flaps 111 may be formed with the remainder of the shell 10, and then folded back to form the opening 105. By having a larger opening through which the bag 20 is inserted into the hollow shell 10, the loading of the bag 20 is easier than if the bag 20 were loaded through the dispensing opening. Rather than a pair of flaps as shown in Figure 13, a single flap or a separate member, such as a cup or plug, may be used to close the opening.

To assist with the introduction of the bag 20 into the opening 105, a guide 124, such as a funnel, is provided in the opening 105 of the container.

As shown, a vacuum picker 110 carrying a bag 20 wrapped around the vacuum picker 110 is inserted into the inside of the shell 10 through the guide 124 and through the opening 105 in the container shell. The vacuum picker 110 is extended through the dispensing opening on the opposite side of the hollow shell 10. In this way, the main body of the bag is loaded into the hollow shell, with the neck portion of the bag extending through the dispensing opening 14. The vacuum picker 110 may include two parts that can be extended with respect to each other to increase the length of the vacuum picker 110 to extend the end carrying the neck of the bag 20 through the dispensing opening 14. The neck portion of the bag that has passed through the dispensing opening 14 of the shell can then be folded around the outside of the dispensing opening and sealed to the outside of the hollow shell or otherwise fixed with respect to the shell, for example using tape, as described herein. Either before or after the neck of the bag is sealed to the outside of the shell, the vacuum picker 110 can be retracted through the opening 105 of the hollow shell 10, leaving the bag 20 in place. After the vacuum picker 110 has been removed, the flaps 124 can be closed to close the hollow shell. This can be achieved through the use of shutter(s) 125 that close from each side of the shell to close the flaps to form the bottom of the container.

It will be appreciated that the bag could be loaded through an opening other than the dispensing aperture with or without the use of an elongate member.

Once the bag 20 is loaded into the hollow shell 10, the neck 24 of the bag 20 is attached with respect to the hollow shell 10. The example of securing the neck of the bag to the outside of the hollow shell by using an adhesive tape or the like will now be described with respect to Figures 10a to 10c. As shown in Figure 10a, the neck 24 of the bag 20 extends through the dispensing aperture 14. As shown in Figure 10b, the opposed sided of the spout are flattened towards each other. When the opposed sides of the spout are flattened towards each other, the neck of the bag may be arranged to drop further into the spout. This can be used as a means to ensure the bag is accurately positioned with respect to the dispensing aperture. When the opposed sides of the spouts are flattened towards each other, as shown in Figure 10c, a piece of tape 40 is adhered across the bridge between the outside of the spout of the shell 10 and the outside of the neck 24 of the bag 20. As shown in Figure 10c, adhesive 42 adhering the tape 40 to the spout, and adhesive 44 adhering the tape 40 to the neck 24 of the bag 20. It will be appreciated that the entire surface of the tape 40 facing the spout and neck of the bag may be coated with adhesive. It will also be appreciated that a single piece of tape 40 may extend around and be adhered to both sides of the spout and the neck of the bag, or separate pieces of tape may be provided on each side of the spout.

The primary function of the tape 40 is to secure the neck 24 of the bag 20 with respect to the hollow shell 10. This ensures that when the container is filled, the bag 20 is retained with respect to the dispensing aperture 14 of the hollow shell 10 enabling the container to be filled and emptied. By joining the neck 24 of the bag 20 to the outside of the spout using tape 40, it is relatively easy to remove the tape 40 from the spout when the contents of the container have been dispensed, and to then separate the bag 20 from the hollow shell 10.

A secondary function of the tape 40 is that this covers and protects the outside of the hollow shell 10 around the dispensing aperture 14. During dispensing of the contents of the container, it is possible that some of the contents will drip or run down the outside of the neck 24 of the bag 20. Should the contents be allowed to pass between the outside of the neck 24 of the bag 20 and the inside of the shell 10, they would come into contact with the shell 10, and may damage this. Further, any such content could become contaminated by contact with the shell, but this contaminated content could be dispensed when further content is dispensed. Providing a tape that bridges the neck 24 of the bag 20 and the outside of the shell 10 prevents any content passing between the bag 20 and the shell 10 and therefore avoids these problems. Furthermore, providing a tape covering the neck of the spout ensures that this vulnerable portion of the hollow shell 10 does not come into contact with the contents of the container as these are dispensed.

Alternatively or in addition to the tape 40, the neck 24 of the bag 20 may be secured to the inside of the spout of the hollow shell 10. This may be achieved using an adhesive provided on the inside of the wall 14a, 14b of the hollow shell 10 which comes into contact with the outer surface of the neck 24 of the bag 20 when the spout is flattened. However, where the attachment between the bag 20 and the hollow shell 10 in on the inside of the hollow shell 10, it becomes more difficult to separate the bag 20 from the shell 10 after use. Where an adhesive, such as a pressure sensitive or contact adhesive is provided on the flanges 16a, 16b, 18a, 18b of the shell to hold the portions of the shell together, a similar adhesive may b simultaneously or separately applied to the wall portions 14a, 14b to adhere to the neck 24 of the bag 20.

When all the contents have been dispensed, and it is desired to dispose of the package, the hollow shell 10 can be split open along the flanges that attach the two sides of the hollow shell 10, allowing the shell to open. The tape 40 may then be removed from the shell 10 and may be removed with the bag 20. The hollow shell 10 and the bag 20 may be disposed of separately. If necessary, the tape 40 may also be separated from the bag 20 to be disposed of separately.

In the preferred example, where the hollow shell 10 is formed from a biodegradable material, the shell can be disposed of on a compost heap. The bag 20, which may not be formed of a biodegradable material, can be either recycled, or can at least be disposed of in the most suitable way for such a material. It would be appreciated that the bag 20 itself could be formed from a material that decomposes, and in this case this could also be disposed of on a compost heap. In this case, the advantage of removing the bag 20 from the hollow shell 10 is that the two components can be disposed of in the most suitable way. A further advantage is that the shell 10 can be formed from a non-food standard material, which does not need to be moisture resistant, since the bag 20 separates the contents from the shell. In use, the container can be filled with liquid or other product to be packaged by introducing this through the open neck 24 of the bag 20. The contents are then stored in the container until they are dispensed through the dispensing aperture 14.

In a particular example, the container of the present invention may be used for containing milk. In this case, a number of open shells may be formed at one location. The shells can be cut to ensure that they are of the correct height, and nested together. The nested shells may then be transported to the dairy or other location where the milk is to be bottled. In this way, the volume of the transported products is minimised compared to the case where the shells are formed as hollow shells before shipping. The open shells may then be folded or otherwise formed to form the hollow shell at this location. In this case, adhesive may be applied to the open shell either before or after transportation.

The bags may also be formed away from the assembly location, and shipped to the assembly location. The bags may be folded prior to or after shipping. At the assembly location, the bags are loaded into the hollow shells, and attached to the hollow shells. The containers are then filled and sealed. The loading of the bag into the shell, the filling of the containers and the sealing of the containers may be done on a single packaging line.

It will be appreciated that the location at which the various steps in the formation of the container are carried out may be varied depending upon the particular application required.

Claims

1. A method of forming a container comprises the steps of: providing a hollow shell including a dispensing aperture; providing a bag having a body portion and a neck; inserting the bag into the hollow shell through an aperture in the hollow shell, with at least the neck of the bag extending through the dispensing aperture; and, securing the neck of the bag with respect to the hollow shell.

2. A method according to claim 1 , wherein the bag is inserted into the hollow shell through the dispensing aperture.

3. A method according to claim 1 or claim 2, wherein the neck of the bag is secured to the outer surface of the hollow shell.

4. A method according to claim 3, wherein tape is provided across the bridge between the outer surface of the hollow shell and the outside of the neck of the bag to secure the neck of the bag to the outer surface of the hollow shell.

5. A method according to claim 4, wherein the tape is an adhesive tape.

6. A method according to claim 4 or claim 5, wherein the dispensing aperture is defined by a spout which is at least partially flattened prior to applying the tape across the bridge between the outer surface of the hollow shell and the outside of the neck of the bag.

7. A method according to any one of the preceding claims, wherein the body of the bag is folded or rolled to reduce its dimensions, to allow it to pass through the dispensing aperture of the hollow shell.

8. A method according to claim 7, wherein the body of the bag is retained in the folded or rolled form by an adhesive, a tape, a band or a clip.

9. A method according to claim 8, wherein the body of the bag is expanded after the bag has been inserted into the hollow shell, by breaking or removing the adhesive, tape, band or clip.

10. A method according to any one of the preceding claims, wherein the bag is hung or suspended over the dispensing aperture of the hollow shell and the bag and shell are moved with respect to each other.

11. A method according to any one of the preceding claims, wherein the bag is supported on an elongate member, and is inserted into the hollow shell by inserting the elongate member through the dispensing aperture.

12. A method according to claim 11 , wherein the bag is supported by the elongate member by wrapping the bag around the elongate member, or by holding the bag on the elongate member using a suction force or an electrostatic force.

13. A method according to claim 11 or claim 12, wherein the elongate member is extended during or after insertion into the hollow shell.

14. A method according to any one of the preceding claims, wherein the hollow shell is formed from biodegradable material, such as wood and/or paper pulp, hemp or coconut husks.

15. A method according to any one of the preceding claims, wherein the neck of the bag includes a zip-seal.

16. A method according to claim 15, wherein the hollow shell includes a pair of opposed recesses, and wherein the opposed ends of the zip-seal are located in the opposed recesses when the bag is positioned within the hollow shell.

17. A method according to any one of the preceding claims, wherein the shell is cut or sliced at the dispensing aperture at a predetermined distance from the opposite end of the hollow shell prior to inserting the bag.

18.A method according to any one of the preceding claims, wherein the container is filled after the container has been assembled.

19.A method according to claim 18, wherein the container is sealed after the container has been filled.

20. A container formed in accordance with the method of any one of the preceding claims.