Container for Thermoplastic Pellets

Abstract

Disclosed are apparatuses and methods including incorporation of additives into a bulk materials container by coating, impregnating, or otherwise applying the additives to at least a portion of the container and/or the material comprising the container. The container may be intended for containing bulk material used in a batch or continuous process, where the container can be consumed by the process along with the bulk material. The additives incorporated into the container can be substances that may be used by the process. The additives can modify the process. The additives can modify and/or condition the product being formed by the process.

Claims

1. A container for thermoplastic pellets, comprising: a bag configured to contain the thermoplastic pellets, each of the bag and the thermoplastic pellets being configured to be consumed by a process, the bag comprising at least one color pigment; the process being used to produce a final product; and, the at least one color pigment configured to influence a color index of the final product.

2. The container recited in claim 1, wherein the at least one pigment is configured to at least one of modify the process, modify the final product, and condition the final product.

3. The container recited in claim 1, wherein the bag further comprises at least one additive in addition to the at least one color pigment.

4. A method of producing a container for thermoplastic pellets, comprising: generating a bag configured to contain thermoplastic pellets by including at least one color pigment with the bag by at least one of coating, impregnating, and applying the color pigment to the bag, wherein the bag is configured for use in a process to produce a final product, the bag and the thermoplastic pellets both configured to be consumed by the process; and, configuring the at least one color pigment to influence a color index of the final product.

5. The method recited in claim 4, wherein the configuring the at least one color pigment further comprises causing the at least one color pigment to at least one of modify the process, modify the final product, and condition the final product.

6. The container recited in claim 1, wherein the generating the bag further comprises including at least one additive in addition to the at least one color pigment.

7. A method, comprising: generating a bulk material comprising a first additive via a bulk material process, the first additive configured to be used in a first process to generate a first final product having a first specification, the first additive also configured to be used in a second process to generate a second final product having a second specification; generating a first container configured to contain the bulk material and configured to be consumed by the first process; generating a second container comprising a second additive, the second container configured to contain the bulk material and configured to be consumed by the second process; introducing the bulk material into the first container and the second container; introducing the first container with the bulk material into the first process to generate the first final product; and, introducing the second container with the bulk material into the second process to generate the second final product.

8. The method recited in claim 7, wherein the bulk material is thermoplastic pellets.

9. The method recited in claim 7, wherein at least one of the first container and the second container is a bag.

10. The method recited in claim 7, wherein at least one of the first final product and the second final product is at least one of paint, a coating, and an adhesive.

11. The method recited in claim 7, wherein at least one of the first additive and the second additive is a pigment.

12. The method recited in claim 7, wherein at least one of the first additive and the second additive is configured to influence a color index of at least one of the first final product and the second final product.

13. The method recited in claim 7, wherein the first additive is configured to generate the first final product having a first color index and the second additive is configured to generate the second final product having a second color index, wherein the first color index is different from the second color index.

14. The method recited in claim 7, further comprising a third process to generate a third final product having a third specification, wherein the first additive is also configured to be used in the third process to generate the third final product having the third specification.

15. The method recited in claim 14, further comprising a third container comprising a third additive, the third container configured to contain the bulk material and configured to be consumed by the third process.

16. The method recited in claim 15, further comprising introducing the bulk material into the third container.

17. The method recited in claim 16, further comprising introducing the third container with the bulk material into the third process to generate the third final product.

18. The method recited in claim 15, wherein at least one of the first additive, the second additive, and the third additive is a pigment.

19. The method recited in claim 15, wherein at least one of the first additive, the second additive, and the third additive is configured to influence a color index of at least one of the first final product, the second final product, and the third final product.

20. The method recited in claim 15, wherein the first additive is configured to generate the first final product having a first color index, the second additive is configured to generate the second final product having a second color index, and the third additive is configured to generate the third final product having a third color index, wherein the first color index, the second color index, and the third color index are different from each other.

21-26. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The above and other objects, aspects, features, advantages and possible applications of the present innovation will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings. Like reference numbers used in the drawings may identify like components.

[0016] FIG. 1 is a cross sectional view of an embodiment of a container that may be used.

[0017] FIG. 2 is an exemplary block diagram of a process that may be used with an embodiment of the container in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description is of exemplary embodiments that are presently contemplated for carrying out the present invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles and features of the present invention. The scope of the present invention is not limited by this description.

[0019] Referring to FIGS. 1-2, embodiments can include a container 2. The container 2 can include a bag, a box, a sack, a bladder, etc. The container 2 may be configured to contain bulk material 4. The bulk material 4 can be material intended to be used as part of a process 6. The process 6 can be a chemical process. The process 6 can be a batch type process, a continuous type process, or both. The process 6 can be used to produce a final product 8. The bulk material 4 can be configured to be used as input to the process 6. The input can be a fuel source, a chemical source, etc. For example, the bulk material 4 can be used to modify the process 6. In some embodiments, the bulk material 4 can be used to make, modify, and/or condition the final product 8. For example, the bulk material 4 can be plastic pellets (e.g., thermoplastic pellets) used for making, modifying, and/or conditioning paint (e.g., the final product 8) in a paint process 6. Other examples can include carbon 4 used for making, modifying, and/or conditioning steel 8 in steelmaking process 6, agglomerate 4 used for making, modifying, and/or conditioning sinter 8 in a sintering process 6, etc.

[0020] In some embodiments, at least a portion of the container 2 can be configured to be sacrificial. For example, the container 2 containing the bulk material 4 can be configured to be consumed by the process 6. In some embodiments, the container 2 can be configured to be consumed by the process 6 without having an effect on the process 6. In some embodiments, the container 2 can be configured to be consumed by the process 6 by having an effect on the process 6. This can include using the container 2 as an input to the process 6. The input can be a fuel source, a chemical source, etc. For example, the container 2 can be used to modify the process 6. In some embodiments, the container 2 can be used to modify and/or condition the final product 8.

[0021] In some embodiments, the container 2 can include at least one additive 10. This can include coating, impregnating, and/or otherwise applying the additive 10 to at least a portion of the container 2. Some embodiments can include generating a film on at least a portion of the container 2, the film including the additive 10. In addition, the additive 10 can be applied to the bulk material 4 within the container 2. The additive 10 can be configured to be used as input to the process 6. The input can be a fuel source, a chemical source, etc. For example, the additive 10 can be used to modify the process 6. In some embodiments, the additive 10 can be used to modify and/or condition the final product 8.

[0022] The additive 10 can be a pigment. However, other additives can be used, such as an element (e.g., powdered titanium, powdered carbon, iron pellets), a mineral (e.g., bauxite, halite, basalt), etc. The pigment 10 may include a fluorescent material, a phosphorescent material, other luminescent material, etc. The pigment 10 may be configured to modify the color, translucence, and/or reflectance of the final product 8.

[0023] The modification and/or conditioning caused by the bulk material 4 can be the same as or different from the modification and/or conditioning caused by the container 2 and/or the additive 10. The modification and/or conditioning caused by the container 2 can be the same as or different from the modification and/or conditioning caused by the bulk material 4 and/or the additive 10. The modification and/or conditioning caused by the additive 10 can be the same as or different from the modification and/or conditioning caused by the bulk material 4 and/or the container 2.

[0024] In some embodiments, the container 2 can include a bag 2. The bag 2 may be fabricated from paper, hemp, canvas, nylon, etc. The bag 2 can be configured to contain thermoplastic pellets 4. The thermoplastic pellets 4 may be intended for use in a painting process 6 to produce paint 8 or some other type of coating or adhesive. The painting process 6 may be a batch process, where bags 2 of thermoplastic pellets 4 can be introduced into the process 6 to provide a desired modification and/or conditioning to the paint 8. An additive 10 can be included with at least a portion of the bag 2. The additive 10 can be a color pigment 10. During the painting process 6, the bag 2, along with the thermoplastic pellets 4, may be consumed by the painting process 6. The consumption of the color pigment 10 in the process 6 can modify the color of the paint 8. The thermoplastic pellets 4 can be placed into a bag 2 without a color pigment 10 to be introduced into a painting process 6 to generate paint 8 having a first color. The thermoplastic pellets 4 can be placed into a bag 2 with a color pigment 10 to be introduced into the painting process 6 to generate paint 8 having a second color. The thermoplastic pellets 4 can be placed into a bag 2 with a different color pigment 10 to be introduced into a painting process 6 to generate paint 8 having a third color. Each of the painting processes 6 can be the same or different from each other. Each of the painting processes 6 can use the same thermoplastic pellets 4. Each of the painting processes 6 can generate paint 8 having different colors without having to modify the color pigment of the thermoplastic pellets 6 during production of the thermoplastic pellets 6.

[0025] Referring to FIG. 2, at least one implementation can include a bulk material formation process 12. This can include forming a bulk material 4. For example, thermoplastic pellets 4 may be formed by introducing at least one ingredient into an extruder 12. The bulk material 4 can be configured for use in a process 6 to form a final product 8. For example, the thermoplastic pellets 4 can be configured for use in a painting process 6 to form paint 8. At least one ingredient of the bulk formation process 12 can include a first additive 10a. The first additive 10a can be a first color pigment 10a, for example. The first additive 10a can be configured to generate a final product 8 having a first specification 14a. The first specification 14a can be a first color index 14a. For example, the first color pigment 10a can be configured to generate paint 8 having a first color index 14a. The first additive 10a may be suitable for a first process 6a and a second process 6b. For example, the first color pigment 10a may be suitable for a first painting process 6a and second painting process 6b. The first additive 10a may also be suitable for use in additional processes 6 (e.g., a third process, a fourth process, etc.). Any of the processes 6 can be the same or different from any other process 6.

[0026] A first container 2a can be generated. This may include generating a first bag 2a. The first container 2a may be configured to contain the bulk material 4. For example, the thermoplastic pellets 4 can be transported from the extruder to the first bag 2a. The first container 2a can be further configured to be an input to the first process 6a. The first container 2a, along with the bulk material 4 contained therein, may be transported to the first process 6a. The first container 2a, along with the bulk material 4 contained therein, may be introduced into the first process 6a to be consumed by the first process 6a. For example, the first bag 2a, along with the thermoplastic pellets 4 contained therein, may be introduced a heating kettle of the first painting process 6a. The consumption of the first additive 10a can modify the first process 6a and/or condition the final product 8 to cause the final product 8 to exhibit the first specification 14a. For example, the consumption of the first color pigment 10a can modify the first painting process 6a and/or condition the paint 8 to cause the paint 8 to exhibit the first color index 14a.

[0027] A second container 2b (e.g., a second bag 2a) can be generated. The second container 2b can be configured to contain the bulk material 4. For example, the thermoplastic pellets 4 can be transported from the extruder to the second bag 2b. The second container 2b can be further configured to be an input to the second process 6b. The second container 2b may include a second additive 10b. The second additive 10a can be a second color pigment 10b. For example, the second color pigment 10b may be applied to the second bag 2b. The second additive 10b may be configured to be an input to the second process 6b. The second container 2b, along with the bulk material 4 contained therein, may be transported to the second process 6b. The second container 2b, along with the bulk material 4 contained therein, may be introduced into the second process 6b to be consumed by the second process 6b. For example, the second bag 2b, along with the thermoplastic pellets 4 contained therein, may be introduced a heating kettle of the second painting process 6b. The consumption of the second additive 10b can modify the second process 6b and/or condition the final product 8 to cause the final product 8 to exhibit the second specification 14b. For example, the consumption of the second color pigment 10b can modify the second painting process 6b and/or condition the paint 8 to cause the paint 8 to exhibit the second color index 14b.

[0028] As noted above, there may be a third process 6, a fourth process 6, etc., each process 6 configured to generate a final product 8 having a third specification 14, fourth specification 14, etc., respectively. A bag 2 with an additive 10 may be generated for each process 6. The consumption of the bag 2 with the additive 10 can modify the process 6 and/or condition the final product 8 to cause the final product 8 to exhibit a third specification 14, fourth specification 14, etc.

[0029] The first specification 14a may be a first color index 14a. The second specification 14b may be a second color index 14b. The first color index 14a can be a white color having some yellowness. The second color index 14b can be a white color with less yellowness than that of the first color index 14a. Reducing the yellowness index can allow the paint 8 to appear whiter. Thus, the method can use the same thermoplastic pellets 4 in the first painting process 6a and in the second painting process 6b to produce a first paint 8a from the first painting process 6a and a second paint 8b from the second painting process 6b. The second paint 8b may have a reduced yellowness index as compared to the first paint 8a.

[0030] In some implementations, the bulk material formation process 12 can be configured to make only white thermoplastic pellets 4. For example, the first color pigment 10a may be a white pigment with some yellowness. This may be done to generate a first paint 8a via the first painting process 6a having a first color index 14a corresponding to the white with some yellowness color. The second bag 2a can include a second color pigment 10b of blue, for example. The second painting process 6b, consuming the second bag 2a and the thermoplastic pellets 4, can be used to generate a second paint 8b having a second color index 14b. The second color index 14b can correspond to a white color with reduced yellowness. Thus, the bag 2 can act as a delivery mechanism for the color pigment 10.

[0031] Examples of the reduction of yellowness index can be demonstrated by the Tables I and II below. Table I shows results of a first test (Test #1) and Table II shows results of a second test (Test #2). Each of Table I and II tested a ThermoDrop White TX Spray (JSW005) formulation used as the first pigment 10a for thermoplastic pellets 4. The test parameters for each test were set to assess property evaluations (e.g., color index) of the final product 8 with film change (e.g., change pigment 10 included with a bag 2). Test #1 and Test #2 were conducted by independent laboratory technicians. For each test, Ultramarine blue pigment was used as the pigment 10 applied to the bag 2. The Ultramarine blue pigment 10 was added at a fixed percentage for each bag 2. The application of the Ultramarine blue pigment 10 resulted in a blue bag film. White thermoplastic pellets 4 were contained in each bag 2. Three sets of bags 2 were made: 1) a set of clear bags (Clear Film); 2) a set of a mixture of blue film and clear film bags (0.94 g Blue Film @2% Blue+0.31 g Clear Film); and 3) a set of 100% blue film bags (1.25 g Blue Film @2% Blue). The film addition rate or 1.25 grams total can correspond to a projected film usage for a final product 8 packaged in a 4.5 mil batch inclusive bag 2. The results show that as the ratio of blue film increases, the final product 8 gets whiter (e.g., the yellowness index decreases)see the YD 1925 Yellowness Index line in the Tables. Other properties of the final product 8 were unaffected by the film change. The results demonstrate that the bag 2 can be used as a color modification delivery system for the final product 8.

[0032] It is contemplated that an orange film can have a similar effect for yellow formulated thermoplastic pellets 4 that may be packaged in a bag 2 including an orange film. It is further contemplated that other color pigments 10 can be used to make modifications to other color indexes 14.

TABLE-US-00001 TABLE I Test # 1 for Tinted Film Effect on Product Color (Ultramarine Blue in 4.5 mil Low Melt Batch Inclusive Bag. 0.94 g Blue Film Clear @2% Blue + 1.25 g Blue Film Test # 1 Film 0.31 g Clear Film @2% Blue Typical Formulation % Maleic Modified Glycerol Ester of Rosin 15.30 15.30 15.30 Plasticizer 1.50 1.50 1.50 Cold Flow and Viscosity Modifier 2.50 2.50 2.50 Flow Modifier (Elastomeric Polymer) 1.00 1.00 1.00 Bag Film 0.25 0.25 0.25 TiO2 (Rutile Grade 96% Pure) 10.50 10.50 10.50 Glass Beads (Type 1 70% Round) 35.00 35.00 35.00 Pellet Coating (Surface Treated) 1.00 1.00 1.00 CaCO3 Filler (STD 325 Mesh) 33.03 33.03 33.03 Binder (%) 20.55 20.55 20.55 Total (%) 100.08 100.08 100.08 Initial (400 F.) Viscosity Initial (400 F.) Viscosity w/SC4-27 Spindle 6 RPM 7750 8958 8042 12 RPM 5125 5854 5438 13 RPM 3525 3667 3633 60 RPM 2708 2833 2833 Color Measurement Color Measurement w/Byk Gardner 45/0 Brightness - L* (C/2) 94.05 93.76 93.17 Red/Green Color Scale - a* (C/2) 0.69 1.71 1.90 Blue/Yellow Color Scale - b* (C/2) 3.68 2.70 2.09 Brightness Y (C/2) 85.38 84.71 83.34 Color Coordinate - x (C/2) 0.3159 0.3127 0.3113 Color Coordinate - y (C/2) 0.3235 0.3223 0.3213 YD 1925 Yellowness Index (C/2) 6.82 4.15 2.83 Shore A Hardness (115 F.) 52 48 54 Ring and Ball Softening Point ( F.) 221 222 222 Weight in Air 1.963 4.651 3.71 Weight in Water 0.968 2.289 1.82 Specific Gravity 2.028 2.032 2.037

TABLE-US-00002 TABLE II Test # 2 for Tinted Film Effect on Product Color (Ultramarine Blue in 4.5 mil Low Melt Batch Inclusive Bag. 0.94 g Blue Film Clear @2% Blue + 1.25 g Blue Film Test # 2 Film 0.31 g Clear Film @2% Blue Typical Formulation % Maleic Modified Glycerol Ester of Rosin 15.30 15.30 15.30 Plasticizer 1.50 1.50 1.50 Cold Flow and Viscosity Modifier 2.50 2.50 2.50 Flow Modifier (Elastomeric Polymer) 1.00 1.00 1.00 Bag Film 0.25 0.25 0.25 TiO2 (Rutile Grade 96% Pure) 10.50 10.50 10.50 Glass Beads (Type 1 70% Round) 35.00 35.00 35.00 Pellet Coating (Surface Treated) 1.00 1.00 1.00 CaCO3 Filler (STD 325 Mesh) 33.03 33.03 33.03 Binder (%) 20.55 20.55 20.55 Total (%) 100.08 100.08 100.08 Initial (400 F.) Viscosity Initial (400 F.) Viscosity w/SC4-27 Spindle 6 RPM 8000 7333 8833 12 RPM 5375 5083 5563 13 RPM 3533 3408 3608 60 RPM 2708 2667 2758 Color Measurement Color Measurement w/Byk Gardner 45/0 Brightness - L* (C/2) 94.24 94.28 93.73 Red/Green Color Scale - a* (C/2) 0.83 1.35 2.24 Blue/Yellow Color Scale - b* (C/2) 4.67 3.50 3.40 Brightness Y (C/2) 85.83 85.92 84.65 Color Coordinate - x (C/2) 0.3175 0.3146 0.3133 Color Coordinate - y (C/2) 0.3254 0.3236 0.3240 YD 1925 Yellowness Index (C/2) 8.56 5.94 5.07 Shore A Hardness (115 F.) 53 57 56 Ring and Ball Softening Point (F.) 222 223 222 Specific Gravity 2.085 2.075 2.079

[0033] It should be understood that modifications to the embodiments disclosed herein can be made to meet a particular set of design criteria. For instance, the number of or configuration of containers 2, bulk materials 4, final product 8, additives 10, processes 6, bulk material formation processes 12, specifications 14, and/or other components or parameters may be used to meet a particular objective. For example, while exemplary implementations may show use of a first container 2a for a first process 6b and a second container 2b for a second process 6b, any number of containers 2 and processes 6 can be used. For example, an embodiment may include only a second container 2b for use with a second process 6b. As another example, there may be first, second, third, fourth, etc. processes 6. Any of the processes 6 can be the same as or different from any other process 6. Any process 6 can be configured to make a final product 8 that is the same as or different from another final product 8 made by another process 6. There may be a first, second, third, fourth etc. containers 2. Any of the containers 2 can be the same as or different from any other container 6. A container 6 may be configured for a single process 6 or multiple processes 6. Any container 6 can include any number of additives 10. Any of the additives 2 can be the same as or different from any other additive 6. Any number of bulk material processes 12 can be used. Any bulk material process 12 can be the same as or different from another bulk material process 12. Any number of bulk materials 4 can be used. Any bulk material 4 can be the same as or different from another bulk material 4. Any number of specifications 14 can be used. Any specification 14 can be the same as or different from another specification 14.

[0034] While exemplary embodiments disclose using the additive 10 for influencing a color index 14 of the final product 8, the additive 10 can be used for influencing any other specification 14 of the final product 8. For example, the additive 10 can be used to influence any other characteristic of the final product 8. For instance, the first specification 14a may be a first viscosity. The first additive 10a may be used by the first process 6a to generate a first final product 8a having the first viscosity. The second specification 14b may be a second viscosity. The second additive 10a may be used by the second process 6b to generate a second final product 8b having the second viscosity. Other specifications 14 of the final product 8 that may be influenced by the additives 10 can include, but are not limited to, a chemical composition, hardness, an electrical property, etc.

[0035] Therefore, while certain exemplary embodiments of apparatuses and methods of making and using the same have been discussed and illustrated herein, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.