Stitchless bulk bag including a baffle insert and method of production

Abstract

A stitchless baffle bulk bag including one or more baffle inserts that are heat sealed to a bag body using a hot melt film. A baffle insert includes a plurality of lateral straps spaced in between longitudinal panels. Tabs extend from the longitudinal panels into the space between lateral straps, above and below the lateral straps. The hot melt film is applied to at least a portion of the longitudinal panel and to the tabs, which is then heat sealed to the body under heat and pressure of heat seal bars. A hot melt sealed tab on both sides of the strap extending beyond the pivot point of the strap counters the forces of peel encountered by the strap and/or by a heat sealed joint of the tab or longitudinal panel.

Claims

1. A bulk bag comprising: a) a top portion; b) a body having an interior surface, and having a first side, a second side, a third side and a fourth side, and a first corner, a second corner, a third corner and a fourth corner, in an expanded configuration; c) a bottom portion; d) a baffle insert including: (i) at least a pair of longitudinal members with a plurality of lateral members spaced in between the longitudinal members; (ii) a plurality of tabs, each tab extending laterally away from one said longitudinal member and into a space in between two said lateral members or into a space above or below a said lateral member; (iii) hot melt film applied to at least a portion of an exterior surface of the pair of longitudinal members along a length of said longitudinal members; (iv) the hot melt film also applied to a tab exterior surface of each of the plurality of tabs; e) a joint formed between the interior surface of the body and the portion of the longitudinal members that includes the hot melt film and said joint formed between the tabs that include the hot melt film, wherein the joint is formed by applying heat and pressure to fabric of the interior surface, the hot melt film, the longitudinal members and the tabs; and f) wherein the baffle insert is positioned in the body so that it extends from the first side to the second side across the first corner with the lateral members positioned along a diagonal across the first corner when the body is in the expanded configuration.

2. The bulk bag of claim 1 wherein four baffle inserts are included in the bulk bag at each of the first, second, third and fourth corners.

3. The bulk bag of claim 2 wherein the hot melt film extends along an entire exterior surface of each of the longitudinal members of the four baffle inserts.

4. The bulk bag of claim 1 wherein the baffle insert comprises four longitudinal members and comprises a tubular shape and each of the four longitudinal members are coupled to the interior surface of the body so that respective lateral members extend across each of the first, second, third or fourth corners along a diagonal.

5. The bulk bag of claim 4 wherein the hot melt film does not extend along an entire exterior surface of each of the longitudinal members of the baffle insert.

6. The bulk bag of claim 1 wherein during heat sealing to form the joint, the body is in a folded gusseted configuration including a pair of body gussets and the baffle insert is folded and overlapped with at least one of the body gussets when the heat and pressure is applied.

7. The bulk bag of claim 2 wherein during heat sealing, the body is in a folded gusseted configuration including a pair of body gussets and two of the baffle inserts are folded and overlapped with one of the body gussets and the other two of the baffle inserts are folded and overlapped with the other body gusset.

8. The bulk bag of claim 3 wherein during heat sealing, the body is in a folded gusseted configuration including a pair of body gussets and the baffle insert is gusseted in a folded gusseted configuration including two baffle gussets and the baffle gussets are overlapped with the body gussets.

9. The bulk bag of claim 1 wherein the plurality of tabs counter peel forces exerted on the joint when the bulk bag is filled with bulk material and/or lifted.

10. The bulk bag of claim 1 wherein the plurality of baffle insert counters both peel and tensile forces exerted on the joint when the bulk bag is filled with bulk material and/or lifted.

11. The bulk bag of claim 1 wherein said tabs that are on both sides of one said lateral member extend beyond a pivot point of said lateral member at a junction of said lateral member and the longitudinal member and counters forces of peel encountered by said lateral member and the longitudinal member.

12. The bulk bag of claim 9 wherein each tab extends at least 2 inches laterally away from the longitudinal member and into the space above or below a said lateral member.

13. The bulk bag of claim 1 wherein said lateral members are free and are not connected to the body.

14. The bulk bag of claim 13 wherein the plurality of tabs protect the joint at a pivot point located where one said lateral member that is free extends away from one said longitudinal member that is coupled to the body at the joint.

15. The bulk bag of claim 1 wherein the body is connected to the top portion and to the bottom portion with heat sealed joints.

16. The bulk bag of claim 1 wherein the body is connected to the top portion and to the bottom portion with stitched seams.

17. A method of forming a heat-sealed baffle body portion that is stitchless, comprising the following steps: a) obtaining a body portion that is a tubular piece of flexible plastic fabric or polyester fabric and that has an interior surface, a first side, a second side, a third side and a fourth side, and a first corner, a second corner, a third corner and a fourth corner, and which has an expanded configuration; b) obtaining one or more baffle inserts that each include: (i) at least a pair of longitudinal members with a plurality of lateral members spaced in between the longitudinal members; (ii) a plurality of tabs, each tab extending laterally away from one said longitudinal member and into a space in between two said lateral members or into a space above or below a said lateral member; (iii) hot melt film applied to at least a portion of an exterior surface of the pair of longitudinal members along a length of said longitudinal members; (iv) the hot melt film also applied to a tab exterior surface of each of the plurality of tabs; c) folding the body portion into a body folded or gusseted configuration; d) folding the one or more baffle inserts into an insert folded or gusseted configuration; e) overlapping the body portion while in the body folded or gusseted configuration with the one or more baffle inserts while in the insert folded or gusseted configuration so that the hot melt film on the one or more baffle inserts is in contact with the interior surface of the body portion; and f) applying heat and pressure to overlapped layers formed in step (e) of the one or more baffle inserts and the body portion to melt the hot melt film and form a joint between the body portion and the one or more baffle inserts.

18. The method of claim 17 wherein during heat sealing in step (f) an upper heat seal bar of a heat seal machine rocks in an end to end or lengthwise direction and a mating lower seal bar rocks in a side to side or widthwise direction to facilitate even heating through overlapped layers, even in areas where fabric thicknesses differ.

19. A stitchless baffle body portion comprising: a) a body that is a tubular piece of flexible plastic fabric or polyester fabric and that has an interior surface, a first side, a second side, a third side and a fourth side, a first corner, a second corner, a third corner and a fourth corner, and which has an expanded configuration; b) one or more baffle inserts made from a flexible plastic fabric or a polyester fabric that each include: (i) at least a pair of longitudinal members with a plurality of lateral members spaced in between the longitudinal members; (ii) a plurality of tab portions, each tab portion extending laterally away from one said longitudinal member and into a space in between two said lateral members or into a space above or below a said lateral member; (iii) hot melt film applied to at least a portion of an exterior surface of the pair of longitudinal members along a length of said longitudinal members; (iv) the hot melt film also applied to a tab exterior surface of each of the plurality of tabs; c) one or more heat sealed joints coupling the one or more baffle inserts to the interior surface of the body, wherein a said heat sealed joint comprises the following layers: (i) body fabric, hot melt, tab portion fabric; or (ii) body fabric, hot melt, longitudinal portion fabric; and d) wherein at least a portion of the plurality of lateral members are free and not coupled to the body.

20. A heat sealing method of manufacturing a baffle bulk bag comprising the following steps: a) overlapping an upper portion of the baffle body portion of claim 19 while in a baffle folded or gusseted configuration with a top portion while the top portion is in a top folded or gusseted configuration so that a baffle body heat seal coating on an exterior surface of the baffle body portion is in contact with a top heat seal coating on an interior surface of the top portion; b) overlapping a lower portion of the baffle body portion of claim 19 while in the baffle folded or gusseted configuration with a bottom portion while the bottom portion is in a bottom folded or gusseted configuration so that the baffle body heat seal coating on the exterior surface of the baffle body portion is in contact with a bottom heat seal coating on an interior surface of the bottom portion; and (c) applying heat and pressure to overlapped layers formed in steps (a) and (b) to melt at least one of the said baffle body heat seal coating or top heat seal coating in the overlapped layers of step (a) and to melt at least one of the said baffle body heat seal coating or bottom heat seal coating in the overlapped layers of step (b) to form a top heat sealed joint between the baffle body portion and the top portion and a bottom heat sealed joint between the baffle body portion and the bottom portion.

21. The bulk bag of claim 1 wherein the top portion, body portion, baffle insert and bottom portion are made from flexible plastic fabric or polyester fabric.

22. The bulk bag of claim 1 wherein the top portion, body portion, baffle insert and bottom portion are made from flexible polypropylene fabric.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein;

(2) FIG. 1 is an exploded view of a first preferred embodiment of the apparatus of the present invention including a first preferred embodiment of a baffle insert of the present invention that is tubular;

(3) FIG. 2 is a front view of the first preferred embodiment of the apparatus of the present invention;

(4) FIG. 3 is a sectional view of the first preferred embodiment of the apparatus of the present invention taken along lines 3-3 of FIG. 2;

(5) FIG. 4 is a sectional view of the first preferred embodiment of the apparatus of the present invention taken along lines 4-4 of FIG. 2;

(6) FIG. 5 is a top view of the apparatus shown in FIG. 2;

(7) FIG. 6 is a top view of a second preferred embodiment of a baffle insert that can be included in one or more preferred embodiments of the apparatus of the present invention that is tubular, in folded, gusseted configuration;

(8) FIG. 7 is another top view of the baffle insert of FIG. 6 in folded, gusseted form;

(9) FIG. 8 is an end view of the baffle insert of FIG. 6 in folded, gusseted form;

(10) FIG. 9 is another front view of the first preferred embodiment of the apparatus of the present invention;

(11) FIG. 10 is another exploded view of the first preferred embodiment of the apparatus of the present invention;

(12) FIG. 11 is a detail cutaway top view of the first preferred embodiment of the apparatus of the present invention;

(13) FIG. 12 is a partial exploded view of the first preferred embodiment of the apparatus of the present invention;

(14) FIG. 13 is another detail cutaway top view of the first preferred embodiment of the apparatus of the present invention;

(15) FIG. 14 is top view of a third preferred embodiment of a baffle insert that can be included in one or more preferred embodiments of the apparatus of the present invention;

(16) FIG. 15 is a perspective view of a body portion that can be used in one or more preferred embodiments of the apparatus of the present invention;

(17) FIG. 16 is a front view of a body portion shown in FIG. 15;

(18) FIG. 17 is a detail view of a body portion shown in FIG. 16;

(19) FIG. 18 is a top view of a body portion shown in FIG. 15 in folded/gusseted configuration;

(20) FIG. 19 is an end view of a body portion shown in FIG. 18; and

(21) FIG. 20 is a detail view of a second preferred embodiment of the apparatus of the apparatus of the present invention in folded, gusseted configuration and including a fourth preferred embodiment of a baffle insert;

(22) FIG. 21 is another detail view of a second preferred embodiment of the apparatus of the apparatus of the present invention in folded, gusseted configuration and including a fourth preferred embodiment of a baffle insert;

(23) FIG. 22 is another detail view of a second preferred embodiment of the apparatus of the apparatus of the present invention in folded, gusseted configuration and including a fourth preferred embodiment of a baffle insert;

(24) FIG. 23 is a partially expanded view of a second preferred embodiment of the apparatus of the apparatus of the present invention including a fourth preferred embodiment of a baffle insert;

(25) FIG. 24 is another partially expanded view of a second preferred embodiment of the apparatus of the apparatus of the present invention including a fourth preferred embodiment of a baffle insert;

(26) FIG. 25 is top view of a fourth preferred embodiment of a baffle insert that can be included in one or more preferred embodiments of the apparatus of the present invention;

(27) FIG. 26 is an end view of a fourth preferred embodiment of a baffle insert in a folded configuration;

(28) FIG. 27 is a top view of a bag body portion and the fourth preferred embodiment of a baffle insert in an overlapped, gusseted configuration;

(29) FIG. 28 is a top view of a bag body portion and the fourth preferred embodiment of a baffle insert in an overlapped, gusseted configuration after heat sealing;

(30) FIG. 29 is a top view of the second preferred embodiment of the apparatus of the apparatus of the present invention including the fourth preferred embodiment of a baffle insert;

(31) FIG. 30 is a partial perspective view of a heat sealing machine of the present invention for heat sealing a baffle insert to a bag body portion;

(32) FIG. 31 is a partial end view of a heat sealing machine of the present invention for heat sealing a baffle insert to a bag body portion;

(33) FIG. 32 is a partial end view of a heat sealing machine of the present invention for heat sealing a baffle insert to a bag body portion;

(34) FIG. 33 is detail view of heat seal bars of the heat sealing machine of FIG. 30;

(35) FIG. 34 is detail view of heat seal bars of the heat sealing machine of FIG. 30;

(36) FIG. 35 is a perspective view of a main body of a heat seal bar as shown in FIGS. 33-34;

(37) FIG. 36 is an end view of the main body of a heat seal bar as shown in FIG. 35;

(38) FIG. 37 is a front view of the main body of a heat seal bar as shown in FIG. 35;

(39) FIG. 38 is a bottom view of the main body of a heat seal bar as shown in FIG. 35;

(40) FIG. 39 is a front view of the main body of a heat seal bar as shown in FIG. 35;

(41) FIG. 40 is a front view of a tension end cap of a heat seal bar as shown in FIGS. 33-34;

(42) FIG. 41 is a rear view of a tension end cap of a heat seal bar as shown in FIGS. 33-34;

(43) FIG. 42 is a side view of a tension end cap of FIG. 41;

(44) FIG. 43 is another side view of a tension end cap of FIG. 41;

(45) FIG. 44 is a perspective view of a carrier plate that can be used in a preferred embodiment of the method of the present invention;

(46) FIG. 45 is a top view of a carrier plate that can be used in a preferred embodiment of the method of the present invention;

(47) FIG. 46 is a perspective view of a heat seal assembly line production area in a preferred embodiment of the method of the present invention;

(48) FIG. 47 is a top view a heat seal assembly line production area in a preferred embodiment of the method of the present invention;

(49) FIG. 48 illustrates heat-sealing 4 baffle inserts to a bag body portion in a preferred embodiment of the method of the present invention, with the overlapped portion taken along lines 48-48 of FIG. 27;

(50) FIG. 49 is a close up detail view of FIG. 48;

(51) FIG. 50 illustrates heat-sealing 4 baffle inserts to a bag body portion in a preferred embodiment of the method of the present invention, with the overlapped portion taken along lines 50-50 of FIG. 27;

(52) FIG. 51 is a close up detail view of FIG. 50;

(53) FIG. 52 illustrates a preferred embodiment of the method of the present invention of heating sealing bulk bag portions together between heat seal bars;

(54) FIG. 53 is a illustrates a preferred embodiment of a heat sealed joint of a bulk bag of the present invention taken along lines 53-53 of FIG. 52;

(55) FIG. 54 illustrates a preferred embodiment of the method of the present invention of heating sealing bulk bag portions together between heat seal bars;

(56) FIG. 55 illustrates a preferred embodiment of a heat sealed joint of a bulk bag of the present invention taken along lines 55-55 of FIG. 54;

(57) FIG. 56 illustrates an image of a swivel mount bracket of preferred embodiment of the present invention; and

(58) FIG. 57 illustrates a lower heat seal bar coupled in a heat seal machine using a swivel mount as shown in FIG. 56.

DETAILED DESCRIPTION OF THE INVENTION

(59) FIGS. 1 to 13 illustrate a first preferred embodiment of the apparatus of the present invention designated generally herein by the numeral 10. The first preferred embodiment 10 of the apparatus of the present invention is sometimes referred to herein as a baffle bulk bag. The first preferred embodiment of the apparatus of the present invention as shown in the figures includes a baffle insert of the present invention that is tubular and is generally designated herein by the numeral 4. A first preferred embodiment of a baffle insert 4 is shown in FIGS. 1, 4, 10-13. A second preferred embodiment of a baffle insert 4 is shown in FIGS. 6-8. Either the first or second preferred embodiments of a baffle insert 4 can be included in a baffle bulk bag 10 as desired. In the different embodiments of a baffle insert 4, the shape of straps or lateral members 9 are different, but otherwise the features of the preferred embodiments of a baffle insert 4 that is tubular as shown in the drawings are at least substantially the same or similar.

(60) A second preferred embodiment of the apparatus of the present invention, designated generally herein by the numeral 50, is shown in FIGS. 14-29, 48-55. The second preferred embodiment 50 of the apparatus of the present invention is sometimes referred to herein as a baffle bulk bag. The second preferred embodiment of the apparatus of the present invention as shown in the figures includes third or fourth preferred embodiments of a baffle insert of the present invention, which is designated herein generally by the numeral 40. The third preferred embodiment of a baffle insert 40 is shown in FIG. 14. The fourth preferred embodiment of a baffle insert 40 is shown in FIGS. 20-29. Either the third or fourth preferred embodiments of a baffle insert 40 can be included in a baffle bulk bag 50 as desired. In the different embodiments of a baffle insert 40, the shape of straps or lateral members 9 are different, but otherwise the features of the preferred embodiments of a baffle insert 40 as shown in the figures are at least substantially the same or similar.

(61) Referring to FIGS. 1-5, 9-13, 15-29, a baffle bulk bag 10 or 50 of the present invention preferably includes a fill spout/fill tube 1, a top/top portion 2, a body/body portion 3, a baffle insert 4 or 40, a bottom/bottom portion 6, and discharge tube/discharge spout 7. In some embodiments, a discharge tube cover 54 (see, e.g., FIG. 29, sometimes referred to as a diaper, can also be included in a baffle bulk bag 10, 50, and reference is made to U.S. Pat. No. 10,745,192 for more details on a discharge tube cover 54. A body 3 can have side walls 33, 34, 35, 36. If desired, a bottom insert or reinforcer 5 can also be included in a baffle bulk bag 10, 50 and reference is made to U.S. Pat. No. 11,319,144, which is incorporated herein by reference, for more detail on including a bottom insert or reinforcer 5.

(62) A fill spout 1 can have opening 55. A top portion 2 can have opening 11. A baffle insert 4 can having opening 12. A body 3 can have opening 13. A bottom insert or reinforcer 5 can have opening 14. A bottom 6 can having opening 15. A discharge tube 7 can have opening 16.

(63) Preferably a baffle bulk bag 10, 50 is manufactured so that joints between fill spout 1 and top 2, between top 2 and body 3, between body 3 and bottom 6 and between bottom 6 and discharge tube 7 are formed via a heat sealing method. If a bottom insert 5 is included, preferably the joint coupling an insert 5 to bottom 6 and discharge tube 7 is also formed via a heat sealing method. Preferably the said joints are all formed via heat sealing so that a containment area of the baffle bulk bag 10, 50 does not include any stitch or sewing holes. A baffle bulk bag 10, 50 can also include one or more lift loop assemblies, wherein preferably a patch 52 of a lift loop assembly is joined to an exterior of a bag body 3 with a heat sealed joint. A lift loop assembly can include a patch 52 with a lift loop 51 stitched to patch 52 or heat sealed to patch 52 (see, e.g., FIGS. 20, 22, 29). Reference is made to the following patents and/or patent applications, which are incorporated herein by reference, for more details on some preferred methods on how to form a bulk bag as described above with joints formed via heat sealing: i) U.S. patent application Ser. No. 14/297,441, filed on 5 Jun. 2014, titled METHOD OF PRODUCTION OF FABRIC BAGS OR CONTAINERS USING HEAT FUSED SEAMS, published as No. US2014/0363106 on 11 Dec. 2014, and issued as U.S. Pat. No. 10,112,739, on 30 Oct. 2018; ii) International PCT Patent Application No. PCT/US2014/041155, filed on 5 Jun. 2014, titled METHOD OF PRODUCTION OF FABRIC BAGS OR CONTAINERS USING HEAT FUSED SEAMS, published as No. WO2014/197728A1 on 11 Dec. 2014; iii) U.S. patent application Ser. No. 15/345,452, filed 7 Nov. 2016, titled INDUSTRIAL BAG DISCHARGE SPOUT, published as No. US2018/0050863A1 on 22 Feb. 2018, and issued as U.S. Pat. No. 10,745,192, on 18 Aug. 2020; iv) International PCT Patent Application No. PCT/US2017/060411, filed 7 Nov. 2017, titled INDUSTRIAL BAG DISCHARGE SPOUT, published as No. WO2018/085843A1 on 11 May 2018; v) U.S. patent application Ser. No. 15/383,841, filed 19 Dec. 2016, titled INDUSTRIAL BAG LIFT LOOP ASSEMBLY, published as No. US2018/0118451A1 on 3 May 2018, and issued as U.S. Pat. No. 10,479,599 on 19 Nov. 2019; vi) International PCT Patent Application No. PCT/US2017/067393, filed 19 Dec. 2017, titled INDUSTRIAL BAG LIFT LOOP ASSEMBLY, published as No. WO2018/118975A1 on 28 Jun. 2018; vii) U.S. patent application Ser. No. 15/807,272, filed 8 Nov. 2017, titled CARRIER PLATE FOR USE IN MANUFACTURING STITCHLESS BULK BAGS WITH HEAT FUSED SEAMS, published as No. US2018/0126661A1 on 10 May 2018, and issued as U.S. Pat. No. 10,618,225 on 14 Apr. 2020; viii) International PCT Patent Application No. PCT/US2017/060652, filed 8 Nov. 2017, titled STITCHLESS BULK BAG WITH HEAT FUSED SEAMS AND METHOD OF PRODUCTION, published as No. WO2018/089504A1 on 17 May 2018; ix) U.S. patent application Ser. No. 16/126,635, filed on 10 Sep. 2018, titled METHOD OF PRODUCTION OF FABRIC BAGS OR CONTAINERS USING HEAT FUSED SEAMS, published as US 2019/0185212A1 on 20 Jun. 2019 and issued as U.S. Pat. No. 10,974,869 on 13 Apr. 2021; X) U.S. patent application Ser. No. 17/007,509, filed on 31 Aug. 2020, titled BULK BAG BOTTOM AND DISCHARGE ASSEMBLY INCLUDING A REINFORCER, issued as U.S. Pat. No. 11,319,144 on 3 May 2022; xi) U.S. patent application Ser. No. 17/007,828, filed on 31 Aug. 2020, titled LIFT LOOP ASSEMBLY TEST PROCESS AND APPARATUS; xii) U.S. patent application Ser. No. 17/219,398, filed on 31 Mar. 2021, titled METHOD OF PRODUCTION OF FABRIC BAGS OR CONTAINERS USING HEAT FUSED SEAMS, published as No. US 2021/0284392A1 on 16 Sep. 2021 and issued as U.S. Pat. No. 11,279,523 on 22 Mar. 2022; xiii) U.S. patent application Ser. No. 17/330,668, filed on 26 May 2021, titled HEAT SEAL BAR SENSORLESS TEMPERATURE SENSING AND CONTROL; xiv) U.S. patent application Ser. No. 16/796,521, filed 20 Feb. 2020, titled HEAT SEAL BAR ASSEMBLY, published as No. US2020/0254697A1 on 13 Aug. 2020, and issued as U.S. Pat. No. 11,338,527 on 24 May 2022; xv) U.S. patent application Ser. No. 17/697,572, filed on 17 Mar. 2022, titled METHOD OF PRODUCTION OF FABRIC BAGS OR CONTAINERS USING HEAT FUSED SEAMS, published as No. US2022/0274740A1 on 1 Sep. 2022; xvi) U.S. patent application Ser. No. 17/715,406, filed 7 Apr. 2022, titled STITCHLESS BULK BAG WITH HEAT FUSED SEAMS AND METHOD OF PRODUCTION, published as No. US2022/0297388A1 on 22 Sep. 2022; and xvii) U.S. patent application Ser. No. 17/731,727, filed on 28 Apr. 2022, titled BULK BAG BOTTOM AND DISCHARGE ASSEMBLY INCLUDING A REINFORCER.

(64) A baffle insert 4 of either the first or second preferred embodiments of a baffle insert of the present invention as shown in FIGS. 1-13 preferably has an irregular tubular shape with four longitudinal panels or longitudinal members 8. Longitudinal panels 8 can have a rectangular or at least a substantially rectangular shape. A plurality of straps or lateral members 9 extend in between longitudinal panels 8 along a diagonal, e.g., preferably at an angle of, or between about, 30 to 45 degrees. The plurality of straps are preferably spaced apart along a longitudinal length of longitudinal panels 8, preferably with spaces 29 left in between two different straps 9.

(65) A preferred width ratio of tab 17 to strap 9 width is 1.3 inch. For example, under a current most preferred embodiment, there is a 1.5 inch tab 17 width at base of a tab 17 to 2 inch strap 9 width at a base of strap 9, and this is the currently most preferred strap 9 width and ratio of tab 17 (and space 29) width to strap 9 width. This ratio can change due to increased adhesion ability of a hot melt film 21. If the adhesion ability of hot melt film 21 increases, then tab 17 width can decrease in relationship to strap 9 width. On the other hand, if the adhesion ability of hot melt film 21 decreases, then tab 17 width would need to increase. With the current preferred formulation of hot melt film 21 using a hot melt film from Cattie Adhesives, this ratio can vary up to 10%. As long as this ratio is maintained, the number of straps 9 can increase or decrease per linear foot without materially affecting the overall strength of a bag 10, 50. For example, if straps 9 are spaced too far apart a bag 10, 50 will try to round out more between the straps 9 than if straps 9 are closer together.

(66) A plurality of tabs 17 extend from each longitudinal panel 8 in a lateral direction into a space 29 that is in between two straps 9. Preferably a tab 17 is located above and below each strap 9 at both ends of each strap 9. Thus, as shown in the figures, some tabs 17 are also located above the topmost straps 9 and some tabs 17 are also located below the bottommost straps 9. A topmost tab 17 can extend to top 27 of a longitudinal panel 8. A bottommost tab 17 can extend to bottom 28 of a longitudinal panel 8. Referring to FIG. 6, tabs 17 are shown in shading.

(67) Referring now to a second preferred embodiment of a baffle bulk bag, designated by the numeral 50, a plurality of baffle inserts designated by the numeral 40 (instead of a single tubular baffle insert 4) are included in a baffle bulk bag 50. A third preferred embodiment of a baffle insert, designated by the numeral 40 is shown in FIG. 14. Baffle insert 40 has a pair of longitudinal panels or members 80. Longitudinal panels or members 80 can have a rectangular or an at least substantially rectangular shape. A plurality of straps or lateral members 9 extend in between longitudinal panels 80 along a diagonal, e.g., preferably at an angle of or between about 30 to 45 degrees. The plurality of straps 9 are spaced apart along a longitudinal length of longitudinal panels 80, preferably with spaces 29 left in between two different straps 9. A plurality of tabs 17 extend from each longitudinal panel 80 in a lateral direction into a space 29 that is in between two straps 9. Preferably a tab 17 is located above and below each strap 9 on both ends of each strap 9. Thus, as shown in the figures, some tabs 17 are also located above the topmost straps 9 and some tabs 17 are also located below the bottommost straps 9. A topmost tab 17 can extend to top 27 of a longitudinal panel 80. A bottommost tab 17 can extend to bottom 28 of a longitudinal panel 80.

(68) A fourth preferred embodiment of a baffle insert is designated generally by the numeral 40 in FIGS. 20-24. This embodiment of baffle insert 40 is substantially the same as the third preferred embodiment shown in FIG. 14 except the straps 9 have a rectangular or at least substantially rectangular shape, whereas the straps 9 in FIG. 14 have a curvature or curved shape. The shape of straps 9 in FIGS. 20-24 are currently the most preferred configuration.

(69) A baffle insert 4 or 40 can be made of the same flexible plastic fabric as body 3, e.g., preferably uncoated (e.g., without a laminate type coating or other heat sealing coating, e.g., a propylene plastomer or elastomer coating, thereon), woven polypropylene fabric. Preferably, instead of using a heat sealing coating as described in the applications incorporated herein by reference, hot melt 21 film is applied to desired portions of an insert 4, 40.

(70) The shape of straps 9 can be changed if desired, e.g., straps 9 can have a shape of the first or second preferred embodiments of baffle insert 4, or of the third or fourth preferred embodiment of a baffle insert 40, or another desired shape. A shape of a strap 9 included in a baffle insert 40 can also be included in a baffle insert 4 and vice versa. But, in all embodiments of a baffle insert 4 or 40, preferably at least some space 29 is left in between straps 9 to enable bulk material contained in a baffle bulk bag 10 or 50 to flow through the spaces 29 and fill corners 20 of a baffle bulk bag 10 or 40.

(71) Portions of exterior surface 25 of a longitudinal panel 8 or 80 and exterior surfaces 31 of tabs 17 of baffle insert 4 or 40 are preferably coupled to an interior surface 26 of body 3 via a heat sealing method as shown in FIGS. 48-49. Body 3 interior surface 26 can be uncoated flexible plastic fabric, e.g., uncoated, woven polypropylene fabric. Hot melt 21 in a film form preferably is applied to the exterior surfaces 31 of tabs 17 and portions of exterior surface 25 of longitudinal panels 8 or 80 that will be joined to interior surface 26 of body 3.

(72) In FIG. 12, a detail view of a first preferred embodiment of insert 4 is shown while in an expanded configuration, e.g., illustrating the shape of insert 4 when it is in baffle bulk bag 10 when filled with bulk material. The shaded portions of tabs 17 and longitudinal panel 8 represent the preferred area where hot melt 21 is applied. The shaded area represents a location where a heat seal joint 32 will be formed between baffle insert 4 and body 3.

(73) FIG. 13 is a cutaway top detail view of a baffle bulk bag 10 that does not include a top 2 or fill spout 1 thereon. The figure illustrates joints 32 formed via a heat sealing method that are coupling body 3 and two tabs 17 together and coupling body 3 and portions of a longitudinal panel 8 together, with the hot melt 21, preferably in film form, in between body 3 and tabs 17, and in between body 3 and portions of a longitudinal panel 8, as shown in a detail view in the joint 32 formed connecting baffle insert 4 to sidewall 33 of body 3.

(74) When baffle insert 4 is coupled to body 3, preferably each longitudinal panel 8 is positioned about centrally on a body 3 sidewall 33, 34, 35, or 36 and the straps 9 extend across corners 20 at a diagonal, e.g., preferably at an angle of, or between, about 30 to 45 degrees from one side wall, e.g., side wall 36, to another side wall, e.g., side wall 33 (see FIGS. 11, 13). In FIG. 11, arrow 22 represents a width of longitudinal panel 8 of baffle insert 4 positioned about centrally along a body 3 side 34.

(75) Along right and left sides of longitudinal panel 8, hot melt 21 film can be applied longitudinally, e.g., preferably at about a two-inch width (designated by arrows 24 in FIG. 12) of hot melt 21 film applied continuously along an exterior surface 25 of a longitudinal length of a right side of longitudinal panel 8 from top 27 to bottom 28 to a right edge 38, and preferably about a two-inch width of hot melt 21 film applied continuously along a longitudinal length of a left side of longitudinal panel 8 from top 27 to bottom 28 to a left edge 37. The width (designated by arrows 24 in FIG. 12) of hot melt 21 film applied along right and left sides of longitudinal panel 8 can also be about 1.5 to 4 inches. All of a panel 8 also potentially could include hot melt 21 film thereon, but testing has showed this is not necessary to achieve desired strength of the joint.

(76) Preferably, hot melt 21 in film form is applied continuously to an entire exterior surface 31 of a tab 17 along a length of tab 17 (designated by arrows 23 in FIG. 12). A tab 17 can extend preferably about 2 inches into space 29 between straps 9, or about 2 inches into a space above or below a strap 9. A tab 17 can also extend about 1.5 to 4 inches into space 29 between straps 9, or into space above or below a strap 9. Preferably a tab 17 is located on both sides of a strap 9 a distance extending beyond pivot point 94 of a strap 9, so that tab 17 can counter or overcome peel forces on strap 9 at the intersection 53 of strap 9 with the bag body 3 and/or longitudinal member 8, 80. A pivot point 94 is a point or location where straps 9 make contact with the bag sidewalls, at a transition area or intersection 53 where straps 9 (which are free and not coupled to a bag body) start to extend away from longitudinal portion 8 or 80 that is coupled with a heat sealed joint to a bag body 3.

(77) Preferred heat sealing methods of heat sealing the first, second, third and fourth preferred embodiments of a baffle insert 4, 40 to bag body 3 will now be discussed.

(78) FIGS. 15-19 illustrate a baffle body 140 of baffle bulk bag 10, that preferably includes a body 3 with a baffle insert 4 therein. Body 3 is preferably a tubular piece of flexible plastic fabric, e.g., polypropylene fabric, that can be folded/gusseted as shown in FIGS. 18 (which is a top view) and 19 (which is an end view). Body 3 is folded as shown in FIGS. 18-19 in a folded/gusseted heat sealing configuration when on a carrier plate 150 and ready to be heat sealed to a top 2 and bottom 6 in a heat sealing machine/baffle heat seal machine 110, e.g., as shown in FIGS. 46-47. Body 3 preferably has a heat sealing coating on an exterior surface that is used in a heat sealing process of forming heat sealed joints with top 2 and bottom 6. An over edge coating 64 portion is preferably included as shown in the FIGS. 16, 17, 19. Body 3 has two open end portions 62, 63 and two fabric edge portions 61 that are not open. Reference is made to U.S. Pat. Nos. 10,618,225 and 10,112,739 for further details on this process.

(79) In FIGS. 6-8 a second preferred embodiment of a baffle insert 4 is shown. In FIGS. 7 and 8, baffle insert 4 is folded/gusseted in a heat-sealing configuration. FIG. 7 illustrates a top view of a folded/gusseted baffle insert 4 that is ready to be inserted into a bag body 3, that is also in a folded/gusseted configuration (see FIGS. 18-19), and to be heat sealed thereto. FIG. 8 illustrates an end view of baffle insert 4 in folded, gusseted configuration. A first preferred embodiment of a baffle insert 4 as shown in FIGS. 1-4, for example, can also be folded/gusseted to form a similar folded/gusseted heat sealing configuration and coupled to a bag body 3 in the same manner as described herein with regard to the second preferred embodiment of a baffle insert 4 as shown in FIGS. 6-8.

(80) Baffle insert 4, in a folded/gusseted heat sealing configuration as shown in FIGS. 7 and 8 can be inserted into body 3 while body 3 is in a folded/gusseted heat sealing configuration as shown in FIGS. 18 and 19. Baffle insert 4 when folded/gusseted has two opposing longitudinal 8 portions drawn inward at sides of the baffle insert 4 to form gussets 41 and 42. Gusset 41 has two gusset edges 43, 44 and gusset 42 has two gusset edges 45 and 46. Portions of straps 9 are also pulled inward at the gussets 41, 42. Preferably gussets 41 and 42 are drawn inward but do not touch one another as shown in the figures.

(81) Body 3 in gusseted configuration as seen in FIGS. 15-19 also has two gussets 69 and 70 formed by drawing opposing fabric edges 61 of body 3 inward. Gusset 69 has two edges 65, 66, and gusset 70 has two edges 67 and 68. Preferably the fabric of gussets 69 and 70 are drawn inward but do not touch one another as shown in the figures.

(82) When heat sealing baffle insert 4 to body 3, the baffle insert 4 is inserted into body 3 with gusset 41 of baffle insert 4 overlapped with gusset 69 of body 3, and with gusset 42 of baffle insert 4 overlapped with gusset 70 of body 3. Preferably the overlapping occurs so that hot melt 21 film on tabs 17 and longitudinal panel 8 is in contact with interior surface 26 of body 3 and aligned about centrally on a side wall of body 3 whether the sidewall is on a top layer of fabric, bottom layer of fabric, or part of a gusset in the folded configuration.

(83) The overlapped baffle insert 4 and body 3 can be moved into a heat sealing machine 110 wherein heat seal bars, e.g., upper and lower heat seal bars, can move into contact with top and bottom surfaces of the gusseted and overlapped body 3 and apply heat and pressure to melt the hot melt 21 film that will then join body 3 to tabs 17 and longitudinal panel 8. Preferably a temperature of about 275 degrees Fahrenheit and about 90 second dwell time is used during heat sealing. Since the body 3 is fully gusseted, a single pair of seal bar assemblies 101, 102 can be used to heat seal a baffle insert 4 to body 3 at all four corners. After heat sealing to form joints 32 coupling body 3 to baffle insert 4 a baffle body 140 is formed and baffle body 140 can open up or expand to a configuration as shown in FIG. 3 with straps 9 extending across body 3 corners 20 along a diagonal, and with a triangular space 30 formed at corners 20 behind straps 9.

(84) Four baffle inserts 40, either of the third preferred embodiment as shown in FIG. 14 or of the fourth preferred embodiment as shown in FIG. 25, can be coupled to a bag body 3 (e.g., as shown in FIGS. 15-19, 20-29) of a baffle bulk bag 50, instead of using a singular tubular baffle insert 4. The shaded portions of FIG. 14 and FIG. 25 illustrate portions of longitudinal panel 80 and tabs 17 having hot melt 21 applied in film form to exterior surfaces 25 and 31. For a baffle insert 40, preferably all of a longitudinal portion 80 has hot melt film 21 thereon and preferably all of each tab portion 17 has hot melt film 21 thereon. This shading also represents where a heat seal joint will be formed between baffle insert 40 longitudinal panels 80 and an interior surface 26 of body 3 and between baffle insert 40 tabs 17 and an interior surface 26 of body 3. Fold line 96 in FIGS. 14, 25, 26 represents where a baffle insert 40 is preferably folded in half to form a folded heat sealing configuration of a baffle insert 40 as shown in an end view in FIG. 26.

(85) When using baffle inserts 40 to form a baffle bulk bag 50, four baffle inserts 40 can be coupled to body 3 across corners 20 of body 3. Hot melt 21 in film form is preferably applied onto exterior surface 31 of tabs 17 and an exterior surface 25 of longitudinal panels 80 for four baffle inserts (one to extend across each corner 20 of body 3) in the shaded area as shown in FIGS. 14, 25, 26. The four folded baffle inserts 40 (one for each corner) are then folded in half (see FIG. 26), e.g., at fold line 96 and inserted into a fully gusseted body 3 (see FIGS. 18-19).

(86) A baffle insert 40 as shown in FIGS. 14, 25 can be folded in half, e.g., about centrally at fold line 96. Baffle inserts 40 can then be inserted into an interior of body 3 gussets 69 and 70 (see FIGS. 48, 50). As shown in FIGS. 19, 48, 50, interior surface 26 of body 3 can have eight interior portions 86, 87, 88, 89, 90, 91, 92, 93 within gussets 69, 70 to which respective baffle inserts 40 will be heat sealed to. One folded baffle insert 40 will be inserted so that the hot melt 21 is in contact with interior surfaces 86 and 87 of folded area 82. One folded baffle insert 40 will be inserted so that the hot melt 21 is in contact with interior surfaces 88 and 89 of folded area 83. One folded baffle insert 40 will be inserted so that the hot melt 21 is in contact with interior surfaces 90 and 91 of folded area 84. One folded baffle insert 40 will be inserted so that the hot melt 21 is in contact with interior surfaces 92 and 93 of folded area 85. A body 3 with four baffle inserts 40 overlapped therein is then placed under heat seal bar assemblies 101, 102 in a machine 110. Since body 3 is fully gusseted, a single pair of heat seal bar assemblies 101, 102, preferably including upper and lower heat seal bars 95 can be used to heat seal all four baffle inserts 40 to body 3 at one time. After heat sealing, joints 32 are formed coupling body 3 to four baffle inserts 40 to form a baffle body 140. Baffle body 3 can open up or expand to a configuration similar to what is shown in FIG. 3 with straps 9 extending across body 3 corners 20 along a diagonal.

(87) A carrier plate 150, described further below herein, can be adapted to also receive the overlapped body 3 and baffle insert 4, 40 if desired and to be moved into heat seal machine 110 during heat sealing. Stops and/or guides can be added to heat seal machine 110 to receive a carrier plate 110 and facilitate proper alignment of an overlapped body 3 and baffle insert 4 or 40 in a machine 110.

(88) FIGS. 20-22 are close up detail views of a body 3 of a bag 50 with four baffle inserts 40 that have been coupled to an interior surface 26 of body 3 using hot melt 21 and a heat sealing process of the present invention. In FIGS. 20-22, body 3 is in a folded, gusseted configuration with baffle inserts 40 folded and overlapped in the gussets 69, 70. In FIG. 20, a top view of the folded, gusseted body is shown with the location of baffle inserts 40 coupled to the interior of body 3 shown in phantom view. The joints 32 are in the location of tabs 17 and longitudinal portion 80.

(89) In FIG. 21, an interior surface view of gussets 69, 70 of the folded/gusseted baffle bag 50 as shown in FIG. 20 is illustrated partially opened at one end with baffle straps 9 folded backward to illustrate that baffle straps 9 are free and not coupled to body 3, whereas tabs 17 and panels 80 are coupled to body 3. In FIG. 22, an exterior surface of gussets 69, 70 of the folded/gusseted baffle bag 50 as shown in FIG. 20 is shown partially opened and illustrates how two baffle inserts 40 overlap one another in the different folded areas of gussets 70, 69.

(90) FIGS. 23-24 are partial interior detail views of a body 3 as shown in FIGS. 20-22 when expanded or unfolded and opened. The figures illustrate the location of a baffle insert 40 at a corner 20 of body 3 when body 3 is open/expanded. These views also illustrate how straps 9 are free and not coupled to body 3.

(91) FIG. 27 is a top of view of baffle body 140 in a folded/gusseted configuration with four folded baffle inserts heat sealed therein. The top two folded baffle inserts 40 are shown in phantom view. The shading on tabs 17 and 80 represent a heat sealed joint 32 where hot melt film 21 that is on tabs 17 and panel 80 melted under heat and pressure from seal bars 95 of heat seal bar assemblies 101, 102 to form a heat sealed joint 32 in the shaded areas as shown in FIG. 27.

(92) In FIG. 28, the rectangular portions designated by the numeral 95 indicate schematically the location on a body 3 (that is in folded/gusseted configuration) where a top or upper heat seal bar 95 of a heat seal bar assembly 101, 102 will make contact with an exterior surface 98 of body 3.

(93) FIG. 48 is a sectional view of a body 3 overlapped with four baffle inserts 40 taken along lines 48-48 of FIG. 27 placed between heat seal bars 95 of heat seal bar assemblies 101, 102. FIG. 50 is a sectional view of body 3 overlapped with four baffle inserts 40 taken along lines 50-50 of FIG. 27 placed between upper and lower heat seal bars 95 of heat seal bar assemblies 101, 102.

(94) Heat and pressure applied to exterior surface 98 of body 3 from heat seal bar assemblies 101, 102 will travel below exterior surface of body 3 through all the layers of fabric of body 3 and baffle insert 40 and holt melt 21 while in folded/gusseted configuration and overlapped together as shown in FIGS. 48-51. As shown, heat and pressure from heat seal bar assemblies 101, 102 melts hot melt 21 on tabs 17 and longitudinal panels 80 to form a heat sealed joint 32 between tabs 17 and an interior surface 26 of body 3 and between longitudinal panels 80 and an interior surface 26 of body 3. A portion of straps 9 are also under heat and pressure from heat seal bar assemblies 101, 102, but a heat sealed joint is not formed between a strap 9 and interior portion 26 of body 3 so that strap 9 remains free to expand across a corner 20 when body 3 is unfolded and expanded to an open configuration.

(95) FIG. 49 is a detail view of FIG. 48 showing layers in a heat sealed joint 32 formed between a tab portion 17 and body 3 and between longitudinal panel 80 and body 3. Arrows 103 represent a junction between tab portion 17 and a longitudinal panel 80 when tab 17 moves into a space 29 between straps 9.

(96) A baffle insert 4, 40 preferably is sealed within a body 3 without overlapping with other bag portions. A baffle body 140 having a body 3 with a baffle insert 4, 40 coupled thereto can then be put into a heat seal assembly line production method as described further below to complete a baffle bulk bag 50.

(97) FIG. 51 is a detail view of FIG. 50 showing layers in a heat sealed joint formed between a body 3 and between longitudinal panel 80. A strap 9 is shown free in this view without a joint coupling strap 9 to body 3. Arrows 94 represent a pivot point and/or junction at the location where longitudinal panel 80 transitions to a strap 9 that is free and not coupled to body 3.

(98) FIGS. 30-34 illustrate a baffle heat seal machine 110 having a pair of heat seal bar assemblies 101, 102, which preferably include upper and lower heat seal bars 95. A baffle heat seal machine 110 can be the same or similar mechanically and electrically to a body sealing machine and loop assembly sealing machine as disclosed in U.S. Pat. Nos. 10,618,225 and 11,338,527, which are incorporated herein by reference, except that the heat seal bar assemblies 101, 102 are adapted to heat seal a baffle insert 4 or 40 of the present invention to a body 3. Heat seal bars 95 of a heat seal bar assembly 101, 102, for example, are preferably 4 inches wide, whereas a heat seal bar used to heat seal a top 2 to a body 3 for example are preferably 2 inches wide. Also, a machine 110 is adapted to support the pair of heat seal bar assemblies 101, 102 in a longitudinal direction, whereas heat seal bars used to seal a body 3 to a top 2 and bottom 5, for example, are positioned in a lateral direction in a body heat sealing machine.

(99) A baffle heat seal machine 110 as shown in the figures includes a table 111 having legs 112. A top 105 of table 111 is adapted to accommodate the pair of lengthwise heat seal bar assemblies 101, 102, each having upper and lower seal bars 95 and includes openings 120. A pair of frames or bridge assemblies 113 can support pneumatic cylinders 114 adapted to raise and lower upper heat seal bars 95. Air tubing or lines 115 can connect a pneumatic cylinder 114 to a heat seal bar 95. Water lines or tubing 116 can be included as part of a heat seal bar 95 to enable cooling of heat seal bars 95 during a cool down time of the process, after applying heat and pressure to a body 3.

(100) A bar code reader 117 can be included if desired. Guide edges 106 and end stop 107 can also be included on the machine to help position and assure proper alignment of a gusseted body 3 with baffle insert 4, 40 overlapped therewith in the machine, e.g., to ensure a body 3 with a baffle insert 4 or 40 overlapped therewith is in proper position in a baffle heat seal machine 110 wherein heat seal bar assemblies 101, 102 are properly aligned above and under the area to be heat sealed. As described, a body 3 and overlapped insert 4, 40 can be manually placed in a machine 110 and guide edges 106 and end stop 107 can be used to ensure proper alignment of the overlapped body 3 and insert 4, 40 with the seal bar assemblies 101, 102. The heat seal bar assemblies 101, 102 can be positioned at about sixteen (16) inches from center to center in a heat sealing machine 110. If desired, a baffle carrier plate that is similar to a carrier plate 150 can also be used to properly place a body 3 and overlapped insert 4, 40 in a machine 110 and guide edges 106 and end stop 107 can be adapted and moved if necessary to ensure proper alignment of a baffle carrier plate with the body 3 and overlapped insert 4, 40 thereon with heat seal bar assemblies 101, 102. To make a baffle carrier plate or carrier, openings 151 can be adjusted and changed to accommodate baffle heat seal bar assemblies 101, 102, for example.

(101) FIGS. 35 to 43 illustrate a heat seal bar 95 body 97 that is part of heat seal bar assemblies 101, 102. Upper heat seal bars 95 can be coupled to pneumatic cylinders 114 with brackets 118, 119. FIG. 34 illustrates a rear yoke assembly 118 with slots for rocking an upper heat seal bar 95 into lengthwise alignment with a lower heat seal bar 95. Bracket 118 can be the same as disclosed in U.S. Pat. No. 11,338,527. A rocking motion during heat sealing enables more even application of heat and pressure, wherein a bolt or pin of a bracket connection 118 can move side to side in the slotted opening 120. Preferably a front attachment bracket 119 has a circular opening, or at least a substantially circular opening that enables rotation or pivoting of a bolt or pin therein while the bolt or pin in the slotted opening of bracket 118 is moving side to side. Reference is made to U.S. Pat. No. 11,338,527 for more details on enabling a rocking motion in heat seal bar assemblies, and in particular to FIGS. 106-108, 180-183 and related discussion in U.S. Pat. No. 11,338,527. The rocking and pivoting motions of upper heat seal bars 95 of heat seal bar assemblies 101, 102 can be the same or similar as described with regard to a body heat sealing machine in U.S. Pat. No. 11,338,527.

(102) Referring to FIGS. 56-57, FIG. 56 is a view of a swivel leveling mount or bracket 129 that can be used in the present invention to enable a widthwise, or left to right, or side to side, rocking motion of a lower heat seal bar 95. Swivel leveling mount or bracket 129 can have an end 136 with openings 134, e.g., threaded openings that can enable attachment to a machine 110, for example, to part of a frame 137 of a machine 110 table 111. Swivel leveling mount or bracket 129 can also have a hex head or nut portion 133 and body 132 including a threaded section 131 at end 135. Threaded section 131 can be screwed into an opening 138 on a bottom of seal bar body 97. A ball 130 can enable the side to side rocking described herein. Preferably a swivel leveling mount or bracket 129 is a high capacity acme threaded leveling swivel mount. Preferably a swivel leveling mount or bracket 129 is a made from zinc plated steel.

(103) FIG. 57 illustrates a lower heat seal bar 95 mounted on two swivel mounts with a swivel bracket 129 at a front and a rear position on lower heat seal bar 95. The swivel mounts allow a slight rocking motion of a lower seal bar 95 during heat-sealing in a left to right direction, or widthwise, or side to side direction, to be in parallel to its mating upper seal bar 95 in order to accommodate slight fabric thickness variations across the width of the heat seal bars 95 (e.g., four inches). Preferably a lower seal bar 95 is not raised or lowered but remains in position with only the side to side rocking.

(104) In the heat sealing machines of U.S. Pat. No. 11,338,527, for example, it was preferred, and only necessary to have an upper heat seal bar have a rocking motion when using heat seal bars that were two inches wide to facilitate even heat sealing over different thickness areas of a piece of fabric. During experimentation when using a wider heat seal bar 95 that is four inches wide for example, it was found that the increased width increased a chance of mis-alignment of upper and lower heat seal bars 95 due to fabric thickness variations. In general, an impact of the fabric thickness variations is a direct function of width. For heat sealing baffle inserts 4 or 40 to a body 3, it is preferred to have a lower seal bar 95 rock in a widthwise or side to side direction while an upper seal bar 95 is rocking in a lengthwise or end to end direction into alignment with the lower seal bar 95 using a slotted yoke bracket and pivot yoke bracket as described in U.S. Pat. No. 11,338,527, for example. Upper seal bars 95 also preferably can be raised to an open position, e.g., when not performing a heat sealing function, e.g., in a manner as described in U.S. Pat. No. 11,338,527. The view as shown in FIG. 31 is a closed position, whereas FIGS. 48, 50 illustrate the seal bar assemblies 101, 102 open where an upper heat seal bar 95 is raised and can be lowered to a closed position.

(105) A heat seal bar 95 can be the same or similar to a seal bar as disclosed in U.S. Pat. No. 11,338,527 (e.g., see in particular FIGS. 104-106, 183 and related discussion in U.S. Pat. No. 11,338,527) or the same or similar to a seal bar as disclosed in U.S. patent application Ser. No. 17/330,668, filed on May 26, 2021 if it is desired to use a sensorless temperature sensing and control system and method (see e.g., FIGS. 2, and 69-70 and related discussion). The dimensions of seal bar 95 can be changed and adapted to enable heat-sealing the desired area of a baffle insert 4 or 40 to body 3. The length and width of a seal bar 95 can be changed based on the dimension of a bulk bag 10, 50 and the dimensions of a baffle insert 4 or 40 to be heat sealed thereto. For example, generally in the industry baffle bulk bags heights range from 30 to 80 (30 to 80 inches) tall with baffles typically ranging from 39 to 71 (39 to 79 inches) in length. A baffle heat seal machine 110 preferably can include heat seal bars 95 adapted to include heating elements that are at or about 39 to 71 (39 to 79 inches) in length to accommodate currently preferred baffle bulk bag dimensions.

(106) Preferably a width of a heating element on a heat seal bar body 97 can be about 4 inches to enable heat sealing about a 2-inch width portion of a longitudinal panel 8 or 80 to a body 3 as well as tabs 17 to body 3 having about a 2-inch length. The width of a heating element can also be about 1 to 6 inches, for example if desired, depending on the width of the area of a baffle insert 4 or 40 to be heat sealed. A length of a heating element can preferably be about 76.6 inches long, or 50 to 100 inches long for example, depending on the length of a baffle insert 4 or 40. A height of a seal bar 97 can be about 2 to 3 inches.

(107) A heat seal bar 95 can have a heat seal bar body 97 having seal bar ends 121, 122. A plurality of openings 123 can be included on each side of a heat seal bar body 97 for receiving a plurality of water lines or tubes 116. A plurality of openings 124, 126 can be included on ends 121, 122 of heat seal bar 97 for receiving a desired fastener 127, 128, 181, e.g., springs, nuts, pins, and washers, screws bolts for coupling end caps 125 to each heat seal bar end 121, 122. An end cap 125 can have a plurality of openings 180 for also receiving a fastener 127, 128, 184. A heating element (not shown) is also included in a heat seal bar 95 with an insulator (not shown) in between the heating element and heat seal bar body 97. Reference is made to U.S. Pat. No. 11,338,527 and U.S. patent application Ser. No. 17/330,668 for more information on heat seal bar components.

(108) If using a heat seal bar apparatus as disclosed in U.S. patent application Ser. No. 17/330,668, then heat seal bar 95 can include a body portion 97 that is shaped according to a desired bag joint shape. An insulating pad (not shown) and a protective sheet 139 can be in between a body portion 97 and heating element. A cover can be on top of heating element. A heating element is also preferably shaped according to a desired bag joint shape. End plates or end caps 125 can be included. End plates or end caps 125 and a heating element can be coupled to the heat seal bar body 97 with a desired fastener assembly, e.g., springs, nuts, pins, and washers. A cover can be coupled to a heat seal bar body 97 with screws, or other desired fasteners. Bumpers and clips can also be coupled to a heat seal bar body with screws. Bumpers are preferably in position to provide a bumper, e.g., for a carrier plate 150 or a baffle carrier plate if used. Cooling lines 116 can also be included on a heat seal bar body 97, which can be coupled to a heat seal bar body 97 with a desired fastener, e.g., with an elbow, screws, and tie holder, or with another desired fastener. A calibration sensor, electrical lines and power wires for connecting transformers, etc. as part of a sensorless heat sealing process can be used with such a heat seal bar 95 if desired in the manner as described U.S. patent application Ser. No. 17/330,668. For example, electrical line/voltage measuring wire from voltage transducer 187, and electrical line/power wires from transformers 188 can be coupled to a heat seal bar 95.

(109) Referring to FIGS. 46-47, an assembly line production area for heat sealing bulk bags 10 or 50 is shown. A baffle heat seal machine 110 in one preferred embodiment is used as a materials prep machine to form a baffle body 140. Although not shown, a baffle heat seal machine can be off to the side of heat seal machines 141, 146. Once a desired number of baffle bodies 140 are formed on baffle heat seal machine 110, they can then be loaded on a bag parts or pieces carrier/carrier 143 in preparation for feeding into a manufacturing assembly line production area as shown in the figures. A baffle body 140 can be used to create a baffle bag 10, 50 in a same or similar way as non-baffled bulk bags using standard tops, bodies, bottoms and spouts as disclosed in the applications of the same inventor incorporated herein by reference.

(110) The carrier plate 150 as shown in the figures, is designed to accommodate heat seal bars for sealing top spout 1 to top 2, top 2 to body 3, body 3 to bottom 6 and bottom 6 to discharge tube 7 with laterally spaced openings and guides to help alignment of these parts. This particular carrier plate is not designed to also accommodate the longitudinal baffle heat seal bar assemblies 101, 102. A carrier plate is not needed to heat seal a baffle insert 4 or 40 to a body 3, but a baffle carrier plate can be used that is similar to a carrier plate 150 and adapted to accommodate the longitudinal heat seal bar assemblies 101, 102 and act as quality check for parts alignment of the overlapped baffle insert 4, 40 and body 3 if desired.

(111) A pre-heat sealed bulk bag 142 can be assembled on a carrier plate 150 as shown in FIGS. 44-45, with bag parts or pieces or portions held on carrier 143 prior to assembling and overlapping the bag portions together to form a pre-heat sealed bulk bag 142. A carrier 150 includes a plurality of openings 151, enabling upper and lower heat seal bars to contact bag portion fabric surfaces during a heat sealing process.

(112) A pre-heated sealed bulk bag 142 can be put together, for example, by overlapping respective bag portions together to form desired joint locations for a bag 10, 50 on a carrier plate 150 (see FIGS. 45-47). Prior to entering a first heat seal machine, e.g., heat seal machine 141, a pre-heat sealed bulk bag 142 can have no heat sealed bag joints, except where baffle insert 4 or 40 is heat sealed to body 3 to form a baffle body 140.

(113) A heat seal machine 141 can include a table 153, a fill spout/top heat seal bar assembly 147, a top/body heat seal bar assembly 154, a bottom/body heat seal bar assembly 160, a discharge tube/bottom heat seal bar assembly 149 and a document pouch/body heat seal bar assembly 155.

(114) Carrier plate 150 with pre-heat sealed bag 142 can be passed through one or more heat sealing machines, e.g., heat seal machine 141, including machine heat seal bar assemblies that have heat seal bars with heating elements. The heat seal bar assemblies can be calibrated at control panels 220, if using a sensorless temperature sensing and control method as disclosed in described U.S. patent application Ser. No. 17/330,668, prior to passing a pre-heat sealed bulk bag 142 through a heat seal machine to undergo a heat sealing process to form a bag 10, 50 with heat sealed joints. Resistance and temperature readings during heat sealing of heat seal bar assemblies can also be gathered at control panels 220.

(115) In a preferred embodiment as shown in FIGS. 46-47, two heat seal machines 141, 146 can be used to manufacture a bulk bag 50. After pre-heat sealed bag 142 passes through heat seal machine 141, a partially completed bag/partially heat sealed bag 171 (with heat sealed joints formed between a discharge tube 7 and bottom 6, bottom 6 and body 3, body 3 and top 2, and top 2 and fill spout 1, and also with a document pouch 156 sealed to body 3 is still on carrier plate 150 and is ready to move into heat seal machine 146. A heat seal machine 146 can include a table 152, a lift loop assembly/body heat seal bar assembly 159, and a bottom cover/body heat seal bar assembly 148. Heat seal machine 146 completes a bag 10, 50 by heat sealing lift loop assemblies 158 and a bottom/discharge tube cover 54 to body 3.

(116) Following heat sealing in machine 146, a completed bag 50 is shown on table 144. A return table 145 for after a pre-heat sealed bulk bag 142 and partially heat sealed bag 171 is finished undergoing a heat sealing process to form a completed bag 10, 50 is also shown in the figures. FIG. 29 illustrates a completed baffle bulk bag 50.

(117) In other embodiments, any desired number of joints for a bag can be formed in a desired heat seal machine. For example, some bags may have less than four lift loop assemblies 158, may not have a document pouch 156 and/or may not have a bottom/discharge tube cover 54. Other styles of bulk bags than what are shown in the figures can also be made with a desired number of heat sealed joints.

(118) FIGS. 46-47 illustrate folded/gusseted bag parts or portions 1, 2, 3, 6, 7 and also a document pouch 156 on carriers 143. Fill spout 1, top 2, baffle body 140, bottom 6 and discharge tube 7 are folded and gusseted on carrier 143 ready to be overlapped with respective bag portions for assembly on carrier plate 150 near heat seal machine 141. Document pouch 156 is also on this carrier 143.

(119) Lift loop assembles 158 are also folded on a carrier 143 that includes bottom/discharge tube cover 54 near heat seal machine 146 and are ready to be assembled on a partially completed bag 171 before entering heat seal machine 146. If a bottom insert 5 is to be included in a bulk bag 10, 50, a bottom insert 5, discharge tube 7 and bottom 6 are preferably overlapped together and bottom 6 can be heat sealed to both insert 5 and discharge tube 7 in a heat sealing machine 146.

(120) Referring to FIGS. 52-53, preferred embodiments of the method of the present invention of heating sealing other bulk bag portions together using a heat seal bar assembly of the present invention is shown. FIG. 52 illustrates heat sealing a top 2 to a baffle body 140, e.g., using heat seal bar assemblies 163 when a baffle body 140 and top 2 are overlapped while folded/gusseted so that respective heat sealing coatings 81 on respective interior or exterior surfaces are in contact. An upper heat seal bar assembly 163 can be lowered in the direction of arrows 161 to make contact with the overlapped bag portions, melt a heat seal coating 81 in the overlapped area and form a joint between coatings 81 in the overlapped area. In FIG. 53, a heat sealed joint 162 between baffle body 140 and top portion 2 is depicted. Arrows 99 represent areas where joints are not formed even when bag surfaces around arrows 99 are pressed together during a heat-sealing process.

(121) A coating 81 on a bag body 3 can be a heat sealing coating 81 that is either a propylene plastomer or elastomer coating or a standard polypropylene laminate type coating. A coating 81 on a bag top 2 can also be a heat sealing coating 81 that is either a propylene plastomer or elastomer coating or a standard polypropylene laminate type coating, depending on what type of coating is on body 3. A propylene plastomer or elastomer coating can be bonded to another propylene plastomer or elastomer coating or to a standard polypropylene laminate type coating. A body 3 to bottom 6, fill spout 1 to top 2, and/or discharge tube 7 to bottom 6 joint can be formed in the same manner when respective bag portions are overlapped together. Reference is made to U.S. Pat. Nos. 10,112,739; 10,618,225 and 11,338,527 for more details on this process.

(122) FIGS. 54-55 illustrate heating sealing a bottom 6/insert 5/discharge tube 7 assembly together using, e.g., heat seal bar assemblies 164, when a discharge tube 7, insert 5 and bottom portion 6 are overlapped together while folded/gusseted so respective heat seal coatings 81 are in contact with one another, wherein an upper heat seal bar assembly 164 can be lowered in the direction of arrows 165 to make contact with the overlapped bag portions, melt a heat sealing coating 81 in the overlapped area and form a joint 162 between heat sealing coatings 81 in the overlapped area. FIG. 55 shows a heat sealed joint 162 formed between a discharge tube 7 and bottom 6 during the heat sealing process.

(123) Other heat-sealed joints of a heat-sealed bag 10, 50 can be formed in a similar or same manner. Preferably bag portions are folded/gusseted so that inner folds or gussets do not touch. This helps prevent an unwanted joint being formed between inner folded portions. This is illustrated in FIGS. 18 to 20, for example, where a space is left about centrally, e.g., along a line 205, in a folded/gusseted body portion 3 between body edges 61.

(124) Other adhesives besides a hot melt film potentially can also be used, such as cold adhesives which would require roller pressure or flat bar pressure to form the seal. Hot melt is currently preferred though because cold adhesives bond at ambient. Under pressure, over time, the bonds tend to gradually stretch and lose strength.

(125) The hot melt beads originally experimented with potentially can be used in the method of the present invention to form a heat sealed joint between a baffle insert and bag body, for example, if the glue can be placed uniformly in the desired locations on the baffle insert.

(126) Including a heat seal coating on a baffle insert and the body interior also potentially can be used to make a heat sealed connection between a baffle insert and body interior surface. For example, a heat seal method that is the same or similar to that disclosed in U.S. Pat. No. 10,112,739 can be used if a plastomer and elastomer coating is included on one piece of flexible plastic fabric, e.g., polypropylene fabric of the baffle insert portion, that would be joined to another plastomer or elastomer coating on another piece of flexible plastic fabric, e.g., polypropylene fabric of a body portion interior. Or, a stitchless baffle bulk bag can be made using a heat seal method that is the same or similar to that disclosed in U.S. Pat. No. 10,112,739 wherein a plastomer and elastomer coating on one piece of flexible plastic fabric, e.g., polypropylene fabric of a baffle portion or body portion, would be joined to a standard fabric coating, e.g., a standard polypropylene fabric coating, on polypropylene fabric of an interior body portion surface or baffle insert exterior surface. Currently, however, as discussed the interior of tubular flexible plastic fabrics are not coated in the industry and it is difficult to coat the interior of a tubular flexible plastic fabric, which is the preferred type of fabric for a body portion of a bulk bag made using the heat sealing process of U.S. Pat. No. 10,112,739, for example, so use of a hot melt film as described herein is currently preferred. A tubular body can also be formed from a flat piece of material. A desired heat seal coating can potentially be applied to both sides of the flat piece of material and then it can be formed into a tube with a single vertical seal. Such a body with a desired coating on an interior surface could be coupled to a baffle insert with a desired coating on an exterior surface when folded, and with heat and pressure applied to join the coatings and form a bond therebetween.

(127) In another preferred embodiment, another to way to make a baffle bag of the present invention is to let the circular bag form an octagonal shape with the cut outs for the product flow on the four diagonals across the corner of the bag. Then add four corner panels to attach on the circular bag just outside the cut outs.

(128) In preferred embodiments as described herein, a baffle insert is heat sealed, and not sewn, to an interior of a bag body. A body having a baffle insert heat sealed therein preferably is used as a body portion in constructing a heat sealed bulk bag with no stitches or sewn seams in a containment area of bag. However, if desired, any of the embodiments of a baffle body portion formed as described herein using heat sealing can also be used as a body portion in other types of bags or bulk bags that have sewn seams.

PARTS LIST

(129) The following is a list of parts and materials suitable for use in the present invention:

(130) TABLE-US-00001 Parts Number Description 1 fill tube/fill spout 2 top/top portion 3 body/body portion 4 baffle insert/baffle insert portion/tubular baffle insert 5 bottom insert/bottom reinforcer 6 bottom/bottom portion 7 discharge tube/discharge spout 8 longitudinal panel/longitudinal member of baffle insert 9 strap/lateral panel/lateral member/lateral portion of baffle insert 10 apparatus of a preferred embodiment of the present invention/baffle bulk bag of the present invention 11 opening 12 opening 13 opening 14 opening 15 opening 16 opening 17 tab/tab portion 20 corner 21 hot melt/hot melt film/hot melt glue 22 arrow for width of longitudinal panel of baffle insert coupled to body portion 23 arrow for width of hot melt film 21 on tab portion of baffle insert 24 arrow for width of hot melt film 21 on longitudinal panel of baffle insert 25 exterior surface of longitudinal panel of baffle insert 26 interior surface of body portion 27 top of longitudinal panel 8 28 bottom of longitudinal panel 8 29 space in between two straps 9, or above or below a strap 9 30 space in between strap 9 and corner 20 31 exterior surface tab 17 32 joint/heat sealed joint 33 side wall of body 3 34 side wall of body 3 35 side wall of body 3 36 side wall of body 3 37 left edge longitudinal panel 8 38 right edge longitudinal panel 8 40 baffle insert portion/baffle insert 41 gusset 42 gusset 43 gusset edge 44 gusset edge 45 gusset edge 46 gusset edge 50 a preferred embodiment of the apparatus of the invention/baffle bulk bag 51 lift loop 52 patch 53 junction of strap 9 and longitudinal panel 80 54 discharge tube cover 55 opening 61 body edge/body fabric edge 62 body open end 63 body open end 64 over edge coating 65 gusset edge 66 gusset edge 67 gusset edge 68 gusset edge 69 gusset 70 gusset 80 longitudinal panel/longitudinal member 81 heat seal coating 82 folded area of gusset 69 83 folded area of gusset 70 84 folded area of gusset 69 85 folded area of gusset 70 86 interior surface 87 interior surface 88 interior surface 89 interior surface 90 interior surface 91 interior surface 92 interior surface 93 interior surface 94 pivot point 95 heat seal bar apparatus 96 fold line 97 heat seal bar body/body portion 98 exterior surface of body 3 99 arrows 101 heat seal bar assembly 102 heat seal bar assembly 103 arrowjunction of tab 17 and longitudinal panel 80 105 table top/top 106 guide edge 107 end stop 110 baffle heat seal machine/heat sealing machine 111 table 112 leg 113 frame/bridge assemblies 114 pneumatic cylinder 115 air line/air tube 116 water line/water tube/cooling lines 117 bar code reader 118 bracket (with slotted opening for bolt or pin)/rear yoke assembly 119 bracket (with circular opening for bolt or pin)/front attachment bracket 120 opening 121 seal bar end 122 seal bar end 123 opening 124 opening 125 end cap/end plate 126 opening 127 fastener/pin 128 fastener/screw 129 swivel bracket/swivel leveling mount 130 ball 131 threaded section 132 body 133 hex head or nut 134 opening/threaded opening 135 end 136 end 137 frame 138 opening/threaded opening 139 protective sheet 140 bag body with baffle insert(s) 4 or 40/baffle body 141 heat seal machine 142 pre-heat sealed bag, including one or more overlapped bag portions prior to heat sealing the one or more bag portions together 143 bag parts or pieces carrier/carrier 144 table, completed/heat sealed bag table 145 table/return table 146 heat seal machine 147 heat seal bar assembly of a preferred embodiment of the present invention, fill spout/top heat seal bar assembly 148 heat seal bar assembly of a preferred embodiment of the present inventionbottom cover/body heat seal bar assembly 149 heat seal bar assembly of a preferred embodiment of the present inventiondischarge tube/bottom heat seal bar assembly 150 carrier plate 151 opening 152 table 153 table 154 heat seal bar assembly of a preferred embodiment of the present inventiontop/body heat seal bar assembly 155 heat seal bar assembly of a preferred embodiment of the present inventiondocument pouch/body heat seal bar assembly 156 document pouch 158 lift loop assembly 159 heat seal bar assembly of a preferred embodiment of the present inventionlift loop assembly/body heat seal bar assembly 160 heat seal bar assembly of a preferred embodiment of the present inventionbottom/body heat seal bar assembly 161 arrows 162 heat sealed joint 163 heat seal bar apparatus 164 heat seal bar apparatus 165 arrows 171 partially completed bulk bag 180 opening 181 fastener, e.g., pin or bolt 187 electrical line/voltage measuring wire from voltage transducer 188 electrical line/power wires from transformers 205 center line body in folded/gusseted configuration 220 control panel

(131) All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.

(132) The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the claims.