BAGS FOR DRY POWDER TRANSPORTATION WITH A FLUIDIZATION SYSTEM

Abstract

A flexible container for containing a flowable material, including a primary chamber having an inlet at an upper part of the primary chamber through which the flowable material is loaded into the flexible container and a secondary chamber extending from a first side of the primary chamber at a lower part thereof and containing an outlet through which the flowable material exits the flowable container, the secondary chamber being configured to fold against the first side and be secured thereto, and when unsecured from the first side, the flowable material is allowed to exit the flexible container wherein the primary chamber and secondary chamber are each formed of an inner layer and an outer layer, wherein an inner layer comprises a laminate layer; and the outer layer comprises raffia.

Claims

1. A flexible container for containing a flowable material, comprising: a primary chamber having an inlet at an upper part of the primary chamber through which the flowable material is loaded into the flexible container; and a secondary chamber extending from a first side of the primary chamber at a lower part thereof and containing an outlet through which the flowable material exits the flowable container, the secondary chamber being configured to fold against the first side and be secured thereto, and when unsecured from the first side, the flowable material is allowed to exit the flexible container; wherein the primary chamber and secondary chamber are each formed of an inner layer and an outer layer, wherein an inner layer comprises a laminate layer; and the outer layer comprises raffia.

2. The flexible container of claim 1, wherein the laminate layer is configured to prevent the transfer of moisture.

3. The flexible container of claim 1, wherein the inner layer constitutes 1 to 20 wt % of the combined inner and outer layers.

4. The flexible container of claim 1, wherein the laminate layer comprises laminated polypropylene, polyethylene or combinations thereof.

5. The flexible container of claim 4, wherein the polypropylene is a polypropylene homopolymer.

6. The flexible container of claim 4, wherein the polyethylene is low density polyethylene.

7. The flexible container of claim 1, wherein the laminate layer is formed from a polymer having a melt flow rate of more than 10 g/10 min according to ASTM D1238 measured at 230 C. and 2.16 kg.

8. The flexible container of claim 1, wherein the raffia comprises a polypropylene homopolymer.

9. The flexible container of claim 1, wherein the raffia is formed from a polymer having a melt flow rate of less than 10 g/10 min according to ASTM D1238 measured at 230 C. and 2.16 kg.

10. The flexible container of claim 1, wherein the outer layer constitutes 80 to 99 wt % of the combined inner and outer layers.

11. The flexible container of claim 1, further comprising: at least one support disposed on at least the primary chamber.

12. The flexible container of claim 11, wherein the at least one support is one of a hook, handle or strap.

13. The flexible container of claim 1, wherein the inlet is a cylindrical structure extending above a top surface of the flexible container.

14. The flexible container of claim 1, wherein at least one fastener secures the secondary chamber against the primary chamber.

15. The flexible container of claim 1, wherein the primary chamber further comprises internal supports configured to secure a fluidizing system.

16. The flexible container of claim 15, wherein the primary chamber further comprises an opening through which the fluidizing system extends into the primary chamber.

17. The flexible container of claim 15, wherein the fluidizing system comprises a partially perforated hose configured to expel a fluidizing agent into the flowable material.

18. The flexible container of claim 17, wherein the fluidizing agent is compressed air.

19. The flexible container of claim 1, wherein the content is cement.

20. The flexible container of claim 1, wherein the primary chamber and secondary chamber form an L-shaped design when the secondary chamber is unsecured.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0005] The present invention is described in connection with the attached FIGs.

[0006] FIG. 1 shows a flexible container in accordance with one or more embodiments.

[0007] FIG. 2 shows a flexible container in accordance with at least one embodiment.

[0008] FIG. 3 shows a lower part of a flexible container in accordance with one or more embodiments.

[0009] FIG. 4 shows an inner part of a flexible container in accordance with one or more embodiment.

DETAILED DESCRIPTION

[0010] In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

[0011] Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms before, after, single, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.

[0012] Embodiments disclosed herein are directed to a flexible container for containing a flowable or powder material, such as but not limited to bulk cement. The flexible container may be useful for the bulk transportation of a flowable material such that the use of pressurized vehicles is not necessary. The present flexible containers may also speed up the inbound and outbound processes and reduce the danger associated with the use of pressurized vehicles.

[0013] Use of the flexible container may allow for the use of tipper trucks/trailers which can be up to 50-60% cheaper than pressurized vehicles. Further, the use of the flexible containers allows for the transportation vehicles to be used to carry a variety of materials, therefore providing a more versatile operation, including allowing the vehicle to carry a load on the return trip.

[0014] Embodiments disclosed herein relate to a flexible container for containing a flowable material that comprises a primary and secondary chamber. A schematic of flexible container is shown in FIG. 1, while a photograph of flexible container mounted on a transportation vehicle is shown in FIG. 2. Referring to both FIGS. 1 and 2, the flexible container 100 may include a primary chamber 102 with an upper part or region 104 and a lower part or region 108. While primary chamber 102 is illustrated as having a generally cuboid shape (a hexahedron with six faces or side surfaces), it is understood that there is no limitation on the general shape of primary chamber. As shown in FIG. 1, the flexible container 100 may comprise a primary chamber 102 having an inlet 112 at an upper part 104 of the primary chamber 102 through which the flowable material is loaded into the flexible container. The inlet 112, as shown in FIG. 1, may be a cylindrical structure extending above the top surface 114 of the flexible container 100; however, it is also understood that it could be on an upper portion of a side surface so long as the flowable material can enter and fill the primary chamber by gravitational flow. The cylindrical structure may be used to introduce the flowable material into the flexible container from a cylindrical outlet of a storage silo. While the inlet 112 may be a cylindrical structure, the shape of the inlet 112 is not limited to a cylinder but could be a shape that matches the outlet of a storage vessel or is capable of receiving a flowable material from an outlet of a storage vessel.

[0015] The inlet 112 may further comprise at least one fastener 116 to securely attach the inlet to an outlet of the storage vessel and/or to secure the inlet against the container 100, thereby preventing flow of flowable material through (either into or out of) inlet 112 and primary chamber 102. As shown in FIG. 1, the at least one fastener 116 may be the one or more ties, such as sewed ropes, attached to the outer portion of the inlet; however, it is also understood that other types of fasteners may be used instead of ties. The at least one fastener 116 may also be used to prevent or reduce moisture from entering the inlet of the primary chamber 102. After the flowable material has entered the primary chamber 102, the inlet may be closed off by tying or securing the at least one fastener 116 together.

[0016] According to one or more embodiments, the flexible container may comprise at least one support 118 disposed on at least the primary chamber 102. As shown in FIG. 1, the primary chamber 102 includes a plurality of supports 118 in the form of straps. While straps are depicted, the at least one support 118 may include but is not limited to a hook, handle or strap. The supports 118 may be used to secure the flexible container in place within a transportation vehicle 150. The transportation vehicle 150 thus may include a suitable retaining element or anchor to grasp or hook onto the supports 118 of the flexible containers. While the supports 118 are depicted on the primary chamber, the secondary chamber may also include at least one support feature(s).

[0017] In one or more embodiments, the flexible container comprises a secondary chamber 130 attached to a lower part 108 of the primary chamber 102. As shown in FIG. 1, the secondary chamber 130 extends from a first side 106 of the primary chamber in a lower part 108 of primary chamber 102. The secondary chamber 130 may contain an outlet 110 through which the flowable material exits the flowable container.

[0018] The secondary chamber 130 may also simultaneously allow for two configurations. The secondary chamber 130 may be configured to fold against the first side 106 of the primary chamber and be secured thereto. When secured to the first side 106 of the primary chamber 102, the secondary chamber 130 may be folded away such that when filling the flexible container 100 with a flowable material, the secondary chamber 130 is not filled with the flowable material. When the secondary chamber 130 folds against the first side 106 of the primary chamber 102, the folding may be secured with the one or more fasteners 116. According to one or more embodiments, the secondary chamber 130 may be secured with sewed ropes. For instance, the one fastener 116A of the primary chamber 106 may be strung through loops 117 of the secondary chamber 130 before being tied. Further, the two fasteners 116B and 116C of the secondary chamber 130 may be secured to the two supports 118 disposed on the primary chamber 102. The folded configuration also aids in more efficient storage of the flowable material, such that presence of the secondary chamber is minimized and allows for more storage space of flowable material in a transportation vehicle. This collapsible/foldable configuration allows for multiple flexible containers to be used alongside one another in transport.

[0019] Following the transport of the flowable material, the secondary chamber 130 may be used to remove the flowable materials. When the one or more fasteners 116 are untied, the secondary chamber 130 is unsecured from the first side 106, and unfolded due to the weight of the flowable material that begins to flow from the primary chamber 102 into the secondary camber 130. The secondary chamber 130 is therefore configured to allow the flowable material to exit the flexible container 100. When the secondary chamber 130 is unsecure, it allows for the full expansion of the secondary chamber 130 and provides the L-shape design of the combined primary and secondary chambers, shown in FIG. 1.

[0020] For removal of the flowable material from flexible container 100, the primary chamber 102 may further comprise a fluidizing system 142 within the primary chamber 102. Furthermore, and in reference to FIG. 1, the primary chamber 102 may include an opening through which the fluidizing system 142 may be introduced and extended into the primary chamber 102. As shown in FIG. 2, the opening through which the fluidizing system 142 may be introduced, for example, through an opening near an upper corner of the primary chamber 102. However, it is envisioned that the opening for the fluidization system 142 may be located at any point of the primary chamber 102. As shown in FIGS. 3 and 4, showing an internal surface of primary chamber 102, the lower part 108 of primary chamber 102 may include a plurality of internal support ties 140 in the form of ties. As shown in FIG. 4, the fluidizing system 142 may comprise a partially perforated hose secured with supports ties 140. The perforated hose of the fluidizing system 142 is configured to expel a fluidizing agent into the flowable material. The fluidizing agent may include but is not limited to compressed air or any suitable liquid or gas capable of fluidizing the flowable material and to prevent the packing of the flowable material in the flexible container 100. Thus, when unloading of the flowable material is desired, fluidizing agent may expel from fluidization system 142 to aid in the flow of flowable material from primary chamber 102, into secondary chamber 130 and out of flexible container 100.

Layers

[0021] In addition to the general physical structure of flexible container, the primary chamber and secondary chamber of the flexible container may be formed from a plurality of layers. The flexible container may include raffia and a laminate polymer. According to one or more embodiments the primary chamber and secondary chamber are each formed of an inner layer and an outer layer, wherein an inner layer comprises a laminate layer; and the outer layer comprises raffia. The inner laminate layer may be configured to prevent the transfer of moisture between the flowable material in the flexible container and the atmosphere. The laminated layer is important to keep the flowable material dry, as it prevents the transfer of humidity into the inner parts of the bag which otherwise would cause the flowable material to harden and/or clump.

[0022] As stated above, the outer layer comprises raffia, such as but not limited to a polypropylene raffia. Suitable polypropylenes useful for the raffia outer layer are polypropylene (PP) homopolymers with low melt flow rates. The low melt flow rates may be less than 10 g/10 min according to ASTM D1238 measured at 230 C. and 2.16 kg and balance between rigidity/impact.

[0023] The inner laminate layer may be formed from a polymer. The polymers may be a laminated polypropylene, polyethylene or combinations thereof. Polypropylenes useful for the laminated layer are polypropylene homopolymers with high melt flow rates. High melt flow rates, for examples, include flow rates of greater than 10 g/10 min according to ASTM D1238 measured at 230 C. and 2.16 kg and balance between rigidity/impact. Suitable polyethylenes useful for the laminated layer include low density polyethylene (LDPE).

[0024] According to one or more embodiments, the outer layer constitutes 80 to 99 wt % of the combined inner and outer layers, such as from a lower limit of any of 80, 82, 84, 86, 88 or 89.8 wt % to an upper limit of any one of 90, 92, 94, 96, or 98 wt %, where any lower limit may be mathematically paired with any upper limit. The inner layer may constitute 1 to 20 wt % of the combined inner and outer layers, such as from a lower limit of any one of 1, 2, 4, 6, 8 or 10.2 wt % to an upper limit of any of 11, 12, 14, 16, 18 and 20 wt %, where any lower limit may be mathematically paired with any upper limit.

Uses of the Flexible Container

[0025] The flexible container described herein includes a primary chamber and a secondary chamber, both of which include a plurality of sides. In at least one embodiment, the flexible container may be used in transportation vehicle with a rectangular shaped bed or cargo hull. Accordingly, the flexible container may be made with a suitable number of sides to accommodate the shape of the transportation vehicle. For example, the flexible container shown in FIG. 1 may be used in a tipper trailer with a rectangular shape, as partially depicted in FIG. 2. Accordingly, the flexible container shown in FIG. 1 includes a primary chamber with four sides to accommodate and maximize the storage space of the tipper trailer. Those skilled in the art would readily understand that given a vehicle with a different storage shape, the shape, overall dimensions and number of sides to the flexible container may be more or less than those shown in FIG. 1.

[0026] The flexible container described herein may be used to contain a flowable material. Further, the term flexible container, bag, and other appropriate terminology may be used interchangeably as appropriate without departing from the scope of this disclosure. The flowable material may be any material with fine granulometry and that may require fluidization and the use of fluidization systems. According to one or more embodiments, the flowable material may be cement. The cement may be transferred from a cement silo with an outlet connected to the inlet of the flexible container, hereinafter, a cement bag. The laminated layer described above is important to keep the cement dry, as it prevents the transference of humidity into the inner parts of the cement bag. The cement bag may also include a fluidization system comprising 13 meters of a 1-inch up to a 2.5-inch diameter hose, with several holes on its length (through which air can be expelled), installed on the lower inside part of the cement bag. Compressed air may be inserted into the fluidization hoses to allow the content of cement to flow. When the secondary chamber is unsecured, the content may be expelled and may flow out via by gravity. While the capacity of the flexible container is not limited, the flexible container may be sized to contain up to 10 tons of flowable material.

[0027] While the scope of the composition and method will be described with several embodiments, it is understood that one of ordinary skill in the relevant art will appreciate that many examples, variations and alterations to the composition and methods described here are within the scope and spirit of the disclosure. Accordingly, the embodiments described are set forth without any loss of generality, and without imposing limitations, on the disclosure. Those of skill in the art understand that the scope includes all possible combinations and uses of particular features described in the specifications.

[0028] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the words means for together with an associated function.