Patent Grant
9120620
This is a national stage application of International Application No. PCT/CA2010/000963 filed on Jun. 22, 2010, which claims priority to Canadian Patent Application No. 2,669,995 filed on Jun. 22, 2009, and the entire contents of each are hereby incorporated herein by reference.
This specification relates to flexible bulk containers.
The following paragraphs are not an admission that anything discussed in them is prior art or part of the knowledge of persons skilled in the art.
Canadian Patent No. 2,139,560 describes a method of manufacturing a bulk bag comprising fabricating a fabric side wall structure and providing a plurality of lift loops each having a first and second leg portion. The legs of each lift loop are aligned at spaced locations around the top of the side wall structure, in positions for ready penetration by the tines of a forklift truck, with both leg portions of each lift loop extending a given distance downwardly from the top edge of the side wall structure. The leg portions of each of the lift loops are stitched to the top of the side wall structure by at least three parallel lines of high-strength thread, preferably by chain stitching or lock stitching. The stitching lines are all sewn in one or at most two passes; they extend horizontally across the lift loop legs to anchor the lift loops securely to the top of the side wall structure. There is no horizontal fold of the top of the side wall structure extending down to the anchor stitching.
U.S. Pat. No. 7,431,173 describes an intermediate bulk container comprising a storage container which is made from a suitable flexible material, a forklift pallet base including pole engaging formations on its upper surface which are arranged about its periphery, a plurality of poles the lower ends of which are releasably engageable with formations on the pallet base to provide a support cage for the storage container, a holed pole location member including pole engaging formations with which the upper ends of the poles are engageable to lock the poles together to inhibit transverse outward bulging of the storage container from between the poles and to preserve the container support cage against a load in the storage container with the underside of the pallet base and the upper surface of the pole locating member including formations, which are releasably engageable with compatible formations on containers below and above it in a stack.
U.S. patent application No. 20080137997 describes a stackable collapsible container for flowable materials. The container has a flexible outer skin and rigid support, having a top frame and bottom frame connected by poles. The top frame and bottom frame are designed for mating engagement when the containers are stacked, as well as for mating engagement when the containers are broken down for transport. The top frame and bottom frame are provided with similar perimeters to prevent undesired movement and contact between adjacent top frame when the containers are filled and transported.
In an aspect of this specification, a flexible bulk container comprises a plurality of side walls coupled to a bottom wall, the side walls and the bottom wall generally enclosing an interior space that is accessible through a top of the flexible bulk container. A support structure comprises a plurality of elongate frame elements, each of the frame elements attached to at least one of the side walls and configured to support the at least one of the side walls generally upright so that the flexible bulk container is maintained in a generally open position, each of the frame elements being detachable from the respective at least one of the side walls.
The frame elements may be arranged externally of the interior space of the flexible bulk container. The frame elements may be coupled to an outer surface of the side walls. Each of the frame elements may be detachable from the respective at least one of the side walls independently of the others of the frame elements. There may be at least one of the frame elements per each of the side walls. There may be two of the frame elements per each of the side walls.
The frame elements may be flexible and resilient. A first one of the frame elements may extend diagonally generally between a first lower corner of the at least one of the side walls and a first upper corner opposite from the first lower corner. A longitudinal dimension of the first one of the frame elements may be greater than a diagonal dimension between the first lower and upper corners, so that the first one of the frame elements is in a flexed condition and biases the first lower and upper corners away from one another. A second one of the frame elements may extend diagonally generally between a second lower corner of the at least one of the side walls and a second upper corner opposite from the second lower corner. A longitudinal dimension of the second one of the frame elements may be greater than a diagonal dimension between the second lower and upper corners, so that the second one of the frame elements is in a flexed condition and biases the second lower and upper corners away from one another.
The corners of the at least one of the side walls comprise corner patches which may be configured to retain ends of the first and second ones of the frame elements. The corner patches may comprise pockets sized and shaped to retain the ends of the first and second ones of the frame elements. The corner patches may be stitched to form the pockets. The ends of the first and second ones of the frame elements may comprise clips configured to grip the respective corner patch. The corners of the at least one of the side walls may comprise corner connectors, the corner connectors comprising a base portion mounted to the at least one of the side walls and a tube portion coupled to the base portion, the tube portion sized and shaped to retain ends of the first and second ones of the frame elements.
A central loop may couple the first and second ones of the frame elements together generally where the first and second ones of the frame elements diagonally overlap. The central loop may be fixed to the at least one of the side walls.
The at least one of the side walls may comprise a plurality of elongate sleeves for coupling the first and second ones of the frame elements to the at least one of the side walls.
Each of the frame elements may comprise two half segments. The at least one of the side walls may comprise a central patch configured to retain inward ends of the half segments, so that each of the half segments extends diagonally between the central patch and a different corner of the at least one of the side walls. The central patch may define four pockets sized and shaped to retain the inward ends of the half segments. The support structure may further comprise a plurality of frame connectors, the frame connectors configured to connect two of the half frame segments in series between opposite corners of the at least one of the side walls. The support structure may further comprise a central connector hub configured to retain inward ends of the half segments, so that each of the half segments extends diagonally between the central connector hub and a different corner of the at least one of the side walls. The central connector hub may be fixed to the at least one of the side walls.
The frame elements may comprise first frame elements that extend generally vertically across the at least one of the side walls. The first frame elements may be arranged generally at corners of the flexible bulk container. The at least one of the side walls may comprise pockets for retaining ends of the first frame elements. The frame elements may comprise a second frame element that extends generally horizontally across the at least one of the side walls. The second frame element may be arranged generally across a middle of the at least one of the side walls. The at least one of the side walls may comprise pockets for retaining ends of the second frame element. The second frame element may comprise first and second half segments separated by a hinge.
The flexible bulk container may further comprise at least one loop coupled to at least one of the side walls for lifting the flexible bulk container. The flexible bulk container may further comprise a lid wall coupled to at least one of the side walls to cover the interior space at the top of the flexible bulk container. The flexible bulk container may further comprise a plurality of peg flaps coupled to at least one of the side walls and the bottom wall for anchoring the flexible bulk container to the ground.
In an aspect of this specification, a kit of parts comprises: at least one flexible bulk container, the at least one flexible bulk container including a bottom wall, a plurality of generally rectangular side walls coupled to the bottom wall, the side walls and the bottom wall generally enclosing an interior space that is accessible through a top of the at least one flexible bulk container, and a plurality of pockets formed on at least one of the side walls, with at least a first and a second pocket disposed generally at opposite corners of the least one of the side walls on an outer surface thereof; and a plurality of elongate, flexible and resilient frame elements, each of the frame elements attachable to the at least one of the side walls by inserting ends of the frame element into the first and second pockets so that the frame element extends diagonally between the opposite corners, a longitudinal dimension of the frame element being greater than a diagonal dimension between the first and second pockets so that the frame element is retained in a flexed condition between the first and second pockets, whereby the plurality of frame elements are attachable to form a support structure that maintains the flexible bulk container in a generally open position.
In an aspect of this specification, a method comprises: providing a first flexible bulk container; providing a support structure; attaching the support structure to at least one side wall of the first flexible bulk container so that the first flexible bulk container is maintained in a generally open position; loading materials in an interior space of the first flexible bulk container; and detaching the support structure from the at least one side wall of the first flexible bulk container.
The method may further comprise, after the step of detaching: providing a second flexible bulk container; attaching the support structure to at least one side wall of the second flexible bulk container so that the second flexible bulk container is maintained in a generally open position; loading materials in an interior space of the second flexible bulk container; and detaching the support structure from the at least one side wall of the second flexible bulk container.
The support structure may comprise a plurality of elongate frame elements, each of the frame elements attached to at least one of the side walls. Each of the frame elements may be independently attachable to and detachable from the respective at least one of the side walls. In the step of attaching, the frame elements may be generally coupled to an outer surface of the side walls. In the step of attaching, two of the frame elements may be attached per side wall. In the step of attaching, the frame elements may be attached to extend diagonally generally between opposite corners of the respective side wall. In the step of attaching, the frame elements may be resiliently flexed to enable ends of the frame elements to be inserted into pockets provided at the opposite corners of the respective side wall.
Other aspects and features of the teachings disclosed herein will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific examples of the specification.
The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
Most waste management systems utilize roll-off dumpster containers to load and transport mixed waste materials. These methods may require transporting the containers to and from landfill or waste transfer facilities for processing. Typically, vehicles used to transport the containers are capable of carrying only one container at a time, whether it is full or empty, and furthermore each container has a fixed material volume and requires removal and replacement once full to continue operation. Transport of containers and use of equipment to sort waste material has environmental implications ranging from dust and noise pollutants to vehicle emissions.
A flexible intermediate bulk container (FIBC), which may be referred to as a bulk bag, is a standardized container for storing and transporting materials, for example but not limited to, sand, fertilizers, granules of plastics or other products. Bulk bags may be made of relatively thick woven polyethylene or polypropylene, and may measure around 110×110 cm and vary in height from 100 cm up to 200 cm. Capacity of a bulk bag may be around 1000 kg or more. Transporting and loading of bulk bags may be done using pallets or by lifting the bulk bag with loops; bulk bags may be made with either one loop or four lifting loops. Emptying may be made easy by an opening in the bottom or by simply cutting it open.
Generally, the concepts disclosed herein relate to a flexible bulk container and a support structure therefor. The support structure is configured to maintain at least portion of the side walls of the flexible bulk container generally upright, so that the flexible bulk container is presented in a generally open position to receive materials loaded into the interior space of the flexible bulk container. During or after loading of materials into the flexible bulk container, the support structure may be detached from the flexible bulk container and then used to support another flexible bulk container.
In the drawings and in this description, like reference numerals will be used to indicate like elements, functions or features as between the drawings and the described examples.
Referring to
The side walls 12a, 12b, 12c, 12d are coupled to a bottom wall 14. The side walls 12a, 12b, 12c, 12d and the bottom wall 14 generally enclose an interior space 16 that is accessible through a top 18 of the flexible bulk container 10. In the example illustrated, the interior space 16 is generally cuboidal.
The flexible bulk container 10 may be formed of various materials, including, for example but not limited to, woven polyethylene or polypropylene having a fabric weight of 7 ounces per square yard or more. Edges of the flexible bulk container 10 may be double hemmed to improve strength and tear resistance. The flexible bulk container 10 may be made in various sizes. In a particular example, the flexible bulk container 10 may have a base size of 72″×72″ and a height of 60″, although this particular size is not intended to be limiting and various different sizes are contemplated.
A support structure is shown generally at 20. The support structure 20 includes elongate frame elements 22a, 22b, 22c, 22d. The frame elements 22a, 22b, 22c, 22d are attached to the side walls 12a, 12b and support the side walls 12a, 12b generally upright so that the flexible bulk container 10 is maintained in a generally open position to load materials in the interior space 16. Although it is not shown in
The frame elements 22a, 22b, 22c, 22d may be arranged externally of the interior space 16 of the flexible bulk container 10. As illustrated, the frame elements 22a, 22b, 22c, 22d may be coupled to an outer surface of the respective side walls 12a, 12b. However, it may be appreciated that in some examples the frame elements 22a, 22b, 22c, 22d may be arranged internally of the interior space 16 of the flexible bulk container 10.
The frame elements 22a, 22b, 22c, 22d are attachable and detachable from the respective side walls 12a, 12b, and may be detached irrespective of whether the flexible bulk container 10 is empty or full of materials loaded in the interior space 16. Furthermore, each of the frame elements 22a, 22b, 22c, 22d may be detachable from the respective side walls 12a, 12b independently of one another.
It may be appreciated that the support structure 20 does not substantially extend beyond a plan view extent of the flexible bulk container 10 when viewed from above. In other words, the support structure 20 does not substantially increase the footprint of the flexible bulk container 10 when the support structure is being used to maintain the flexible bulk container 10 in a generally open position.
Referring to
In the example illustrated, the corners 24a, 24b, 26a, 26b of the side wall 12a each include a corner patch 30a, 30b, 30c, 30d, respectively. The corner patches 30a, 30b, 30c, 30d may each define a pocket 32a, 32b, 32c, 32d, respectively, sized and shaped to retain ends of the frame elements 22a, 22b.
The frame elements 22 may be formed to be generally flexible and resilient. The inventors have determined that Xenoy™ resin may be a suitable material for forming the frame elements 22. The frame elements 22 may be tubular in construction, and a low density filler (e.g., polymer foam) may be used to fill the tubes to reduce the potential of kinking or crushing. Furthermore, in some other examples the frame elements 22 may be formed of generally rigid materials, or a combination of rigid and flexible materials. Moreover, it may be appreciated that in some examples the frame elements 22 may not each be an integral component, but may be formed from a plurality of segments that are assembled together to form the full longitudinal dimension of the frame element 22, thus reducing the size of the unassembled support structure 20.
In accordance with a particular example, each of the frame elements 22 may be formed of tubular Xenoy™ resin having a 27 mm outer diameter and a 2 mm wall section thickness, although this particular material and configuration is not intended to be limiting and various different materials and configurations are contemplated.
In some examples, referring particularly to
In a particular example, given a width dimension 34 of the side wall 12a of about 72″ and a height dimension 36 of about 60″, a longitudinal dimension of the frame elements 22a, 22b of about 91″ or 92″ may be suitable. However, it may be appreciated that the frame elements having a given longitudinal dimension may be operable with a range of dimensions 28, 34, 36, allowing adjustability for various sizes and volumes of the flexible bulk container 10.
In some examples, referring particularly to
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The flexible bulk container 10 may include at least one loop 68 coupled to at least one of the side walls for lifting the flexible bulk container 10. Hooks 72 may be used to pick up the flexible bulk container 10 by the loops 68 to move it, load it onto a vehicle, etc.
Although not shown, in some examples lifting loops also may be provided along the bottom perimeter of the flexible bulk container 10 to assist with dumping the flexible bulk container 10 or securing it to the ground (e.g., four loops, with one arranged at each bottom corner).
Referring particularly to
It may be appreciated that the various examples of flexible bulk containers and support structures described herein may be used in a waste management system for the loading and sorting of bulk waste materials, such as construction debris, rubbish, industrial waste and the like, which deals with materials for the purposes of recycling and/or disposal. The teachings herein may enable a simple, cost effective, portable and generally easy to use waste management system, which consists of relatively few components and a set up procedure that places relatively modest physical demands upon a user. No specialized tools required may be required, and the system may allow for the ability for components to be readily replaced after long use or loss.
For example, at a given site where bulk waste materials are being generated, a supply of flexible bulk containers may be provided at a staging area. A support structure may be attached to a first flexible bulk container so that the first flexible bulk container is maintained in a generally open position. Bulk waste materials may then be loaded into the interior space of the first flexible bulk container. Either during loading of the first flexible bulk container or after it is fully loaded, the support structure may be detached from the first flexible bulk container and attached to a second flexible bulk container so that the second flexible bulk container is maintained in a generally open position. Bulk waste materials may then be loaded into the interior space of the second flexible bulk container. This cycle may be repeated continuously; the flexible bulk containers which are fully loaded may then be picked up from the staging area, and transported away for disposal or other processing.
The flexible bulk containers and support structures may be relatively light and compact, and the sorting of materials may be completed at its origin, and thus a decrease in carbon footprint may result as compared to waste management systems which utilize roll-off dumpster containers.
Multiple flexible bulk containers may be set up and loaded at the waste origin, enabling the sorting of materials to be carried out at the time of disposal. Different color flexible bulk containers may allow for identification of recyclables versus mixed waste material. The flexible bulk containers and support structures may be distributed through a retail network. For example, one or more of the flexible bulk containers and a support structure may be sold or rented as a kit of parts.
While the above description provides examples of one or more processes or apparatuses, it will be appreciated that other processes or apparatuses may be within the scope of the accompanying claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2669995 | Jun 2009 | CA | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/CA2010/000963 | 6/22/2010 | WO | 00 | 12/21/2011 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2010/148497 | 12/29/2010 | WO | A |
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| Written Opinion of the International Searching Authority issued Sep. 21, 2010 in respect of corresponding International Application No. PCT/CA2010/000963. |
| Number | Date | Country | |
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| 20120103981 A1 | May 2012 | US |
