FLEXIBLE CONTAINER, BULK BAG AND MATERIAL DISCHARGE ASSEMBLY

BACKGROUND

Known are “bulk bags,” i.e., large volume bags made from flexible fabric, typically woven polypropylene or woven polyethylene, and having the durability, strength, and suitable interior volume to contain, store, ship, or otherwise transport a “bulk amount,” or 500 pounds or more (220 kilograms or more) of flowable granular material. Bulk bags are routinely used in industries involved in storing and transporting bulk amounts of granular material such as sand, fertilizer, granules of plastic, powdered chemicals, carbon black, grains, and food products. Bulk bags are also commonly known as flexible intermediate bulk containers, industrial bags, or big bags.

Discharge of the granular material from the bulk bag typically requires the bulk bag to be lifted up, or otherwise raised, so that an operator can reach under the bulk bag and untie the close-off strap on the discharge spout of the bulk bag. The bulk bag discharge process is dangerous because it exposes the operator to the risk injury from falling bulk material. The operator is also exposed to the dust that forms as the bulk material is discharged creating workplace health and safety risk. Dust resulting from bulk bag discharge is also deleterious to other surrounding plant equipment, the dust negatively impacting plant operations by imposing the additional time, energy, and cost of remedial dust clean-up.

Consequently, the art recognizes the need for a bulk bag and a material discharge assembly that reduces, or eliminates, the risk of injury to plant operators tasked with emptying the contents of the bulk bag. A need further exists for a bulk bag and a material discharge assembly that reduces, or eliminates, dusting from occurring during discharge of a bulk amount of a flowable granular material from a bulk bag.

SUMMARY

The present disclosure provides a flexible container. In an embodiment, the flexible container incudes an outer bag and a liner positioned within in the outer bag. The liner substantially corresponds to the outer flexible bag. The outer bag and the liner each include (i) a body having a sidewall, (ii) a top panel, and (iii) a bottom panel. The sidewall has a height, a top end, and an opposing bottom end. The top panel extends from the sidewall top end and an inlet extends from the top panel. The bottom panel extends from the sidewall bottom end and an elongated discharge spout extends from the bottom panel. The outer bag elongated discharge spout and the liner elongated discharge spout each has a length from 0.40 times to 1.0 times the height of the respective outer bag sidewall and the liner sidewall.

The present disclosure provides an assembly. In an embodiment, the assembly includes a support frame and a hoist support engaged with the support frame. A hoist is movably engaged with the hoist support. A container transport component is engaged to the hoist and adapted to engage a flexible container having an elongated discharge spout. The assembly includes a container support surface attached to the support frame. The container support surface has a receiving aperture. An access chamber is located below the container support surface. The access chamber has a ceiling and an opposing floor. The access chamber also includes (i) a port in fluid communication with the receiving aperture, and (ii) a discharge tube extending through the floor. The discharge tube has a top rim in the access chamber and a bottom rim below the floor. The elongated discharge spout of the flexible container extends into and through the receiving aperture, the port, and the discharge tube. The assembly includes a sealing device movable between an engaged position and a disengaged position. The sealing device secures a distal end of the elongated discharge spout to the bottom rim and an affixing member when the sealing device is in the closed position.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a flexible container in accordance with an embodiment of the present disclosure.

FIG. 2 is a front elevation view of the flexible container of FIG. 1.

FIG. 3 is a perspective view a liner in accordance with an embodiment of the present disclosure.

FIG. 4 is a top plan view of the flexible container of FIG. 1.

FIG. 5 is a bottom plan view of the flexible container of FIG. 1.

FIG. 6 is a perspective view showing the liner fitting into the outer bag, in accordance with an embodiment of the present disclosure.

FIG. 7 is a perspective view of the flexible container showing the liner in the outer bag in accordance with an embodiment of the present disclosure.

FIG. 8 is a front elevational view showing the liner within the outer bag in accordance with an embodiment of the present disclosure.

FIG. 9 is a sectional view of the flexible container of FIG. 1 taken along line 9-9 of FIG. 4.

FIG. 10 is an enlarged view of Area AA of FIG. 9.

FIG. 11 is a perspective view of the flexible container of FIG. 1 filled with a bulk amount of a material and with the elongated discharge spout closed.

FIG. 12 is a front perspective view of an assembly for material discharge in accordance with an embodiment of the present disclosure.

FIG. 13 is a front perspective view of the assembly of FIG. 12 showing the elongated dispensing spout of the flexible container in operative communication with an access chamber and a sealing device of the assembly.

FIG. 13A is an enlarged view of Area BB of FIG. 13 showing a sealing device in a disengaged position in accordance with an embodiment of the present disclosure.

FIG. 13B is an enlarged view of Area BB of FIG. 13 showing the sealing device in an engaged position in accordance with an embodiment of the present disclosure.

FIG. 14 is a front perspective view of the assembly of FIG. 12 in accordance with an embodiment of the present disclosure.

FIG. 14A is an enlarged view of Area CC of FIG. 14, showing a discharge gate in a closed position, in accordance with an embodiment of the present disclosure.

FIG. 15 is a front perspective view of the assembly of FIG. 12 with a close-off strap being removed from the elongated discharge spout in accordance with an embodiment of the present disclosure.

FIG. 16 is a perspective view of the assembly of FIG. 12 unloading flowable granular material from the flexible bag in accordance with an embodiment of the present disclosure.

FIG. 16A is an enlarged view of Area DD from FIG. 16 showing discharge gate in an open position in accordance with an embodiment of the present disclosure.

FIG. 17 is a perspective view of the assembly of FIG. 12 having a vacuum system and the flexible container is in a collapsed state, in accordance with and embodiment of the present disclosure.

DEFINITIONS

The numerical ranges disclosed herein include all values from, and including, the lower and upper value. For ranges containing explicit values (e.g., a range from 1 or 2, or 3 to 5, or 6, or 7), any subrange between any two explicit values is included (e.g., the range 1-7 above includes 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).

Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percents are based on weight and all test methods are current as of the filing date of this disclosure.

The terms “comprising,” “including,” “having” and their derivatives, are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is specifically disclosed. In order to avoid any doubt, all compositions claimed through use of the term “comprising” may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. In contrast, the term “consisting essentially of” excludes from the scope of any succeeding recitation any other component, step, or procedure, excepting those that are not essential to operability. The term “consisting of” excludes any component, step, or procedure not specifically delineated or listed. The term “or,” unless stated otherwise, refers to the listed members individually as well as in any combination. Use of the singular includes use of the plural and vice versa.

An “ethylene-based polymer” is a polymer that contains more than 50 weight percent (wt %) polymerized ethylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer. Ethylene-based polymer includes ethylene homopolymer, and ethylene copolymer (meaning units derived from ethylene and one or more comonomers). The terms “ethylene-based polymer” and “polyethylene” may be used interchangeably.

An “olefin-based polymer” or “polyolefin” is a polymer that contains more than 50 weight percent polymerized olefin monomer (based on total amount of polymerizable monomers), and optionally, may contain at least one comonomer. A nonlimiting examples of an olefin-based polymer is ethylene-based polymer.

A “polymer” is a compound prepared by polymerizing monomers, whether of the same or a different type, that in polymerized form provide the multiple and/or repeating “units” or “mer units” that make up a polymer. The generic term polymer thus embraces the term homopolymer, usually employed to refer to polymers prepared from only one type of monomer, and the term copolymer, usually employed to refer to polymers prepared from at least two types of monomers. It also embraces all forms of copolymer, e.g., random, block, etc. The terms “ethylene/α-olefin polymer” and “propylene/α-olefin polymer” are indicative of copolymer as described above prepared from polymerizing ethylene or propylene respectively and one or more additional, polymerizable α-olefin monomer. It is noted that although a polymer is often referred to as being “made of” one or more specified monomers, “based on” a specified monomer or monomer type, “containing” a specified monomer content, or the like, in this context the term “monomer” is understood to be referring to the polymerized remnant of the specified monomer and not to the unpolymerized species. In general, polymers herein are referred to as being based on “units” that are the polymerized form of a corresponding monomer.

A “propylene-based polymer” is a polymer that contains more than 50 weight percent polymerized propylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer. Propylene-based polymer includes propylene homopolymer, and propylene copolymer (meaning units derived from propylene and one or more comonomers). The terms “propylene-based polymer” and “polypropylene” may be used interchangeably.

DETAILED DESCRIPTION
1. Flexible Container

The present disclosure provides a flexible container. In an embodiment, the flexible container includes an outer bag and a liner positioned within in the outer bag, the liner corresponding to, or substantially corresponding to, the outer bag. The outer bag and the liner each respectively include (i) a body having a sidewall, (ii) a top panel, and (iii) a bottom panel. The sidewall for each of the outer bag and the liner has a respective height. The sidewall for each of the outer bag and the liner each has a respective top end, and an opposing bottom end. For each of the outer bag and the liner, a top panel extends from the top end and an inlet extends from the top panel. For each of the outer bag and the liner, a bottom panel extends from the bottom end and an elongated discharge spout extends from the bottom panel. The outer bag elongated discharge spout and the liner elongated discharge spout each has a length from 0.40 times to 1.0 times the height of the respective outer bag sidewall and the liner sidewall.

Referring now to the drawings, and in particular to FIGS. 1-3, a flexible container 10 is shown. Flexible container 10 is a “bulk bag” (also known as “flexible intermediate bulk container” or (“FIBC”)) and is an industrial flexible container for storing and/or transporting a “bulk amount” which is from 500 pounds to 5,000 pounds, or from 1,000 pounds to 4,000 pounds, or from 1500 pounds to 3500 pounds of a flowable granular material. In other words, flexible container 10, a bulk bag, is constructed to hold or otherwise contain a bulk amount of a flowable granular material. Nonlimiting examples of suitable flowable granular material include, sand, salt, fertilizer, carbon black, dry food, spices, granules of plastic, and chemicals. Nonlimiting examples of suitable forms for the flowable granular material include granule, powder, pellet, flake, and combinations thereof.

In an embodiment, flexible container 10 has a substantially square, or a square, cross-sectional shape (from top plan view, FIG. 4). A square cross-sectional shape for flexible container 10 is advantageous as the square (or substantially square) cross-sectional shape (i) reduces the risk of pallet overhang, thereby concomitantly reducing the risk of damage to flexible container 10, and (ii) facilitates stacking.

Outer bag 12 is made from a woven material. The woven material is durable and resilient and suitable for holding a bulk amount of the flowable granular material without rupture or tearing. Nonlimiting examples of suitable materials for the woven material include woven natural fiber (cotton, wool, hemp, and combinations thereof) and/or woven synthetic fiber (woven polypropylene fiber, woven polyethylene fiber, woven polyester fiber, and combinations thereof). In an embodiment, outer bag 12 includes electrically conductive threads and/or electrically conductive tape integrated into the woven material. The electrically conductive threads/tape control, and ground, any electrostatic charge that may be created with handling and movement of the bulk amount of the flowable granular material within, into, or out of, flexible container 10.

In an embodiment, a fusion coating covers, some, part, or all of the surface of the woven material for outer bag 12.

Outer bag 12 includes lift loops 16. Lift loops 16 are attached to the corners of outer bag 12 as shown in FIG. 1. Nonlimiting examples of suitable attachment for lift loops 16 to outer bag 12 include sewn, adhesive attachment (by way of adhesive material such as glue), heat fused, and any combination thereof. Flexible container 10 is hung from lift loops 16 for discharge of the flowable granular material therefrom, as will be described below. In an embodiment, liner 14 includes lift loops (not shown). The lift loops of liner 14 (when present) correspond to lift loops 16 of outer bag 12.

Liner 14 is a flexible single layer structure or is a flexible multilayer structure composed of one or more polymeric materials. Nonlimiting examples of suitable polymeric material for liner 14 include olefin-based polymer, polyester, polyamide and combinations thereof. Nonlimiting examples of suitable olefin-based polymer include propylene-based polymer (propylene homopolymer, propylene/ethylene copolymer, propylene/C₄-C₈alpha-olefin copolymer), ethylene-based polymer (ethylene homopolymer, ethylene/C₃-C₈alpha-olefin copolymer, high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE)). Nonlimiting examples of suitable polyester include ethylene vinyl acetate copolymer (EVA), ethylene acrylate copolymer, ethylene methacrylate copolymer, and polyethylene terephthalate (PET). Nonlimiting examples of polyamide include nylon 6, and nylon 12. When liner 14 is a multilayer structure, liner 14 may or may not include a moisture barrier layer, such as a layer containing ethylene vinyl alcohol (EVOH) for example. When liner 14 is a multilayer structure, liner 14 may or may not include one or more tie layers. Liner 14 has a thickness from 50 microns to 250 microns, or from 60 microns to 150 microns.

Flexible container 10 includes outer bag 12 and liner 14. Liner 14 substantially corresponds to, or corresponds to, outer bag 12. The term liner 14 “corresponds to” (or “corresponding to”) outer bag 12, as used herein, refers to the dimensional relationship between liner 14 and outer bag 12 whereby liner 14 (i) has substantially the same, or the same, configuration (body, top/bottom panels, inlet, discharge spout) as outer bag 12, (ii) has substantially the same, or the same, dimensions (height, width, depth) as outer bag 12, (iii) such that liner 14 fits snugly within outer bag 12 and the outer surface of liner 14 is substantially coextensive with, or is coextensive with, the inner surface of outer bag 12, as shown in FIGS. 6, 7, 8, and 9.

Direction arrow A in FIG. 6 shows liner 14 fits into and is placed within the interior volume of outer bag 12. Dashed line B in FIG. 7 depicts the configuration and orientation of liner 14 within the interior of outer bag 12. In FIG. 8, dashed line C represents liner 14 within outer bag 12 and shows that liner 14 fits snugly into the interior of outer bag 12. FIG. 9 is a sectional view of flexible container 10. FIG. 9 shows the outer surface of liner 14 substantially coextensive with, or coextensive with, the inner surface of outer bag 12. As shown in FIGS. 6-9, liner 14 substantially corresponds to, or corresponds to, outer bag 12, and liner 14 is a “form-fitted liner” with respect to outer bag 12.

Outer bag 12 and liner 14 each includes a body, a top panel, a bottom panel, an inlet, and an elongated discharge spout. The body, top panel, bottom panel, inlet, and elongated discharge spout of liner 14 substantially correspond to, or correspond to, respective body, top panel, bottom panel, inlet, and elongated discharge spout of outer bag 12. In identifying and describing the components for outer bag 12 and liner 14, the reference numeral for the outer bag component will be provided with the reference numeral for the liner component shown in closed parentheses directly adjacent to the reference numeral for the outer bag component. Referring to FIGS. 1, 2, 3, 8, and 9, outer bag 12/liner 14 each respectively has a sidewall 18 (18a), a top end 20 (20a), and an opposing bottom end 22 (22a). Sidewall 18 (18a) has a height 24 (24a). A top panel 26 (26a) extends from top end 20 (20a), and an inlet 28 (28a) extends from top panel 26 (26a). Inlet 28 (28a) has a length 29, (29a), as shown in FIG. 2.

As shown in FIGS. 1-5, outer bag 12/liner 14 each respectively has a bottom panel 30 (30a) extending from bottom end 22 (22a). An elongated discharge spout 32 (32a) extends from bottom panel 30 (30a). Outer bag elongated discharge spout 32 and the liner elongated discharge spout 32a each has a respective length 34 (34a) from 0.40 times to 1.0 times the height 24 (24a) of the respective outer bag sidewall 18 and the liner sidewall (18a). FIGS. 1, 2, 3, 5 and 8 show elongated discharge spout 32 (32a) each has an elliptical (substantially circular, or circular) cross sectional shape as opposed to a polygonal (square or rectangular) cross-sectional shape.

FIG. 2 and FIG. 8 show height 24 (24a) of sidewall 18 (18a) and length 34 (34a) of elongated discharge spout 32 (32a). The length (or extent) of length 34 (34a) (of elongated discharge spout 32 (32a)) is from 0.4 times (0.4×) to 1.0× of the length of height 24 (24a) (of sidewall 18 (18a)). In an embodiment, length 34 (34a) (of elongated discharge spout 32 (32a)) is from 0.4 times (0.4×) to 1.0×, or from 0.4× to 0.8×, or from 0.4× to 0.6×, or from 0.4× to 0.5× the length of height 24 (24a) (of sidewall 18 (18a)).

In an embodiment, the length of height 24 (24a) is from 55 inches to 75 inches, or from 60 inches or 70 inches, or 60 inches and length 34 (34a) of elongated discharge spout (32 (32a) is from 25 inches to 60 inches, or from 26 inches to 40 inches, or from 27 inches to 35 inches, or from 27 inches to 30 inches, or 27 inches with the length 34 (34a) being from 0.4× to 1.0× the length of height 24 (24a).

Length 34 (34a) of elongated discharge spout 32 (32a) is greater than length 29, (29a) of inlet 28, (28a) as shown in FIG. 2. Length 34 (34a) of elongated discharge spout 32 (32a) has a length (or an extent) that is from 1.1× to 1.6×, or from 1.2× to 1.5× greater than the length (or extent) of length 29, (29a) of inlet 28, (28a).

FIG. 4 shows inlet 28, 28a each has an elliptical (substantially circular, or circular) cross section shape as opposed to a polygonal (square or rectangular) cross-sectional shape. FIG. 2 shows diameter 31 of inlet 28, (28a). In an embodiment, the diameter 31 is from 13 inches (33 cm) to 22 inches (56 cm), or from 14 inches (36 cm) to 20 inches (51 cm), or from 15 inches (38 cm) to 20 inches (51 cm), or from 14 inches (36 cm) to 18 inches (46 cm), or 14 inches (36 cm), or 15 inches (38 cm), or 20 inches (51 cm).

In an embodiment, liner 14 is attached, or otherwise is affixed, to outer bag 12. Attachment between liner 14 and outer bag 12 is by way of stitching (sewn), attachment member, adhesive attachment, and combinations thereof. FIGS. 1, 2, 3, 4, and 8 show outer bag inlet 28 and liner inlet 28a each has a respective topmost edge. Outer bag inlet 28 has topmost edge 36 and liner inlet 28a has topmost edge 36a. A stitching 38 attaches topmost edge 36 (of outer bag inlet 28) to topmost edge 36a (of liner inlet 28a) along substantially the entire, or the entire, circumference of topmost edges 36, 36a. Stitching 38 advantageously prevents separation of outer bag inlet 28 from liner inlet 28a, particularly during the stresses imposed when filling flexible container 10 with a bulk amount of flowable granular material.

FIG. 5 shows elongated discharge spout 32, (32a) each has an elliptical (substantially circular, or circular) cross sectional shape as opposed to a polygonal (square or rectangular) cross-sectional shape. FIG. 2 shows a diameter 35 for elongated discharge spout 32. In an embodiment, the diameter of elongated discharge spout 32, (32a) is from 13 inches (33 cm) to 22 inches (56 cm), or from 14 inches (36 cm) to 20 inches (51 cm), or from 15 inches (38 cm) to 20 inches (51 cm), or from 14 inches (36 cm) to 18 inches (46 cm), or 14 inches (36 cm), or 15 inches (38 cm), or 20 inches (51 cm).

FIGS. 1, 2, 3, 5, and 8 show outer bag elongated discharge spout 32 and liner elongated discharge spout 32a each has a respective distalmost edge. Outer bag elongated discharge spout 32 has distalmost edge 40 and liner elongated discharge spout has distalmost edge 40a. A stitching 42 attaches distalmost edge 40 (of outer bag elongated discharge spout 32) to distalmost edge 40a (of liner elongated discharge spout 32a) along substantially the entire, or the entire, circumference of distalmost edges 40, 40a. Stitching 42 advantageously prevents separation of outer bag elongated discharge spout 32 from liner elongated discharge spout 32a, particularly during the stresses imposed upon elongated discharge spout 32 (32a) when discharging and/or evacuating the bulk amount of flowable granular material from flexible container 10.

In an embodiment, an attachment member is located between liner 14 and outer bag 12. Nonlimiting examples of suitable attachment members include attachment tabs, an adhesive material, and combinations thereof. Attachment tabs enable liner 14 to be sewn, tied, and/or glued to outer bag 12.

In an embodiment the attachment member is adhesive material 44, as shown in FIGS. 9-10. Adhesive material 44 is located, or is otherwise disposed, between the inner surface of outer bag 12 and the outer surface of liner 14 to attach, adhere, or otherwise bond, outer bag 12 to liner 14. Adhesive material 44 can be coextensive with the outer surface of liner 14. Alternatively, adhesive material 44 can be non-coextensive with the outer surface of liner 14. FIGS. 9-10 show adhesive material 44 being non-coextensive with the outer surface of liner 14, whereby adhesive material 44 is located between a portion of corresponding sidewall 18 (18a), a portion of corresponding bottom panel 30, (30a), with other areas between outer bag 12/liner 14 free of adhesive material.

In an embodiment, flexible container 10 includes a strap 46 as shown in FIG. 11. Strap 46 is used to tie-off, or otherwise close off, elongated discharge spout 32 (32a). Strap 46 can be attached to elongated discharge spout 32. Alternatively, strap 46 can be a stand-alone component, not attached to flexible container 10 (other than when closing-off elongated discharge spout 32 (32a)).

Flexible container 10 (with elongated discharge spout 32 (32a)) has a discharge spout that is longer than the discharge spout of conventional bulk bags. In an embodiment, elongated discharge spout 32 (32a) has length from 25 inches to 60 inches, or from 26 inches to 40 inches, or from 27 inches to 35 inches, or from 27 inches to 30 inches with the length of elongated discharge spout 32 (32a) having a length (or extent) from 0.4× to 1.0× the height respective outer bag sidewall 18 and liner sidewall 18a. The additional length provided by elongated discharge spout 32 (32a) allows for improved handling and improved clamping with unloading equipment. Elongated discharge spout 32 (32a) reduces exposure of flexible bag 10 contents to operators and contributes to a dust-tight material discharge assembly.

2. Assembly

The present disclosure provides an assembly. In an embodiment, the assembly includes a support frame, a hoist support engaged with the support frame, and a hoist movably engaged with the hoist support. A container transport component is engaged to the hoist, the container transport component adapted to engage the flexible container with elongated discharge spout. The assembly includes a container support surface attached to the support frame, the container support surface having a receiving aperture. The assembly includes an access chamber located below the container support surface. The access chamber has a ceiling and an opposing floor. The access chamber also has (i) a port in fluid communication with the receiving aperture and (ii) a discharge tube. The discharge tube extends through the floor, the discharge tube having a top rim in the access chamber and a bottom rim below the floor. The elongated discharge spout of the flexible container extends into and through the receiving aperture, the port, and the discharge tube. The assembly includes a sealing device movable between an engaged position and a disengaged position. The sealing device secures a distal end of the elongated discharge spout to the bottom rim and an affixing member when the sealing device is in the closed position.

Assembly 110 includes a support frame 112 and a hoist support 114 engaged with the support frame as shown in FIGS. 12-13. Assembly 110 is an assembly for discharging a bulk amount of flowable granular material from a bulk bag, such as flexible container 10. Hoist support 114 is an I-beam engaged to, or otherwise attached to, support frame 112 with one or more support brackets. A hoist 116 is movably engaged with hoist support 114. A container transport component 118 is engaged to hoist 116, by way of a chain or a cable, for example. Assembly 110 includes cross support members 117, which are welded to the other portions of frame 112 to provide additional strength.

Hoist 116 is operably coupled to a heavy-duty chain 120, a heavy-duty cable, or other lifting member. The lifting strength of hoist 116 is typically from one ton to five tons, or from one ton to four tons. A hook 122 is mounted to chain 120 such that the hook 122 is allowed to rotate without binding the chain.

Container transport component 118 includes one or more arms 124 that engage with lift loops 16 of flexible container 10. Container transport 118 further includes loop retention members (not shown) to prevent lift loops 16 from unintentionally disengaging from container transport component 118 during lifting and moving of the flexible container 10.

As shown in FIGS. 12-13, hoist 116 lifts, or otherwise suspends, flexible container 10 from the ground. Hoist 116 subsequently moves along hoist support 114 in the direction of arrow D (FIG. 12) to move flexible container 10 above container support surface 126; container support surface 126 attached to support frame 112 as shown in FIGS. 12-17. Hoist 116 lowers flexible container 10 so that bottom panel 30 of flexible container 10 comes to rest upon container support surface 126. A receiving aperture 128 of container support surface 126 receives elongated discharge spout 32 (32a) of flexible container 10, elongated discharge spout 32 (32a) extending through receiving aperture 128 as shown in FIGS. 12-13.

In an embodiment, container support surface 126 is a vibration plate. The vibration plate includes two vibrator motors operatively engaged to a square or a rectangular mass flow dish with steeped sides leading down to the receiving aperture. Four vibration isolation mounts attach the vibration plate to the support frame. As the hoist lowers flexible bag 10 onto vibration plate, elongated discharge spout 32 is fed through the receiving aperture 128. Vertical (and horizontal) vibration loosens the flowable granular material and shapes the bottom of flexible container 10 for flow and discharge of the flowable granular material from flexible container 10.

In an embodiment, two massage paddles 130 are mounted on opposing sides of container support surface 126 as shown in FIGS. 12-17. Massage paddles 130 massage the bottom portion of flexible container 10. Massage paddles 130 are typically made of steel tubing and are pneumatically driven. A pneumatic mechanism (not shown) moves the massage paddles 130 each independently to provide a force of up to 1000 pounds on each side of flexible container 10. Massage paddles 130 are adjustable in force and in frequency. The force is adjusted by setting the pressure regulator to the desired setting and the frequency is adjusted by setting an adjustable timer. Also massage paddles 130 can be set to stroke into flexible container 10 in alternating fashion. The massage paddle on the right will stroke in, then, as it retracts, the massage paddle on the left will stroke in and vice-versa. Alternatively, the massage paddles 130 can be set to stroke in and out simultaneously.

The vibration plate and/or the massage paddles may be used in conjunction with one another to prevent bridging and rat-holing by any combination of vibration and stroking forces.

Assembly 110 includes access chamber 132 attached to, and below, container support surface 126. Access chamber 132 has a ceiling 134, an opposing floor 136, and walls 138 extending between ceiling 134 and floor 136. Access door 140 provides access to the interior of access chamber 132. A port 142 (FIG. 13) is present in ceiling 134, port 142 aligned with and in fluid communication with receiving aperture 128 of container support surface 126. In an embodiment, access chamber 132 is dust-tight.

A discharge tube 144 extends through the floor 136 of access chamber 132. Discharge tube 144 has an upper portion 146 with a top rim 148 (FIG. 12) and a lower portion 150 with a bottom rim 152 (FIG. 12). Upper portion 146 and top rim 148 are located in the interior of access chamber 132. Lower portion 150 and bottom rim 152 are located below the floor 136. Upper portion 146 and lower portion 150 each can be a discrete component, a discrete part, whereby lower portion 150 is a separate part removably and mechanically attached to the bottom of access chamber 132, and aligned with upper portion 146 which is a separate part. Alternatively, discharge tube 144 is an integral structure whereby upper portion 146 and lower portion 150 are sections of a single unitary component that is the discharge tube 144.

Elongated discharge spout 32 (32a) of flexible container 10 (i) extends into and through receiving aperture 128 (of container support surface 126), (ii) extends into and through port 142, (iii) extends into and through access chamber 132, and (iv) extends into and through discharge tube 144. Assembly 110 includes a sealing device 154. Sealing device 154 is moveable between a disengaged position and an engaged position. When moved to the engaged position, securing device 154 secures a distal end of elongated discharge spout 32 (32a) to bottom rim 152 and an affixing member to form a dust-tight seal.

In an embodiment, sealing device 154 includes an affixing member that is an exit ring 156 as shown in FIGS. 13, 13A, and 13B. The distal end of the elongated discharge spout 32 (32a), which is located inside the lower portion 150 of the discharge tube 144, is placed around the outer surface of exit ring 156 as shown in FIG. 13A. Once the distal end of the elongated discharge spout 32 (32a) is skirted around the exterior surface of exit ring 156, pneumatic cylinders 158 move exit ring 156 from a disengaged position shown in FIG. 13A, to an engaged position, shown in FIG. 13B. Pneumatic cylinders 158 pull exit ring 156 toward bottom rim 152 sandwiching the distal end of the elongated discharge spout 32 (32a) between bottom rim 152 and the exit ring 156, thereby securing the distal end of the elongated discharge spout in place. When the sealing device is in the engaged position, exit ring 156 and bottom rim 152 mate, in male-female relation, to form a closed and dust-tight seal with the distal end of the elongated discharge spout immobilized therebetween.

In an embodiment, sealing device 154 includes an affixing member that is a feed tube 160 as shown in FIGS. 14-16. Feed tube 160 is an inlet to receive flowable granular material from discharge tube 144, feed tube 160 being a conduit for the flowable granular material to move from discharge tube 144 to other downstream processing equipment such as a receptacle for the flowable granular material, or a conveyor system, for example. The distal end of the elongated discharge spout 32 (32a), which is located inside the lower portion 150 of the discharge tube 144, is placed around the outer surface of feed tube 160. Once the distal end of the elongated discharge spout 32 (32a) is skirted around the exterior surface of feed tube 160, feed tube 160 is moved from a disengaged position to an engaged position whereby feed tube 160 engages with bottom rim 152 sandwiching the distal end of the elongated discharge spout 32 (32a) between bottom rim 152 and the feed tube 160, thereby securing the distal end of the elongated discharge spout in place. When the sealing device is in the engaged position, feed tube 160 and bottom rim 152 mate, in male-female relation, to form a closed and dust-tight seal with the distal end of the elongated discharge spout immobilized between feed tube 160 and bottom rim 152.

Sealing device 154 is in operative communication, or otherwise is in fluid communication, with a slide valve 162. Slide valve 162 can be a component of the sealing device. The slide valve 162 can be a component of exit ring 156 or can be a component of feed tube 160, for example. Alternatively, slide valve 162 is a stand-alone component. Slide valve is in operative and fluid communication with additional processing equipment such as a receptacle, a conveyor system, or other downstream processing equipment. Slide valve 162 is openable (to an open position) and closable (to a closed position) and controls the flow of the flowable granular material. Slide valve 162 forms a dust-tight seal between the sealing device 154 and downstream processing equipment.

Assembly 110 includes a discharge gate 164, located in access chamber 132 as shown in FIGS. 14, 14A, 16, and 16A. Discharge gate 164 includes a track 166 which is attached to ceiling 134 of the access chamber 132. Discharge gate 164 includes an orifice 168, and a plate 170. Orifice 168 is aligned with, and is in fluid and operative communication with, port 142 and receiving aperture 128. With flexible container 10 placed on container support surface 126, elongated discharge spout 32 (32a) is extended into and through receiving aperture 128, port 142, orifice 168, discharge tube 144, as previously described. A pneumatic cylinder moves plate 170 in the direction of arrow E to a closed position as shown in FIGS. 14, 14A. Once the distal end of elongated discharge spout 32 (32a) is secured to the affixing member by way of sealing device 154, an operator unties strap 46 (arrow G in FIG. 15) in access chamber 132. Discharge gate 170 is moved in the direction of arrow F to an open position (FIG. 16A) and flowable granular material 180 flows into and through the elongated discharge spout and concomitantly flows into and through receiving aperture 128, port 142, orifice 168, discharge tube 144, and sealing device 154, reaching slide valve 162. During unloading of the flowable granular material, plate 170 can be moved in the direction of arrow E (FIG. 14A), moving plate 170 back to the closed position stopping flow, and enabling strap 46 to tie-close elongated discharge spout 32 (32a), if desired.

The diameter of elongated discharge spout is less than the diameter of discharge tube 144 as shown in FIGS. 14-16. A gap 174 (FIG. 13) is present between top rim 148 of discharge tube and ceiling 134 of the access chamber. When slide valve 162 is in the closed position (and plate 170 is in the open position), flow of the flowable granular material stops at slide valve 162. Flowable granular material accumulates in the slack 176 of elongated discharge spout causing a portion of the elongated discharge spout to expand to an expanded diameter length that is greater than the diameter of the discharge tube 144, as shown in FIG. 15. Since elongated discharge spout 32 (32a) is placed inside discharge tube 144, the outer surface of elongated discharge spout contacts (wholly or partially) the inner surface of upper portion 146 and the inner surface of lower portion 150 of the discharge tube 144, advantageously creating a dust-tight seal.

In an embodiment, assembly 110 includes a vacuum system 178, as shown in FIG. 17. Vacuum system 178 is in operative and fluid communication with the interior volume of access chamber 144. At the end of the unloading process, vacuum system 178 enables capture of residual flowable granular material still present in the flexible container by collapsing flexible container 10. In an embodiment, vacuum system 144 is in operative communication with access door 140 so that when access door 140 is closed, vacuum system activates and applies a negative pressure within the access chamber, advantageously reducing, or eliminating, dust in the access chamber interior.

In an embodiment, the hoist, vibration plate, massage paddles, sealing device, discharge gate, slide valve, and vacuum system are all electronically controlled by an operator utilizing a control panel. The control panel includes a central processing unit to automate these functions.

Assembly 110 and flexible container 10 (with elongated discharge spout 32 (32a)), advantageously provide a material discharge assembly for bulk bags that is substantially dust-tight, or dust-tight, providing a safe work environment for operators and surrounding equipment.

It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.

FLEXIBLE CONTAINER, BULK BAG AND MATERIAL DISCHARGE ASSEMBLY

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