1. Field of the Invention
The present invention relates generally to packaging and, more particularly, to packaging and methods for packaging for particulate and granular materials.
2. Description of Related Art
Particulate and granular materials are commonly packaged in bags, sacks or other packaging materials (collectively referred to herein as “bags”) constructed of paper. As used herein, the term “particulate materials” refers to powdery materials that generate dust when disturbed, such as during packaging. For purposes of example only and not limitation, particulate materials can include cementitious materials, such as cement and concrete mixes, limestone, fly ash, bottom ash, powdered sugar, etc. As used herein, the term “granular materials” refers to materials that are composed of granules or grains, or have a grainy texture, and which may or may not generate dust when disturbed. For purposes of example only and not limitation, granular materials can include sand, pea gravel, sugar, salt, etc.
The conventional paper bags used to package particulate and granular materials are generally closed at one end either when the bag is made or prior to filling by folding the sides of the bag inwardly in an overlapping configuration and then securing the sides together using an adhesive. The bags are filled with the particulate or granular material through the open end of the bag, which is then closed by folding the sides of the bag inwardly in an overlapping configuration and then securing the sides together using an adhesive.
Conventional paper bags are structured to allow air to escape from the interior of the bags so that the bags can be compressed when the bags are stacked, such as on a pallet. However, conventional paper bags have several disadvantages. For example, in addition to allowing air to escape, conventional paper bags also can allow fine particles from the particulate or granular material inside the bag to escape, which can result in appreciable amounts of dust, particularly when storing the bags in an enclosed space such as a warehouse or inside a store. Conventional paper bags also are susceptible to rupturing or tearing if not handled properly, which can result in product spillage and waste. Conventional paper bags also allow moisture to permeate the bag, which will typically have an adverse effect on the particulate or granular material inside the bag. For example, where the bag is used to package cementitious material, moisture can lead to curing of the cementitious material inside the bag thereby rendering the product useless. This can be particularly problematic when storing or handling the bags outside where the bags can be exposed to rain, condensation or other wet ambient conditions. Conventional paper bags also can be difficult to load and unload manually when the bags are filled with particulate or granular material. For example, bags used to package cementitious material are typically offered in 29 lb, 44 lb, 50 lb, 60 lb and 80 lb bags, which are heavy and can be difficulty to carry.
Accordingly, there remains a need for packaging for particulate and granular material generally and cementitious materials in particular. The packaging should be capable of being filled and sealed using an automated filling machine and should allow the particulate or granular material to be stored so as to minimize leakage, spillage and exposure to moisture. The packaging should also be stackable when filled with particulate or granular material, such as on a pallet, and should also facilitate manual loading and unloading of the filled packaging.
The present invention provides package for particulate and granular material. According to one embodiment, the package includes a bag formed of a polymeric material. The bag has first and second ends. The first end of the bag is sealed and the second end of the bag is open. The first end of the bag has a first tab extending therefrom defining at least one aperture therethrough so that the first tab defines a first handle. In one embodiment, the edge of the at least one aperture in the first tab is at least partially sealed. The second end of the bag is structured to be sealed after filling the bag with the particulate or granular material. The second end of the bag has an excess portion structured to be formed into a second tab defining at least one aperture therethrough upon sealing of the second end of the bag so as to define a second handle. In one embodiment, the bag has first and second sides, wherein at least a portion of the first side and/or the second side of the bag defines a textured surface.
The present invention provides package for cementitious material. According to one embodiment, the package includes a bag formed of a polymeric material. The bag has first and second ends. The first end of the bag is sealed and the second end of the bag is open. The first end of the bag has a first tab extending therefrom defining at least one aperture therethrough so that the first tab defines a first handle. In one embodiment, the edge of the at least one aperture in the first tab is at least partially sealed. The second end of the bag is structured to be sealed after filling the bag with the cementitious material. The second end of the bag has an excess portion structured to be formed into a second tab defining at least one aperture therethrough upon sealing of the second end of the bag so as to define a second handle. In one embodiment, the bag has first and second sides, wherein at least a portion of the first side and/or the second side of the bag defines a textured surface.
The present invention also provides a packaged product containing particulate or granular material. According to one embodiment, the packaged product includes a bag formed of a polymeric material. The bag has first and second sealed ends. The first sealed end has a first tab extending therefrom defining at least one aperture therethrough so that the first tab defines a first handle. The second sealed end has a second tab extending therefrom defining at least one aperture therethrough so that the second tab defines a second handle. In one embodiment, the edge of the at least one aperture in the first tab and/or second tab is at least partially sealed. A particulate or granular material is sealed within the bag, wherein the first and second handles facilitate the handling of the packaged product. In one embodiment, the bag has first and second sides, wherein at least a portion of the first side and/or the second side of the bag defines a textured surface.
The present invention also provides a packaged cementitious product. According to one embodiment, the packaged cementitious product includes a bag formed of a polymeric material. The bag has first and second sealed ends. The first sealed end has a first tab extending therefrom defining at least one aperture therethrough so that the first tab defines a first handle. The second sealed end has a second tab extending therefrom defining at least one aperture therethrough so that the second tab defines a second handle. In one embodiment, the edge of the at least one aperture in the first tab and/or second tab is at least partially sealed. A cementitious product is sealed within the bag, wherein the first and second handles facilitate the handling of the packaged cementitious product. In one embodiment, the bag has first and second sides, wherein at least a portion of the first side and/or the second side of the bag defines a textured surface.
The present invention also provides a method for packaging particulate or granular material. According to one embodiment, the method includes providing a bag formed of a polymeric material, the bag having first and second ends. In one embodiment, the providing step includes forming the bag. The first end of the bag is sealed and the second end of the bag is open. The first end of the bag has a first tab extending therefrom defining at least one aperture therethrough so that the first tab defines a first handle. In one embodiment, the providing step includes heating a die and forming the at least one aperture through the first tab using the heated die. In one embodiment, the heating step comprises heating the die to between approximately 420° F. to approximately 460° F. The bag is filled with a predetermined amount of particulate or granular material. The second end of the bag is sealed so as to form a second tab extending therefrom. At least one aperture is formed through the second tab so that the second tab defines a second handle. In one embodiment, the forming step comprises heating a die and forming the at least one aperture through the second tab using the heated die. In one embodiment, the heating step comprises heating the die to between approximately 420° F. to approximately 460° F. In one embodiment, substantially all of the air is removed from the interior of the bag. In one embodiment, the removing step comprises compressing the bag. In another embodiment, the removing step comprises evacuating air from the bag prior to the sealing step. In another embodiment, the filling step and the evacuating step are done concurrently. In yet another embodiment, a plurality of bags are stacked on a pallet. In still another embodiment, the plurality of bags are secured to the pallet.
The present invention also provides a method for packaging cementitious material. According to one embodiment, the method includes providing a bag formed of a polymeric material, the bag having first and second ends. In one embodiment, the providing step includes forming the bag. The first end of the bag is sealed and the second end of the bag is open. The first end of the bag has a first tab extending therefrom defining at least one aperture therethrough so that the first tab defines a first handle. In one embodiment, the providing step includes heating a die and forming the at least one aperture through the first tab using the heated die. In one embodiment, the heating step comprises heating the die to between approximately 420° F. to approximately 460° F. The bag is filled with a predetermined amount of cementitious material. In one embodiment, the filling step includes filling the bag with approximately 29 lbs, 44 lbs, 50 lbs, 60 lbs or 80 lbs of cementitious material. The second end of the bag is sealed so as to form a second tab extending therefrom. At least one aperture is formed through the second tab so that the second tab defines a second handle. In one embodiment, the forming step comprises heating a die and forming the at least one aperture through the second tab using the heated die. In one embodiment, the heating step comprises heating the die to between approximately 420° F. to approximately 460° F. In one embodiment, substantially all of the air is removed from the interior of the bag. In one embodiment, the removing step comprises compressing the bag. In another embodiment, the removing step comprises evacuating air from the bag prior to the sealing step. In another embodiment, the filling step and the evacuating step are done concurrently. In yet another embodiment, a plurality of bags are stacked on a pallet. In still another embodiment, the plurality of bags are secured to the pallet.
The present invention also provides an apparatus for forming handles in polymeric packaging for particulate and granular material. The apparatus includes a die structured to form at least one aperture in the packaging. The apparatus also includes at least one heating element structured to heat the die such that the die seals the edges of the at least one aperture. In one embodiment, the die comprises a forming portion and a backing member. In another embodiment, the at least one heating element is structured to heat the die to between approximately 420° F. to approximately 460° F.
Accordingly, there has been provided packaging and associated packaging methods for particulate and granular material generally and cementitious materials in particular. The packaging is capable of being formed, filled and sealed using an automated forming, filling and sealing machine and allows the particulate or granular material to be stored so as to minimize leakage, spillage and exposure to moisture. The packaging is stackable when filled with the particulate or granular material, such as on a pallet, and also facilitates manual loading and unloading of the filled packaging.
The foregoing and other advantages and features of the invention, and the manner in which the same are accomplished, will become more readily apparent upon consideration of the following detail description of the invention taken in conjunction with the accompanying drawings, which illustrate preferred and exemplary embodiments and which are not necessarily drawn to scale, wherein:
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. This invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
Referring to
As illustrated in
As illustrated in
In forming the apertures 20, 26, the excess material 21 within the apertures can be removed entirely or, as illustrated in
As discussed more fully below, the apertures 20, 26 in the first and second tabs 18, 24 can be formed using a heated die such that the edges 25 of the apertures are at least partially sealed. In one embodiment, the die can include a rim so that the seal at the edges 25 of the apertures 20, 26 extends beyond the edges a predetermined distance. It has been found that using a heated die to at least partially seal the edges 25 of the apertures 20, 26 strengthens the material around the apertures and increases the tear resistance of the material and, thus, strengthens the first and second handles 22, 28 of the bag 12. Advantageously, the first and second handles 22, 28 of the bag 12 of the present invention do not require any further reinforcement, such as the application of reinforcing tape, in order to support the material stored in the bag. In addition, apertures 20, 26 having sealed edges 25 have the further benefit of containing any material that may escape into the first or second tabs 18, 24 due to a ruptured or defective first or second sealed end 14, 16, respectively, thus further minimizing product spillage.
As illustrated in
As illustrated in
Referring to
According to one embodiment, the product 10 is formed from the package 36 in several steps, as illustrated in
As illustrated in
According to another embodiment of the present invention (not shown), the evacuation of the air from the bag 42 can occur concurrently with the step of filling the bag with the material 60. For example, one or more probes can be inserted into the interior of the bag 42 and can evacuate the air from the bag as the bag is filled with material 60. Thereafter, the second end 46 of the bag 42 can be sealed, as discussed above.
In one embodiment, the package 36 is preformed. In another embodiment, the package 36 is formed from a roll of tubular film material (not shown). According to this embodiment, the first end of the bag is sealed to thereby form a first sealed end 44 and a first tab 48. At least one aperture 50 can be formed in the first tab 48 (such as by cutting or die stamping the second tab) so as to define a first handle 52. In one embodiment, the apertures 50 are formed in the first tab 48 and then the first end of the bag is sealed to form the first sealed end 44. The package 36 can be cut from the roll of tubular film material prior to, concurrently with, or after forming the first sealed end 44.
Referring to
Referring to
Referring to
The heated die 82 can be used to form the first and second handles 22, 28 of the bag 12 of the present invention or, in another embodiment (not shown), the heated die 82 can also be used to form packaging having a single handle by forming one or more apertures in a tab, as discussed above. It has been determined that using a heated die 82 to at least partially seal the edges of the apertures forming the handles strengthens the material around the apertures and increases the tear resistance of the material and, thus, provides a more robust handle. Advantageously, handles formed using the heated die 82 of the present invention do not require any further reinforcement, such as the application of reinforcing tape, in order to support the material stored in the bag 12. In addition, handle apertures having sealed edges have the further benefit of containing any material that may escape into the corresponding tab due to a ruptured or defective sealed end, respectively, thus further minimizing product spillage.
The present invention also provides a method of packaging particulate and granular material generally and cementitious materials in particular. According to one embodiment, as illustrated in
According to another embodiment, as illustrated in
Advantageously, the packaging of the present invention is capable of being filled and sealed using an automated filling machine. This feature is particularly important in connection with particulate materials (such as cementitious materials), which are notoriously difficult to package using automated packaging machinery since the dust can inhibit the machinery from forming a proper seal. The packaging also allows the particulate or granular material to be stored so as to minimize leakage, spillage and exposure to moisture. The packaging is stackable when filled with particulate or granular material, such as on a pallet, and also facilitates manual loading and unloading of the filled packaging. Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application claims benefit of U.S. Provisional Application No. 60/672,704, filed Apr. 19, 2005, and U.S. Provisional Application 60/574,860, filed May 27, 2004, which are hereby incorporated herein in their entirety by reference.
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