SYSTEMS AND METHODS FOR EMPLOYING A BULKHEAD BAG IN INTERMODAL SHIPPING OF DRY FLOWABLE COMMODITIES

Abstract

Systems and methods for employing a bulkhead bag in intermodal shipment of dry flowable commodities are disclosed. An example system includes a bulkhead bag configured to be positioned on a loading floor, between sidewalls, and proximate loading doors of an intermodal shipping container. The example system includes one or more straps configured to extend between and couple to connection points of the bulkhead bag and eyelets of the intermodal shipping container to hold an upper edge of the bulkhead bag aloft from the loading floor. The bulkhead bag is configured to expand when filled with a first portion of the dry flowable commodity such that end portions of the bulkhead bag engage sidewalls of the intermodal shipping container to form a partition between the loading doors and an interior of the intermodal shipping container used to contain a second larger portion of the dry flowable commodity.

Description

TECHNICAL FIELD

The present disclosure generally relates to logistical shipment systems and methods, and more specifically, to systems and methods used for the shipment of dry flowable commodities, such as, for example, corn, rice, soybeans, malt, barley and other bulk grains.

BACKGROUND

Grain and other dry flowable commodities are shipped around the world from where they are harvested and plentiful to places where they are in demand on a daily basis. For example, wheat and grain grown in the American Midwest are frequently shipped to China. While domestic transport is typically done by loading the commodities from large silos into open-topped railroad cars, international transport requires the use of covered, stackable intermodal containers that typically must be end-loaded. The grain (for example) is not boxed or separately contained, but rather poured onto the floor of the container. Because of the nature of the “flowable” material, as it piles up it spreads out and would eventually spill out the loading doors on the end of the container. Thus, a bulkhead, or brace, is positioned just inside the doors to hold the grain in place and allow the doors to close. The bulkhead serves the additional purpose of helping keep the grain from moisture that may seep under or around the doors during oversea shipment.

Traditionally, and for many years, bulkheads have been supported with long wooden boards, such as 2″×6″ boards cut to fit across the width of the container. The boards extend across the width of the intermodal container and stack just inside the door, such as illustrated in the video available at https://www.youtube.com/watch?v=ToQ9TXzuqD0. While effective, this can be expensive depending on the cost of wood. There is typically no recovery of the materials used to create or support the bulkhead. Once the shipping container reaches its destination, the bulkhead is disassembled and discarded or put to other uses, but is not returned to the entity that shipped the commodities. Moreover, removal of the boards at the destination may be difficult due to the pressure of the grain (or other commodity) pushing against them and pinning them to the rear frame edges of the container.

SUMMARY

The present invention provides a new and unique solution to these issues that actually employs the commodity itself to help secure the bulkhead. In essence, the systems and methods disclosed involve filling a bin or other expandable tub with the commodity to be shipped that is pre-positioned to serve as a bulkhead to hold the commodity loaded beyond the bin in an intermodal container.

An example system disclosed herein for loading and transporting a dry flowable commodity comprises an intermodal shipping container that comprises a loading floor, a ceiling, sidewalls, a closed end wall, loading doors opposite the closed end, and eyelets fixed to at least one of the ceiling and the sidewalls adjacent the loading doors and the ceiling. The example system also comprises a bulkhead bag that extends between the sidewalls on the loading floor and proximate the loading doors. The bulkhead bag comprises a bottom portion engaging the loading floor, end portions for engaging the sidewalls of the intermodal shipping container, an upper edge opposite the bottom portion and defining an opening of the bulkhead bag, and connection points proximate the upper edge. The example system also comprises one or more straps extending between and coupled to eyelets of the intermodal shipping container and the connection points of the bulkhead bag. The one or more straps hold the upper edge of the bulkhead bag aloft from the loading floor of the intermodal shipping container. The bulkhead bag is configured to expand when filled with a first portion of the dry flowable commodity such that the end portions engage the sidewalls to form a partition between the loading doors and an interior of the intermodal shipping container used to contain a second larger portion of the dry flowable commodity.

In some examples, the bulkhead bag is configured to form a rectangular cuboid when the upper edge of the bulkhead bag is held aloft by the one or more straps and the bulkhead bag is filled with the first portion of the dry flowable commodity.

In some examples, the bulkhead bag comprises one or more baffles that define the intermodal shipping container into different sections across a width of the intermodal shipping container. In some such examples, at least some of the one or more baffles defines openings configured to allow the passage of the dry flowable commodity between the different sections of the bulkhead bag.

In some examples, at least a portion of the bulkhead bag is formed of a polypropylene material.

In some examples, the eyelets include inner eyelets and outer eyelets, where the outer eyelets are positioned between the loading doors and the inner eyelets. The connection points include inner connection points and outer connection points, where the outer connection points are positioned between the loading doors and the inner connection points. The one or more straps include an inner strap and an outer strap, where the outer strap is positioned between the loading doors and the inner strap. In some such examples, the outer strap extends between and is coupled to the outer eyelets and the outer connection points, and the inner strap extends between and is coupled to the inner eyelets and the inner connection points. Further, in some such examples, the inner eyelets and the outer eyelets each include two eyelets, the inner connection points and the outer connection points each include three anchor loops, and the inner strap and the outer strap each is configured to form an M-shaped pattern.

Some examples further comprise a diverting line coupled to an auger and a flow valve for controlling flow of the dry flowable commodity through the diverting line. The flow valve has an open position and a closed position that enables and prevents, respectively, the flow of the dry flowable commodity through the diverting line. In some such examples, when the flow valve is in the open position, the diverting line is configured to fill the bulkhead bag with the first portion of the dry flowable commodity while the auger fills the intermodal shipping container with the second larger portion of the dry flowable commodity.

Another example system is disclosed herein for loading and transporting a dry flowable commodity within an intermodal shipping container. The intermodal shipping container has a loading floor, a ceiling, sidewalls, a closed end, loading doors, and eyelets. The example system comprises a bulkhead bag configured to be positioned on the loading floor, between the sidewalls, and proximate the loading doors of the intermodal shipping container. The bulkhead bag comprises a bottom portion configured to engage the loading floor, end portions configured to engage the sidewalls, an upper edge opposite the bottom portion and defining an opening of the bulkhead bag, and connection points proximate the upper edge. The example system also comprises one or more straps configured to extend between and couple to the connection points of the bulkhead bag and the eyelets of the intermodal shipping container to hold the upper edge of the bulkhead bag aloft from the loading floor. The bulkhead bag is configured to expand when filled with a first portion of the dry flowable commodity such that the end portions engage the sidewalls to form a partition between the loading doors and an interior of the intermodal shipping container used to contain a second larger portion of the dry flowable commodity.

An example method is disclosed herein for loading and transporting a dry flowable commodity within an intermodal shipping container. The intermodal shipping container has a loading floor, a ceiling, sidewalls, a closed end, loading doors, and eyelets. The example method comprises the step of positioning a bulkhead bag on the loading floor, between the sidewalls, and proximate the loading doors of the intermodal shipping container. The bulkhead bag comprises a bottom portion configured to engage the loading floor, end portions configured to engage the sidewalls, an upper edge opposite the bottom portion and defining an opening of the bulkhead bag, and connection points proximate the upper edge. The example method also comprises the steps of extending one or more straps between and coupling the one or more straps to the connection points of the bulkhead bag and the eyelets of the intermodal shipping container, raising the upper edge of the bulkhead bag away from the loading floor of the intermodal shipping container, and filling the bulkhead bag with a first portion of the dry flowable commodity via an auger. The bulkhead bag expands when filled such that the end portions engage the sidewalls to form a partition between the loading doors and an interior of the intermodal shipping container used to contain a second larger portion of the dry flowable commodity.

Some examples further comprise the step of filling the intermodal shipping container with the second larger portion of the dry flowable commodity via the auger. In some such examples, the step of filling the bulkhead bag with the first portion of the dry flowable commodity is performed simultaneously with the step of filling the intermodal shipping container with the second larger portion of the dry flowable commodity until the bulkhead bag is substantially full. Further, in some such examples, the step of filling the intermodal shipping container with the second larger portion of the dry flowable commodity continues after the bulkhead bag is filled with the first portion of the dry flowable commodity.

In some examples, the step of filling the bulkhead bag with the first portion of the dry flowable commodity comprises the step of filling the bulkhead bag via a diverting line coupled to the auger. Some such examples further comprise the step of opening a flow valve to enable the dry flowable commodity to flow through the diverting line and into the bulkhead bag. Further, some such examples further comprise the step of closing the flow valve to prevent the dry flowable commodity from flowing through the diverting line and into the bulkhead bag.

In some examples, the step of extending the one or more straps between and coupling the one or more straps to the connection points of the bulkhead bag and the eyelets of the intermodal shipping container comprises extending an inner strap between and coupling the inner strap to inner connection points and inner eyelets and extending an outer strap between and coupling the outer strap to outer connection points and outer eyelets. The outer strap, the outer connection points, and the outer eyelets are positioned between the loading doors and the inner strap, the inner connection points, and the inner eyelets.

Some examples further comprise the step of cutting the bulkhead bag after the intermodal shipping container has been transported with the dry flowable commodity to empty the first portion of the dry flowable commodity from the bulkhead bag, remove the partition, and subsequently empty the second portion of the dry flowable commodity from the intermodal shipping container.

As will be understood and appreciated by those of skill in the art from a review of the full written description below, variations may be made to the routing of the straps described above in some embodiments, and additional components or steps may be used in some particular embodiments. Still other embodiments and/or features are identified in the disclosure and claims below, in combination with the associated figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Where dimensions are provided, they are used for reference and understanding, and are not limiting unless the feature in question expressly claimed to be of a particular dimension. In the drawings, like reference numerals designate corresponding parts throughout the several views.

FIG. 1 is an isometric view of an empty intermodal shipping container with the loading doors open.

FIG. 1A is an exploded view of an eyelet anchor fixed to an interior wall of the intermodal shipping container.

FIG. 2 is a side view of a standard-length intermodal shipping container loaded with grain and cutaway on one side to show certain internal features.

FIG. 3 is an isometric view of the intermodal shipping container of FIG. 2 showing the end of the container with a traditional bulkhead in place.

FIG. 4 is a side view of a large bag for containing waste and/or recyclable materials.

FIG. 5 is perspective view of a baffle bag with upper handles and a bottom opening.

FIG. 6 is a top view of a baffle bag with corner baffles or stiffeners.

FIG. 7 is a perspective view of an example bulkhead bag in accordance with the teachings herein.

FIG. 8 is another perspective view of the bulkhead bag of FIG. 7.

FIG. 9 is a top view of the bulkhead bag of FIG. 7.

FIG. 10 is a side view of an example baffle of the bulkhead bag of FIG. 7 in accordance with the teachings herein.

FIG. 11 is a partial rear view of an open intermodal shipping container with the bulkhead bag of FIG. 7 positioned in accordance with the teachings herein.

FIG. 12 is a partial front view of the bulkhead bag of FIG. 7 from within the intermodal shipping container of FIG. 11.

FIG. 13 is a partial rear view of the bulkhead bag of FIG. 7 keeping a load of grain within the intermodal shipping container of FIG. 11.

FIG. 14 is a side view of the intermodal shipping container of FIG. 11 with the bulkhead bag of FIG. 7 in place prior to filling.

FIG. 15 is a side view of the bulkhead bag of FIG. 7 installed on the intermodal shipping container of FIG. 11.

FIG. 16 is a side view of the intermodal shipping container of FIG. 11 and the bulkhead bag of FIG. 7 with an auger in place to fill the bulkhead bag and the intermodal shipping container with grain.

FIG. 17 is a side view of the auger of FIG. 16 filling the bulkhead bag of FIG. 7 and the intermodal shipping container of FIG. 11.

FIG. 18 is a side view of the auger of FIG. 16 continuing to fill the intermodal shipping container of FIG. 11 after the bulkhead bag of FIG. 7 has been filled.

FIG. 19 is a side view of the intermodal shipping container of FIG. 11 and the bulkhead bag of FIG. 7 after the bulkhead bag has been cut to empty the grain from the bulkhead bag and the intermodal shipping container.

FIG. 20 is a partial rear view of two augers in place to fill the intermodal shipping container of FIG. 11 and the bulkhead bag of FIG. 7.

FIG. 21 is a top view of another example bulkhead bag in accordance with the teachings herein.

FIG. 22 is a top view of the bulkhead bag of FIG. 21 with a strap for installing the bulkhead bag onto the intermodal shipping container of FIG. 11.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The description that follows describes, illustrates and exemplifies one or more particular embodiments of the present invention in accordance with its principles. This description is not provided to limit the invention to the embodiments described herein, but rather to explain and teach the principles of the invention in such a way to enable one of ordinary skill in the art to understand these principles and, with that understanding, be able to apply them to practice not only the embodiments described herein, but also other embodiments that may come to mind in accordance with these principles. The scope of the present invention is intended to cover all such embodiments that may fall within the scope of the appended claims, either literally or under the doctrine of equivalents.

The example systems and methods disclosed herein relate to the shipment of dry flowable commodities, which can be of a variety of types such as corn, soybeans, wheat, rice or other lentils or grains as well as animal feed products such as DDGS, soybean meal, corn gluten meal, etc. It could also be used with the shipment of small particulate materials that spread laterally in all directions when piled up, such as dirt, sand, pea gravel and other loose materials. One of skill in the art would understand that certain adjustments may need to be made to the load specifications and materials described herein depending on the density/weight of the particulate to be contained. For the purpose of describing the invention, “grain” is used as a surrogate for all dry flowable materials such as those described above, with the understanding that the invention is not limited to the containment of grain.

Grain is typically shipped internationally in intermodal containers that are generally standard-sized containers and configured to attach to a container chassis for hauling by truck over road as well as a container car for rail transport. The containers can be moved from truck to rail and vice versa using overhead cranes, and also lock in to one another for purposes of stacking on ocean ships. The containers are typically 40, 45, or 53 feet in length, 8 feet wide and either 8 feet, 6 inches or 9 feet, 6 inches (high cube) tall, exterior dimensions. The containers are constructed of steel, and feature ribbing along the sides for extra support.

FIG. 1 shows a standard intermodal shipping container 10 from an end view, where the loading doors 20 are opened to allow the container to be filled. As shown, the container 10 features a loading floor 40 that is flat, a ceiling 50, and left and right sidewalls 30. The sidewalls 30 and the ceiling 50 are reinforced with ribs 60 that pass circumferentially around the container 10 and under the loading floor 40. Tie down features may be located at various points throughout the container 10. As shown in FIG. 1, and more clearly in the closeup of FIG. 1A, the container 10 used in the present invention include three anchor points (also called “u-channels” in the art, but referred to herein as eyelet anchors or simply “eyelets”) that each consist of a horizontal steel rod (e.g., eyelet 70) spanning two of the ribs 60 that are vertical, and inset from one of the sidewalls 30 of the container 10. In the illustrated example, two of the eyelets 70 are a few inches off the loading floor 40, a third of the eyelets 70 is near the ceiling 50, and a fourth of the eyelets 70 is approximately between the other of the of the eyelets 70. These three eyelets 70 are located just inside the loading doors 20 on both of the sidewalls 30 of the container 10, thus the container 10 includes eight of the eyelets 70 total. In other examples, the container 10 may include more, less, and/or differently positioned of the eyelets 70. For example, each side of the container 10 may include two of the eyelets 70 that are near the loading floor 40 and another two of the eyelets 70 that are upper eyelets near the ceiling 50 (as shown in FIGS. 11-13 and 20). Additionally, those of skill in the art will appreciate that some containers have four eyelets 70 along the ribs 60 just inside each of the loading doors 20, equally spaced such that none of the eyelets 70 are in the vertical center of the container, but rather one of the eyelets 70 is about 12″ up from the vertical center and one of the eyelets 70 about 12″ down from the vertical center. The designations “L” and “R” (such as 70L and 70R) are used to refer to left and right taken from the perspective of a rear view of the container, such as in FIG. 1.

Notably, the grain cannot be filled through the top of the container 10 because there is no opening. Rather, a conveyer is inserted through the loading doors 20 that are open and into the interior of the container 10 along its ceiling 50. Grain is then deposited onto the loading floor 40. The result is a pile of grain highest in the center and lowest at the ends, as shown in FIG. 2, which depicts a side view of an intermodal container with grain loaded and a side removed to show the load distribution. As the grain fills, the grain presses out against the sidewalls 30 and a closed end wall 25 of the container 10. Because the loading doors 20 are opened, a bulkhead 110 must be installed prior to loading the grain to provide a barrier to prevent the grain from spilling out the end of the container 10 with the loading doors 20 that are open. One or more conveyers or augers (e.g., an auger 300 of FIGS. 16-19 and/or augers 300L, 300R of FIG. 20) is inserted over the top of the bulkhead 110 to load the grain; thus, the bulkhead 110 cannot extend all the way to the ceiling 50. Additionally, the bulkhead 110 need not extend to the ceiling 50, because the grain will only fill a few feet up from the loading floor 40 at the container ends.

Imagined in three dimensions, it will be appreciated that the load against the bulkhead 110 is greatest at its base (where it extends from the loading floor 40) and its center. The weight of the grain against the bulkhead 110 decreases as one move vertically and laterally to the sides. Thus, more resistive force is required at the lower center than at other places along the bulkhead to keep the bulkhead 110 in place during loading and shipping.

The bulkhead 110, when properly installed, allows the loading doors 20 to close and provides an air gap between the bulkhead 110 and the loading doors 20 during shipment. Oftentimes, the seals on the loading doors 20 wear over time and allow some intrusion of moisture during ocean transit. The bulkhead 110 is spaced slightly inward of the loading doors 20, when properly installed, to keep the moisture away from the grain and, in turn, prevent mildew and spoilage of the grain. At the destination site, the loading doors 20 are opened without grain spillage because the bulkhead 110 is still in place. The bulkhead 110 is then removed to allow the grain to be emptied largely by force of gravity.

As explained in the background section above, traditional bulkhead systems use wooden boards for support. Others, such as that shown at bulk-liner.com/products/door-bulkhead, use steel bars. Both of these prior art bulkhead means are expensive and, while re-usable, typically are not returned to the entity that prepared and shipped the grain. Rather, the materials are either repurposed or disposed of at the receiving end, resulting in a loss for the shipper. Moreover, they can be difficult to disassemble once the weight of the grain has settled against the bulkhead.

FIG. 3 shows an isometric rear view of the container 10 loaded with a dry flowable commodity 100 and the bulkhead 110 in place. The bulkhead 110 shown in FIG. 3 is a traditional bulkhead system that is typically comprised of a cardboard ply 105 braced into place by a series of wood planks or boards 120—typically 2×6 boards—stacked behind the cardboard and pressing against the door frame 90 of the container at either side. While sufficiently sturdy, such a design is relatively expensive and carries with it market fluctuations in the price of lumber. It is also heavy to load and can be difficult to unload on the far end. The boards 120 must be unloaded one at time, each one allowing the grain level to drop slightly in order to take pressure off the next lower board and allow it to be lifted out. Even then, the boards 120 sometimes become stuck or have too much weight against them such that they must be cut out, which can be dangerous due to the load against them.

Example systems and methods disclosed herein utilize a large, expandable bag that is configured to form a bulkhead for an intermodal container. These bags are referred to herein as “bulkhead bags.” The bulkhead bag, such as bulkhead bag 200 of FIGS. 7-19 and another bulkhead bag of FIGS. 20-22, may be composed of relatively cheap material, such as polypropylene, that carries with it reduced market fluctuations compared to that of lumber. Further, the bulkhead bag may be composed of recyclable material, such as polypropylene, to reduce waste generated for the transportation process.

Large bags composed of similar material, such as bag 1000 of FIG. 4 or bag 2000 of FIGS. 5-6, are known, but have not been configured or adapted for use as a bulkhead. The bag 1000 includes a body 1100 and handles 1200 and is configured to contain and transport waste and/or recyclable materials. The handles 1200 are used to lift the bag 1000 into, for example, a garbage truck. The bag 2000 is configured to contain and discharge dry flowable commodities, but is sized and shaped to be lifted by a standard forklift using handles 2200 or held aloft for emptying. As shown in FIGS. 5-6, the bag 2000 includes a body 2100 defining a cavity 2150, handles 2200, a discharge chute 2300, and corner baffles 2400 (also referred to as corner stiffeners) positioned in the cavity 2150. The corner baffles 2400 define holes 2450 through which particulate contained in the cavity 2150 can flow. When the bag 2000 is lifted by a forklift via the handles 2200, the body 2100 is lifted off the flat surface, the discharge chute 2300 unfolds, and the dry flowable commodity is discharged through an outlet 2350 of the discharge chute 2300. Such bags are known to be used for storage and local transport (such as within a warehouse).

Contrarily, the bulkhead bags of examples disclosed herein are configured to be installed proximate loading doors of an intermodal container to securely retain grain within the intermodal container during shipment. They are not intended or designed to lift or transport grain separate from the intermodal container, but rather to serve as part of a long-haul system. Indeed, attempting to lift the bulkhead bags once they are substantially filled would be counterproductive and would likely cause them to tear because they are very heavy (weighing several thousands pounds), which allows them to prevent seepage of the grain loaded in the container beyond them and serve as an effective bulkhead. While the mass of dry flowable commodities or other materials that can be transported by this system vary, the bulkhead bags are sufficiently large that their weight (when full) proportionate to the force placed against them by more of the same material filling the intermodal container beyond the bag is not sufficient to laterally shift the bulkhead bag.

In some embodiments, the bulkhead bags includes a bottom portion that engages the loading floor and opposing end portions that extend between and engage the opposing sidewalls of the intermodal container. The bulkhead bags may include an upper edge opposite the bottom portion that defines an opening of the bulkhead bag. Anchor loops or other connection points may extend from the upper edge. One or more straps may extend from the anchor loops of the bulkhead bag to upper eyelets of the intermodal container to hold the upper edge of the bulkhead bag aloft from the loading floor of the intermodal container while the lower portion remains engaged to the loading floor.

After a bulkhead bag is installed within an intermodal container, an auger fills the bulkhead bag with grain, for example, via a diverting line (e.g., a flexible hose) extending from the auger. A flow valve controls when grain is to flow through the diverting line and into the bulkhead bag. As the bulkhead bag is filled with grain, the bulkhead bag expands such that the end portions sealingly engage the sidewalls and the bottom portion sealingly engages the loading floor to form a partition or bulkhead proximate the loading doors of the intermodal container. Subsequently or concurrently, the auger can fill the inner portion of the intermodal container adjacent the bulkhead bag with additional grain, which is kept within the intermodal container by the filled and expanded bulkhead bag. After the auger fills the intermodal container with grain, the auger is removed from the intermodal container and the loading doors are closed adjacent the bulkhead bag. Upon the intermodal container transporting the grain to its target destination, the bulkhead bag is cut or torn to facilitate the easy unloading of the grain from both the bulkhead bag and the inner portion of the intermodal container.

Turning to FIGS. 7-10, an example bulkhead bag 200 is disclosed in accordance with the teachings herein. The bulkhead bag 200 includes a bottom portion 210, an upper edge 220, end portions 230, and side portions 240. The end portions 230 extend between the bottom portion 210 and the upper edge 220 at respective opposing ends of the bulkhead bag 200. The side portions 240 extend between the bottom portion 210 and the upper edge 220 and between the end portions 230 at respective opposing sides of the bulkhead bag 200. The bottom portion 210, the end portions 230, and the side portions 240 define a cavity 250 in which material, such as a dry flowable commodity, may be contained. The upper edge 220 is opposite the bottom portion 210 and defines an opening through which the cavity 250 may be filled with the material.

The bulkhead bag 200 also includes one or more baffles 255 that provide additional structural support to the bulkhead bag 200 when filled with material, such as a dry flowable commodity. The one or more baffles 255 extend from the bottom portion 210 to the upper edge 220 to provide the additional structural support. In the illustrated example, the baffles 255 include two parallel baffles that extend between the side portions 240 of the bulkhead bag 200 and divide the cavity 250 into three sections. Each of the baffles 255 define holes 257 that enable material, such as a dry flowable commodity, to flow between different sections of the cavity 250. In other examples, the bulkhead bag 200 may include more (e.g., three, four, etc.) or less (e.g., one) of the baffles 255. Additionally or alternatively, the baffles 255 of the bulkhead bag 200 may be arranged in different configurations. For example, the baffles 255 may extend between the end portions 230 and/or between adjacent ones of the end portions 230 and the side portions 240 in the corners of the cavity 250.

Portions of the bulkhead bag 200, including the bottom portion 210, the end portions 230, and the side portions 240, and the baffles 255, are formed of a material, such as a polypropylene material, that is flexible, durable, and cuttable. For example, portions of the bulkhead bag 200 may be formed of a 90-gram polypropylene layer that is coated on both sides with a 20-gram polyethylene coating. The polyethylene coating deters the material from fraying once the bulkhead bag is cut. The bulkhead bag 200 is formed of a material that is flexible to enable the bulkhead bag 200 to expand when filled with a dry flowable commodity. The bulkhead bag 200 is formed of a material that is durable to enable the bulkhead bag 200 to maintain its form while being filled with and transporting the dry flowable commodity. The bulkhead bag 200 is formed of a material that is cuttable, as disclosed in greater detail below, to enable an operator to cut or tear the bulkhead bag 200 open in order to discharge the dry flowable commodity from the bulkhead bag 200 and the container 10 at a target destination.

The bulkhead bag 200 of the illustrated example also includes connection points 260, 265 that are proximate to and/or extend from the upper edge 220 of the bulkhead bag 200. In the illustrated example, the connection points 260, 265 are anchor loops. While loops are shown, one of skill in the art will recognize that the loops could be substituted with reinforced slits or openings along the top edge of the bulkhead bag, embedded hooks or grommets, or any other known means for connecting and securing the top edge, as discussed below, without changing the spirit of the invention. As disclosed below in greater detail, each of the connection points 260, 265 is configured to receive one or more straps (e.g., straps 270, 275 of FIGS. 11-13, a strap 370 of FIG. 22) hanging from upper eyelets of the container 10 to hold the upper edge 220 of the bulkhead bag 200 aloft from the loading floor 40 of the container 10 to form a partition or bulkhead between the loading doors 20 and an interior of the container 10. In the illustrated example, the straps are ropes. Here again, one of ordinary skill in the art will understand that ropes may be substituted with chords, cables, or other traditional connection means capable of extending from the top edge to the eyelets on the container walls and securing the two together at the appropriate distance. The connection points 260, 265 of the illustrated example are preferably formed of a flexible and durable material, such as polypropylene to enable the upper edge 220 of the bulkhead bag 200 to be securely held aloft during loading.

In the illustrated example, the connection points 260, 265 are securely attached to the side portions 240 and/or the end portions 230, for example, via sewing, mechanical fasteners, adhesive, etc. The connection points 260, 265 include inner connection points 260 and outer connection points 265. The inner connection points 260 include three connection points that are attached to one of the side portions 240. For example, the first of the inner connection points 260 is attached to the respective side portion 240 and one of the end portions 230 at a corner of the bulkhead bag 200, the second of the inner connection points 260 is attached to the respective side portion 240 and the other of the end portions 230 at another corner of the bulkhead bag 200, and the third of the inner connection points 260 is attached to the respective side portion 240 equidistantly between the other two of the inner connection points 260. The outer connection points 265 include three connection points that are attached to the other of the side portions 240. For example, the first of the outer connection points 265 is attached to the respective side portion 240 and one of the end portions 230 at a corner of the bulkhead bag 200, the second of the outer connection points 265 is attached to the respective side portion 240 and the other of the end portions 230 at another corner of the bulkhead bag 200, and the third of the outer connection points 265 is attached to the respective side portion 240 equidistantly between the other two of the outer connection points 265.

The bulkhead bag 200 of the illustrated example also includes anchor ties 262, 267 that are proximate to and/or extend from the bottom portion 210 of the bulkhead bag 200. As disclosed below in greater detail, each of the anchor ties 262, 267 is configured to be tied to lower eyelets of the container 10 to further secure the bulkhead bag 200 to the container 10. The anchor ties 262, 267 are formed of a flexible and durable material, such as polypropylene. The anchor ties 262, 267 are securely attached to the side portions 240 and/or the end portions 230, for example, via sewing, mechanical fasteners, adhesive, etc. In the illustrated example, each of the anchor ties 262, 267 extends from a respective lower corner of the bulkhead bag 200. For example, each of the anchor ties 262 extends from opposing lower corners of one of the side portions 240 proximate the bottom portion 210 and a respective one of the end portions 230. Each of the anchor ties 262 extends from opposing lower corners of the other of the side portions 240 proximate the bottom portion 210 and a respective one of the end portions 230.

FIGS. 11-13 depict a bulkhead system installed within the container 10 proximate the loading doors 20 to form a partition or bulkhead that retains dry flowable commodity within the container 10. The bulkhead system includes the bulkhead bag 200 and one or more straps (e.g., straps 270, 275) for securing the bulkhead bag 200 to the container 10 in a manner that forms a partition or bulkhead for the dry flowable commodity.

The container 10 includes the loading doors 20, the closed end wall 25, the sidewalls 30, the loading floor 40, and the ceiling 50. In the illustrated example, the eyelets 70 of the container 10 includes inner eyelets 71, 72 and outer eyelets 73, 74. Each of the inner eyelets 71, 72 and the outer eyelets 73, 74 are fixed to the ceiling 50 and/or one of the sidewalls 30 proximate the loading doors 20. The inner eyelets 71, 72 are positioned further within the container 10, relative to the outer eyelets 73, 74, such that (1) the inner eyelets 71, 72 are positioned between the outer eyelet 73, 74 and the closed end wall 25 and (2) the outer eyelets 73, 74 are positioned between the inner eyelets 71, 72 and the loading doors 20.

In the illustrated example, the bulkhead bag 200 is positioned within the container 10 proximate the loading doors 20 such that the inner connection points 260 are proximate the closed end wall 25 and the outer connection points 265 are in a direction toward the loading doors 20. The bulkhead bag 200 is positioned on the loading floor 40 such that the bottom portion 210 of the bulkhead bag 200 engages the loading floor 40. The bulkhead bag 200 extends between the sidewalls 30 such that each of the end portions 230 of the bulkhead bag 200 engages a respective one of the sidewalls 30 of the container 10.

In the illustrated example, the one or more straps of the bulkhead system include an inner strap 270 and an outer strap 275. The straps 270, 275 extend between, extend through, and couple to the respective connection points 260, 265 of the bulkhead bag 200 and the eyelets 71, 72, 73, 74 of the container 10 to hold the upper edge 220 aloft from the loading floor 40 of the container 10 in an installed position of the bulkhead bag 200. For example, the inner strap 270 extends between, extends through, and couples to the inner connection points 260 and the inner eyelets 71, 72 in an M-shaped pattern to securely hold open the bulkhead bag 200 in the installed position. The outer strap 275 extends between, extends through, and couples to the outer connection points 265 and the outer eyelets 73, 74 in an M-shaped pattern to securely hold open the bulkhead bag 200 in the installed position. That is, the outer strap 275 of the illustrated example is positioned between the inner strap 270 and the loading doors 20 of the container 10. Additionally, the anchor straps 262, 267 of the bulkhead bag 200 are configured to couple to lower eyelets of the container 10 proximate the loading floor 40 to further secure the bulkhead bag 200 to the container 10 in the installed position.

When the straps 270, 275 bring the bulkhead bag 200 into the installed position, the bulkhead bag forms a rectangular cuboid shape (e.g., having dimensions of 96″×36″×36″). The bulkhead bag 200 is configured to expand when filled with a portion of dry flow commodity (e.g., dry flowable commodity 175 of FIG. 17) such that the bottom portion 210 sealingly engages the loading floor 40 and the end portions 230 sealingly engage the respective sidewalls 30 to form a partition or bulkhead between the loading doors 20 and an interior of the container 10. As disclosed below in greater detail, an interior of the container 10 is able to be securely filled with additional dry flowable commodity 150 once the bulkhead bag 200 is installed and filled with dry flowable commodity 175. The fastening of the bulkhead bag 200 to the container 10 and the weight of the dry flowable commodity 175 contained within the bulkhead bag 200 (e.g., about 3,000 pounds) combine to withstand a force applied by the weight of the dry flowable commodity 150 contained within the interior of the container 10, thereby preventing the dry flowable commodity 150 from spilling out through the loading doors 20.

FIGS. 14-19 depict a sequence of steps for installing the bulkhead bag 200, filling the container 10 and the bulkhead bag 200 with the dry flowable commodity 150, 175, and subsequently discharging the dry flowable commodity 150, 175 from the container 10.

FIG. 14 depicts the bulkhead system after the bulkhead bag 200 has been placed on the loading floor 40 proximate the loading doors 20. FIG. 15 depicts the bulkhead system installed on the container 10. The straps 270, 275 have been extended between and coupled to the connection points 260, 265 of the bulkhead bag 200 and the eyelets 71, 72, 73, 74 of the container 10. For example, the inner strap 270 has been extended between and coupled to the inner connection points 260 and the inner eyelets 71, 72, and the outer strap 275 has been extended between and coupled to the outer connection points 265 and the outer eyelets 73, 74. Additionally, the upper edge 220 of the bulkhead bag 200 has been raised away from the loading floor 40 of the container 10 via the straps 270, 275.

FIG. 16 depicts the bulkhead system and the container 10 after an auger 300 has been positioned to extend over the bulkhead bag 200 and into the container 10. The auger 300 is configured to fill the container 10 and the bulkhead bag 200 with dry flowable commodity. For example, the dry flowable commodity 150 is configured to be discharged into the interior of the container 10 from a distal end of the auger 300, and the dry flowable commodity is configured to be discharged into the bulkhead bag via a diverting line 280 of the bulkhead system that is coupled to the auger 300. In the illustrated example, the auger 300 is positioned relative to the container 10 such that the diverting line 280 is positioned over and/or near the opening of the bulkhead bag 200 to facilitate the filling process. In some examples, the diverting line 280 is a flexible hose (e.g., having a 4 inch or other sized diameter) to provide a tolerance between the alignment of the diverting line 280 and the bulkhead bag 200. Other examples may feature multiple diverting lines so as to simultaneously fill two portions of the bulkhead bag.

The bulkhead system also includes a flow valve 290 coupled to the auger 300 to control the flow of material through the diverting line 280. The flow valve 290 has an open position that enables material to flow through the diverting line 280 and a closed position that prevents material from flowing through the diverting line 280. In other examples, the flow valve is substituted with a gate that is opened and closed electronically or manually.

FIG. 17 depicts the auger 300 filling the container 10 and the bulkhead bag 200 with the respective dry flowable commodity 150, 175. The flow valve 290 has been placed in the open position by an operator, electronically or mechanically, to enable the auger 300 and the diverting line 280 to fill the bulkhead bag 200 with the dry flowable commodity 175 (also referred to as a “first portion of dry flowable commodity”) while the auger 300 fills the interior of the container 10 with the dry flowable commodity 150 (also referred to as a “second portion of dry flowable commodity”). That is, the auger 300 simultaneously fills the bulkhead bag 200 and the container 10 when the flow valve 290 is opened. Further, as shown in FIG. 18, the second portion of the dry flowable commodity is much larger than the first portion of the dry flow commodity. As the bulkhead bag 200 is filled with the dry flowable commodity 175, the bulkhead bag 200 expands such that the end portions 230 sealingly engage the sidewalls 30 and the bottom portion 210 sealingly engage the loading floor 40 to form a partition or bulkhead between the loading doors 20 and an interior of the container 10. The partition or bulkhead formed by the bulkhead bag 200 securely retains the dry flowable commodity 175 within the container 10 between the closed end wall 25 and the bulkhead bag 200.

FIG. 18 depicts the auger 300 continuing to fill the interior of the container 10 with the dry flowable commodity 150 after the flow valve 290 has been closed, electronically or mechanically, by the operator, e.g., once the bag is sufficiently full to serve as a bulkhead and to prevent the diverting line 280 from further filling and/or overfilling the bulkhead bag 200 with the dry flowable commodity 175. In some examples, the interior of the container 10 continues to be filled with the dry flowable commodity 150 until the dry flowable commodity 175 within the container 10 approaches the upper edge 220 of the bulkhead bag 200.

Once the interior of the container 10 is filled with dry flowable commodity 150, the operator causes the auger 300 to stop filling the container 10 with the dry flowable commodity 150. The auger 300 is backed out of the container 10, the loading doors 20 are closed, and the container 10 is transported to its target destination.

FIG. 19 depicts the container 10 and the bulkhead bag 200 after the container 10 has been transported from its target destination. Once the container 10 has reached its target destination, the loading doors 20 are opened and the dry flowable commodity 150, 175 is emptied from the container 10. An operator removes or tears down the bulkhead system to enable the dry flowable commodity 150, 175 to pour out of the container 10. To remove the bulkhead system, the operator cuts or tears the bulkhead bag 200 to empty the dry flowable commodity 150, 175 from the container 10. The bulkhead bag 200 is formed of a relatively cuttable material, such as polypropylene, to facilitate the operator in cutting or tearing the bulkhead bag 200. This is much simpler, quicker and safer than cutting away prior art lumber, which may break and will cause rapid unloading of the grain rather than controlled unloading. In some examples, the operator also disconnects the straps 270, 275 from the eyelets 71, 72, 73, 74 and/or the connection points 260, 265 (e.g., by untying or cutting the straps 270, 275) to further tear down the bulkhead system. Further, in some examples, the operator also disconnects the anchor straps 262, 267 from lower eyelets (e.g., by untying or cutting).

Once the bulkhead bag 200 is cut, the dry flowable commodity 175 flows out from the bulkhead bag 200 and the container 10. As the dry flowable commodity 175 is discharged from the bulkhead bag 200, the upper edge 220 of the bulkhead bag 200 sags downward, thereby lowering the partition or bulkhead that has retained the dry flowable commodity 150 within the interior of the container 10. In turn, the dry flowable commodity 175 is able to be emptied from container 10 as the bulkhead bag 200 is emptied and sags toward the loading floor 40.

FIG. 20 depicts the bulkhead bag 200 installed in the container 10 with two augers 300L, 300R used to fill the bulkhead bag 200 and the container 10 with the dry flowable commodity 150, 175, respectively. In the illustrated example, each of the augers 300L, 300R is configured to fill both the bulkhead bag 200 and the container 10. For example, the augers 300L, 300R include respective diverting lines 280L, 280R and flow valves 290L, 290R to control the filling of the bulkhead bag 200 with the dry flowable commodity 175. In other examples, one of the augers 300L, 300R is configured to fill the bulkhead bag 200 with the dry flowable commodity 175 and the other of the augers 300L, 300R is configured to fill the interior of the container 10 with the dry flowable commodity 150.

FIGS. 21-22 depict another bulkhead system in accordance with the teachings herein. The bulkhead system includes a bulkhead bag 400 and a strap 470. The bulkhead bag 400 of the illustrated example includes components that are identical and/or substantially similar to respective components of the bulkhead bag 200 of FIGS. 7-20, unless otherwise disclosed below. For example, the bulkhead bag 400 includes a bottom portion, an upper edge, end portions, side portions, and baffles that are substantially similar to those of the bulkhead bag 200. Additionally, the bulkhead bag 400 is configured to function as a container partition or bulkhead and be filled by an auger in a manner similar to that of the bulkhead bag 200. Because components and features of the bulkhead bag 200 have been described in detail in connection with FIGS. 7-20, some of those components and features of the bulkhead bag 400 that are substantially similar to that of the bulkhead bag 200 to are not described in further detail below for conciseness purposes.

FIGS. 21-22 depict a top view of the bulkhead bag 400. The bulkhead bag 400 includes one or more upper panels 452 that define one or more openings 451 for filling a cavity 450 of the bulkhead bag 400 with the dry flowable commodity 175. In the illustrated example, the bulkhead bag 400 includes three of the upper panels 452 that define two of the openings 451. In other examples, the bulkhead bag 400 may include more or less of the upper panels 452 and may define more or less of the openings 451.

The bulkhead bag 400 also includes inner connection points 460 and outer connection points 465. In the illustrated example, one of the inner connection points 460 is at a corner of the bulkhead bag 400, another of the inner connection points 460 is at an opposing corner of the bulkhead bag 400, and another the inner connection points 460 is positioned equidistantly between the other two of the inner connection points 460. One of the outer connection points 465 is at a corner of the bulkhead bag 400, another of the outer connection points 465 is at an opposing corner of the bulkhead bag 400, and another the outer connection points 465 is positioned equidistantly between the other two of the outer connection points 465.

As shown in FIG. 21, the bulkhead system includes the strap 470 that is configured to hold the bulkhead bag 400 in an installed position within the container 10. The strap 470 is configured to extend between, extend through, and couple to the connection points 460, 465 of the bulkhead bag 400 and the eyelets 70 of the container 10. In the illustrated example, the strap 470 extends from a left-hand side eyelet (e.g., the eyelet 71), to the left-hand side outer connection point 465, to the left-hand side inner connection point 460, back to the left-hand side eyelet, to the middle outer connection point 465, to the middle inner connection point 460, to a right-hand side eyelet (e.g., the eyelet 72), to the right-hand side outer connection point 465, to the right-hand side inner connection point 460, and back to the right-hand side eyelet.

It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of systems and methods disclosed in this application, as would be understood to a person of skill in the art and based on the design constraints provided. Moreover, the specific dimensions of the bulkhead, strap(s), flow valve, and/or and diverting line (e.g., flexible hose) could be different than shown in the illustrated embodiments without departing from the concepts claimed below and enabled herein. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the novel techniques without departing from its scope. Therefore, it is intended that the novel techniques not be limited to the particular techniques disclosed, but that they include all techniques falling within the scope of the appended claims.

Claims

1. A system for loading and transporting a dry flowable commodity, the system comprising: an intermodal shipping container comprising a loading floor, a ceiling, sidewalls, a closed end, loading doors opposite the closed end, and eyelets fixed to at least one of the ceiling and the sidewalls adjacent the loading doors and the ceiling;a bulkhead bag that extends between the sidewalls on the loading floor and proximate the loading doors, the bulkhead bag comprising a bottom portion engaging the loading floor, end portions for engaging the sidewalls of the intermodal shipping container, an upper edge opposite the bottom portion and defining an opening of the bulkhead bag, and connection points proximate the upper edge; andone or more straps extending between and coupled to the eyelets of the intermodal shipping container and the connection points of the bulkhead bag, the one or more straps operating to hold the upper edge of the bulkhead bag aloft from the loading floor of the intermodal shipping container;wherein the bulkhead bag is configured to expand when filled with a first portion of the dry flowable commodity such that the end portions engage the sidewalls to form a partition between the loading doors and an interior of the intermodal shipping container used to contain a second larger portion of the dry flowable commodity.

2. The system of claim 1, wherein the bulkhead bag is configured to form a rectangular cuboid when the upper edge of the bulkhead bag is held aloft by the one or more straps and the bulkhead bag is filled with the first portion of the dry flowable commodity.

3. The system of claim 1, wherein the bulkhead bag comprises one or more baffles that define the intermodal shipping container into different sections across a width of the intermodal shipping container.

4. The system of claim 3, wherein at least some of the one or more baffles defines openings configured to allow the passage of the dry flowable commodity between the different sections of the bulkhead bag.

5. The system of claim 1, wherein at least a portion of the bulkhead bag is formed of a polypropylene material.

6. The system of claim 1, wherein: the eyelets include inner eyelets and outer eyelets, the outer eyelets being positioned between the loading doors and the inner eyelets;the connection points include inner connection points and outer connection points, the outer connection points being positioned between the loading doors and the inner connection points; andthe one or more straps include an inner strap and an outer strap, the outer strap being positioned between the loading doors and the inner strap.

7. The system of claim 6, wherein the outer strap extends between and is coupled to the outer eyelets and the outer connection points, and wherein the inner strap extends between and is coupled to the inner eyelets and the inner connection points.

8. The system of claim 7, wherein the inner eyelets and the outer eyelets each include two eyelets, the inner connection points and the outer connection points each include three connection points, and the inner strap and the outer strap each is configured to form an M-shaped pattern.

9. The system of claim 1, further comprising a diverting line coupled to an auger and a flow valve for controlling flow of the dry flowable commodity through the diverting line, the flow valve having an open position and a closed position that enables and prevents, respectively, the flow of the dry flowable commodity through the diverting line.

10. The system of claim 9, wherein when the flow valve is in the open position, the diverting line is configured to fill the bulkhead bag with the first portion of the dry flowable commodity while the auger fills the intermodal shipping container with the second larger portion of the dry flowable commodity.

11. A system for loading and transporting a dry flowable commodity within an intermodal shipping container having a loading floor, a ceiling, sidewalls, a closed end, loading doors, and eyelets, the system comprising: a bulkhead bag configured to be positioned on the loading floor, between the sidewalls, and proximate the loading doors of the intermodal shipping container, the bulkhead bag comprising a bottom portion configured to engage the loading floor, end portions configured to engage the sidewalls, an upper edge opposite the bottom portion and defining an opening of the bulkhead bag, and connection points proximate the upper edge; andone or more straps configured to extend between and couple to the connection points of the bulkhead bag and the eyelets of the intermodal shipping container to hold the upper edge of the bulkhead bag aloft from the loading floor;wherein the bulkhead bag is configured to expand when filled with a first portion of the dry flowable commodity such that the end portions engage the sidewalls to form a partition between the loading doors and an interior of the intermodal shipping container used to contain a second larger portion of the dry flowable commodity.

12. A method for loading and transporting a dry flowable commodity within an intermodal shipping container having a loading floor, a ceiling, sidewalls, a closed end, loading doors, and eyelets, the method comprising the steps of: positioning a bulkhead bag on the loading floor, between the sidewalls, and proximate the loading doors of the intermodal shipping container, the bulkhead bag comprising a bottom portion configured to engage the loading floor, end portions configured to engage the sidewalls, an upper edge opposite the bottom portion and defining an opening of the bulkhead bag, and connection points proximate the upper edge;extending one or more straps between and coupling the one or more straps to the connection points of the bulkhead bag and the eyelets of the intermodal shipping container;raising the upper edge of the bulkhead bag away from the loading floor of the intermodal shipping container; andfilling the bulkhead bag with a first portion of the dry flowable commodity via an auger, the bulkhead bag expanding when filled such that the end portions engage the sidewalls to form a partition between the loading doors and an interior of the intermodal shipping container used to contain a second larger portion of the dry flowable commodity.

13. The method of claim 12, further comprising the step of filling the intermodal shipping container with the second larger portion of the dry flowable commodity via the auger.

14. The method of claim 13, wherein the step of filling the bulkhead bag with the first portion of the dry flowable commodity is performed simultaneously with the step of filling the intermodal shipping container with the second larger portion of the dry flowable commodity until the bulkhead bag is substantially full.

15. The method of claim 14, wherein the step of filling the intermodal shipping container with the second larger portion of the dry flowable commodity continues after the bulkhead bag is filled with the first portion of the dry flowable commodity.

16. The method of claim 12, wherein the step of filling the bulkhead bag with the first portion of the dry flowable commodity comprises the step of filling the bulkhead bag via a diverting line coupled to the auger.

17. The method of claim 16, further comprising the step of opening a flow valve to enable the dry flowable commodity to flow through the diverting line and into the bulkhead bag.

18. The method of claim 17, further comprising the step of closing the flow valve to prevent the dry flowable commodity from flowing through the diverting line and into the bulkhead bag.

19. The method of claim 12, wherein the step of extending the one or more straps between and coupling the one or more straps to the connection points of the bulkhead bag and the eyelets of the intermodal shipping container comprises: extending an inner strap between and coupling the inner strap to inner connection points and inner eyelets; andextending an outer strap between and coupling the outer strap to outer connection points and outer eyelets;wherein the outer strap, the outer connection points, and the outer eyelets are positioned between the loading doors and the inner strap, the inner connection points, and the inner eyelets.

20. The method of claim 12, further comprising the step of cutting the bulkhead bag after the intermodal shipping container has been transported with the dry flowable commodity to empty the first portion of the dry flowable commodity from the bulkhead bag, remove the partition, and subsequently empty the second portion of the dry flowable commodity from the intermodal shipping container.