U.S. patent application number 15/200992 was filed with the patent office on 2017-01-05 for bulk bag apparatus and unique bulk sack solution for storage and transport of torrefied materials.
The applicant listed for this patent is Torresak, LLC. Invention is credited to Thomas M. Nelson.
Application Number | 20170001796 15/200992 |
Document ID | / |
Family ID | 57683693 |
Filed Date | 2017-01-05 |
United States Patent
Application |
20170001796 |
Kind Code |
A1 |
Nelson; Thomas M. |
January 5, 2017 |
BULK BAG APPARATUS AND UNIQUE BULK SACK SOLUTION FOR STORAGE AND
TRANSPORT OF TORREFIED MATERIALS
Abstract
A container receives and holds product. The container includes a
multilayered composite film combination forming a bag defining a
product fill opening. The multilayered composite film combination
includes first and second polymer film inner and outer layers each
having vacuum holding properties, and a third polymer film disposed
between the first and second polymer films. The third polymer film
has oxygen barrier properties. Product is packed into the container
by coupling a fill spout of the container with a fill tube of a
product filling apparatus, and oxygen is drawn from an inner cavity
of the container. Product is flowed through the fill spout of the
container, and nitrogen is added into the inner cavity through the
fill spout of the container. The fill spout of the container is
sealed while a negative pressure is drawn within the inner cavity
thereby immobilizing the product within the container.
Inventors: |
Nelson; Thomas M.; (Chagrin
Falls, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Torresak, LLC |
Chagrin Falls |
OH |
US |
|
|
Family ID: |
57683693 |
Appl. No.: |
15/200992 |
Filed: |
July 1, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62187895 |
Jul 2, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 7/04 20130101; B65B
7/02 20130101; B65B 31/044 20130101; B65B 1/28 20130101; B65B
39/007 20130101; B32B 27/32 20130101; B65D 88/1618 20130101; B32B
27/08 20130101; B32B 2439/40 20130101; B32B 2307/7244 20130101;
B65B 1/26 20130101; B32B 7/12 20130101; B65B 1/22 20130101; B32B
27/306 20130101; B65D 88/1668 20130101; B65B 1/00 20130101; B65B
39/08 20130101; B32B 1/02 20130101; B32B 2307/7242 20130101 |
International
Class: |
B65D 88/16 20060101
B65D088/16; B65B 39/00 20060101 B65B039/00; B65B 1/04 20060101
B65B001/04; B65B 7/02 20060101 B65B007/02; B65D 88/22 20060101
B65D088/22; B65D 88/74 20060101 B65D088/74 |
Claims
1. A container (10) for receiving and holding associated filled
product (2), the container (10) comprising: a multilayered
composite film combination (20) forming a bag (22) defining a
product fill opening (30), the multilayered composite film
combination (20) comprising: a first polymer film (22) having
vacuum holding properties, the first polymer film acting as an
inner layer (23) of the container; a second polymer film (24)
having vacuum holding properties, the second polymer film acting as
an outer layer (25) of the container; and a third polymer film (26)
disposed between the first (22) and second (24) polymer films, the
third polymer film (26) having oxygen barrier properties.
2. The container (10) according to claim 1 wherein: the first
polymer film (22) comprises a first low density polyethylene (LDPE)
film (22'); the second polymer film (24) comprises a second LDPE
film (24'); and the third polymer film (26) comprises an
ethylene-vinyl acetate (EVA) film (26').
3. The container (10) according to claim 2, wherein: the first and
second LDPE films (22', 24') provide an airtight vacuum seal; and
the EVA film (26') is impervious to a flow of oxygen
therethrough.
4. The container (10) according to claim 3, wherein the EVA film is
impervious to a flow of nitrogen therethrough.
5. The container (10) according to claim 2, wherein the
multilayered composite film combination (20) is a co-extrusion of
the LDPE and EVA films.
6. The container (10) according to claim 2, wherein the LDPE and
EVA films are in intimate contact with each other.
7. The container (10) according to claim 2, wherein the LDPE and
EVA films are fused together as a single unitary film
structure.
8. The container (10) according to claim 2, further comprising: a
first adhesive (ADH) film (27) disposed between the first LDPE film
(22') and the EVA (26') film, the first ADH film (27) having
bonding properties for connecting the first LDPE film with the EVA
film; and a second ADH film (28) disposed between the second LDPE
film (24') and the EVA film (26'), the second ADH film (28) having
the bonding properties for connecting the second LDPE film with the
EVA film.
9. The container (10) according to claim 2, further comprising: a
fill spout (32) operatively coupled with the bag at the opening,
the fill spout (32) having a generally cylindrical conformation
defining a first opening (33) in fluid tight connection with the
product fill opening (30) of the bag (22), and a second opening
(34) configured to receive the associated filled product (2) into
the bag through the fill spout (32) and the product fill opening
(30); and a flexible bladder (40) member carried on the fill spout
adjacent to the second opening, the bladder member being configured
to be selectively inflatable for selectively coupling the fill
spout (32) with an associated fill tube (3) communicating the
associated product (2), the bladder member (40) being operative to
couple the fill spout (32) with the associated fill tube (3) when
the bladder (40) is in an inflated condition and to decouple and
release the fill spout (32) from the associated fill tube (3) when
the bladder member (40) is in a deflated condition.
10. A composite bulk storage and transport apparatus (1)
comprising: a flexible intermediate bulk container (FIBC) device
(110); and an in-liner container (10) for receiving and holding
associated filled product (2), the in-liner container (10) being
operatively coupled with the FIBC device (110) and comprising: a
multilayered composite film combination (20) forming a bag (22)
defining a product fill opening (30), the multilayered composite
film combination (20) comprising: a first polymer film (22) having
vacuum holding properties, the first polymer film acting as an
inner layer (23) of the in-liner container; a second polymer film
(24) having vacuum holding properties, the second polymer film
acting as an outer layer (25) of the in-liner container; and a
third polymer film (26) disposed between the first (22) and second
(24) polymer films, the third polymer film (26) having oxygen
barrier properties.
11. The composite apparatus (1) according to claim 10 wherein: the
first polymer film (22) of the in-line container comprises a first
low density polyethylene (LDPE) film (22'); the second polymer film
(24) of the in-line container (10) comprises a second LDPE film
(24'); and the third polymer film (26) of the in-line container
(10) comprises an ethylene-vinyl acetate (EVA) film (26').
12. The composite apparatus (1) according to claim 11, wherein: the
first and second LDPE films (22', 24') of the in-line container
(10) provide an airtight vacuum seal; and the EVA film of the
in-line container (10) is impervious to a flow of oxygen
therethrough.
13. The composite apparatus (1) according to claim 12, wherein the
EVA film of the in-line container (10) is impervious to a flow of
nitrogen therethrough.
14. The composite apparatus (1) according to claim 11, wherein the
multilayered composite film combination (20) is a co-extrusion of
the LDPE and EVA films.
15. The composite apparatus (1) according to claim 11, wherein the
LDPE and EVA films are in intimate contact with each other.
16. The composite apparatus (1) according to claim 11, wherein the
LDPE and EVA films are fused together as a single unitary film
structure.
17. The composite apparatus (1) according to claim 11, wherein the
multilayered composite film combination (20) further comprises: a
first adhesive (ADH) film (27) disposed between the first LDPE film
and the EVA film, the first ADH film (27) having bonding
properties; and a second ADH film (28) disposed between the second
LDPE film and the EVA film, the second ADH film (28) having the
bonding properties.
18. The composite apparatus (1) according to claim 11, further
comprising: a fill spout (32) operatively coupled with the bag at
the opening, the fill spout (32) having a generally cylindrical
conformation defining a first opening (33) in fluid tight
connection with the product fill opening (30) of the bag (22), and
a second opening (34) configured to receive the associated filled
product (2) into the bag through the fill spout (32) and the
product fill opening (30); and a flexible bladder member (40)
carried on the fill spout adjacent to the second opening, the
bladder member being configured to be selectively inflatable for
selectively coupling the fill spout (32) with an associated fill
tube (3) communicating the associated product (2), the bladder
member (40) being operative to couple the fill spout (32) with the
associated fill tube (3) when the bladder (40) is in an inflated
condition and to decouple and release the fill spout (32) from the
associated fill tube (3) when the bladder member (40) is in a
deflated condition.
19. A method (150) of packing a container (10) with an associated
product (2), the method (150) comprising: coupling (152) a fill
spout of the container with a fill tube of an associated filling
apparatus; flowing (153) the associated product into the inner
cavity through the fill spout of the container; drawing (154)
oxygen from an inner cavity of the container; adding nitrogen (155)
into the inner cavity through the fill spout of the container;
drawing a negative pressure (156) within the inner cavity relative
to areas outside of the container; and sealing (157) the fill spout
of the container.
20. The method (150) according to claim 19 wherein the drawing the
negative pressure comprises immobilizing the associated product
within the inner cavity by inward pressure of a wall of the
container on the associated product.
21. The method (150) according to claim 20 wherein the sealing
comprises sealing the fill spout of the container while the inner
chamber is under a negative pressure relative to the areas outside
of the container.
22. The method (150) according to claim 19 wherein the coupling the
fill spout of the container with the fill tube of the associated
filling apparatus comprises inflating a flexible bladder disposed
on the fill spout of the container.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of priority to U.S.
Provisional Patent application Ser. No. 62/187,895, filed on Jul.
2, 2015, the disclosure of which is incorporated herein by
reference in its entirety.
TECHNICAL FIELD
[0002] The embodiments herein relate generally to containers and to
methods of filling containers for storage and transportation of
solid filled products in powder, granule or chip form, in the form
of pieces or in any form convenient for filling, storage and
shipping, and more specifically to containers and to methods of
filling containers for storage and transportation of solid filled
torrefied materials in any form as may be necessary or desired for
convenient and efficient filling, shipping and storage. The example
embodiments herein will be described in connection with a big bulk
bag such as for example a flexible intermediate bulk container
(FIBC). However, it is to be appreciated that the embodiments are
not limited to these applications, but also find use in many other
applications including for example bulk packaging for perishable
dry foods, spices, chemicals and other materials in solid form.
BACKGROUND
[0003] Torrefied or pyrolized biomass is the product of a new and
emerging market. Torrefied biomass has many uses in the energy,
agricultural, chemical and construction industries. This new
carbonized material has, in certain conditions, a calorific energy
value similar to coal. Indeed, one of the principal applications
for torrefied biomass is "biocoal," which is a more environmentally
friendly fuel for generating electricity.
[0004] When biomass is torrefied (heated at 500 C to 600 C in the
absence of oxygen), volatile elements of the biomass are vaporized.
As the material cools, some of these vaporized volatiles condense
back onto the surface of the char. This new carbonized material is
highly flammable and explosive. Under certain conditions, these
condensed volatiles can self-ignite. In addition, grinding the
torrefied biomass during processing thereof can act as an
accelerant to this pyrophoric reaction. It is also possible that
static electric discharge (sparking) could function as an igniter.
It is further possible that friction caused by vibration of the
char during processing, handling or transport could function as an
igniter.
[0005] Given the above, therefore, transporting and storing of
torrefied materials such as biomass or other fuels presents risks
including for example, possible risk of fire and/or explosions.
[0006] It became clear by 2013 that the nascent torrefaction
industry needs to develop new safety protocols, products and
procedures to help reduce the risk of fire and explosion associated
with the handling, storage and transportation of torrefied
biomass.
[0007] A flexible intermediate bulk container (FIBC) or bulk bag,
or big bag, is an industrial container made of flexible fabric that
is designed for storing and transporting dry, flowable products,
such as sand, fertilizer, and granules of plastic. FIBC bulk bags
are available in various standardized configurations including
Types A-D FIBC bulk bags and are compatible for use with virtually
any free-flowing granule, powder, pellet or flake.
[0008] The current package of choice for the torrefaction industry
is merely a regular Type A bulk sack, which is made from plain
woven polypropylene or polyethylene fibers. There are no safety
features inherent to the Type B bulk sack, as the fibers present no
significant barrier to O.sub.2 or H.sub.2O transfer, and there is
no provision for static discharge or friction. Type C bulk sacks
are conductive as they are in general constructed from electrically
conductive fabric, designed to control electrostatic charges by
grounding using integral conductive threads or tape, but they lack
impermeable barrier properties to prevent the transfer of gasses,
moisture and/or other vapors. Lastly, industry standard Type D FIBC
bulk bags have anti-static or static dissipative properties without
the requirement of grounding, but they are also deficient in
providing impermeable barrier properties to prevent the transfer of
gasses, moisture and/or other vapors
[0009] It is therefore desirable to provide a container for the
safe bulk storage and transport of hazardous dry flowable products
such as torrefied materials without these limitations and to a
method for filling such container. In particular, a container that
provides a modified atmosphere environment to help reduce the risk
of fire and explosion inherent to the transport and storage of
torrefied biomass is desirable. A bulk bag container that provides
a significant barrier to O.sub.2 and H.sub.2O transfer is
desirable. Further, a bulk bag container that provides for static
discharge is desirable. Yet still further, a bulk bag container
that substantially controls the movement of the torrefied materials
within the bulk bag is desirable. It is further desirable to
provide systems and methods for easily, efficiently, and safely
filling such containers with torrefied or other hazardous
materials.
BRIEF SUMMARY OF EXAMPLE EMBODIMENTS
[0010] Example embodiments herein relate to a bulk bag apparatus
for safe storage and transport of torrefied materials, and to a
method for filling the bulk bag apparatus.
[0011] In accordance with an example embodiment herein, a bulk
container presents a unique and innovative use of Modified
Atmosphere Packaging (MAP) design and construction to help reduce
the risk of fire and explosion inherent to the transport and
storage of torrefied biomass.
[0012] In accordance with an example embodiment herein, a container
is provided for receiving and holding associated filled product. In
an exampler embodiment, the container includes a multilayered
composite film combination forming a bag defining a product fill
opening. The multilayered composite film combination includes an
inner layer first polymer film having vacuum holding properties, an
outer layer second polymer film having vacuum holding properties,
and a third polymer film disposed between the first and second
polymer films, wherein the third polymer film has oxygen barrier
properties. In an embodiment the first polymer film is a first low
density polyethylene (LDPE) film, the second polymer film is a
second LDPE film, and the third polymer film is an ethylene-vinyl
acetate (EVA) film. The first and second LDPE films provide an
airtight vacuum seal. The EVA film is impervious to flows of oxygen
and nitrogen therethrough.
[0013] In accordance with a further example embodiment, a composite
bulk storage and transport apparatus includes a flexible
intermediate bulk container (FIBC) container and an in-liner
container for receiving and holding associated filled product. The
in-liner container is operatively coupled with the FIBC container
and includes a multilayered composite film combination forming a
bag defining a product fill opening. The multilayered composite
film combination includes a first polymer film having vacuum
holding properties, the first polymer film acting as an inner layer
of the in-liner container; a second polymer film having vacuum
holding properties, the second polymer film acting as an outer
layer of the in-liner container; and a third polymer film disposed
between the first and second polymer films, the third polymer film
having oxygen barrier properties.
[0014] In accordance with yet a further example embodiment, A
method of packing a container with an associated product is
provided. In the method, a fill spout of the container is coupled
with a fill tube of an associated filling apparatus and oxygen is
drawn from an inner cavity of the container. The associated product
is flowed into the inner cavity through the fill spout of the
container and nitrogen is added into the inner cavity through the
fill spout of the container. A negative pressure is drawn within
the inner cavity relative to areas outside of the container, and
the fill spout of the container is sealed. In the example
embodiment, the sealing includes sealing the fill spout of the
container while the inner chamber is under a negative pressure
relative to the areas outside of the container. The drawing of the
negative pressure and the sealing while under the negative pressure
advantageously results in an immobilization of the associated
product within the inner cavity by inward pressure of a wall of the
container on the associated product. In an embodiment the coupling
of the fill spout of the container with the fill tube of the
associated filling apparatus includes inflating a flexible bladder
disposed on the fill spout of the container.
[0015] In accordance with a further example embodiment herein, a
bulk bag apparatus as shown and described herein provides a
significant barrier to O.sub.2 and H.sub.2O transfer; provides for
static discharge; and substantially controls the movement of the
torrefied materials within the bulk bag apparatus thereby
eliminating of substantially abating or friction in and between the
torrefied materials within the bulk bag apparatus.
[0016] Example embodiments of the subject bulk bag apparatus for
safe storage and transport of torrefied materials provide a unique
innovative vacuum packaging with N.sub.2 purge to prevent fire of
torrefied biomass. This is an emerging industry with new and unique
safety concerns, which require novel solutions such as are provided
by the embodiments of the subject bulk bag apparatus.
[0017] Heretofore, commercial bulk sacks failed to use and realize
the benefits of vacuum sealing. Also heretofore, commercial bulk
sacks failed to use and realize the benefits of an N.sub.2 purge
during the bag filling operation. Yet still further heretofore,
commercial bulk sacks failed to use and realize the benefits of
vacuum sealing with an N.sub.2 purge. Embodiments of the container
and of the container filling method herein use one or more of the
vacuum sealing, the N.sub.2 purge during the bag filling operation,
and/or the combination of the vacuum sealing with the N.sub.2
purge
[0018] Additional advantages and features of the embodiments herein
will become apparent from the following description and appended
claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The foregoing and other features of the embodiments herein
will become apparent to those skilled in the art to which the
present surround view systems, calibration systems, and calibration
methods relate, upon reading the following description with
reference to the accompanying drawings, in which:
[0020] FIG. 1 is a perspective schematic view of a composite bulk
storage and transport apparatus in accordance with an example
embodiment.
[0021] FIG. 2 is a diagrammatical view of the composite bulk
storage and transport apparatus shown in FIG. 1.
[0022] FIG. 3 is a diagrammatical view showing an in-liner
container portion removed from the composite bulk storage and
transport apparatus shown in FIG. 2.
[0023] FIG. 3A is a cross-sectional view of the in-liner portion of
the composite bulk storage and transport apparatus in accordance
with a first embodiment taken through line A-A of FIG. 3.
[0024] FIG. 3B is a cross-sectional view of the in-liner portion of
the composite bulk storage and transport apparatus in accordance
with a second embodiment taken through line A-A of FIG. 3.
[0025] FIG. 4 is a diagrammatical view showing a flexible
intermediate bulk container portion of the composite bulk storage
and transport apparatus of FIG. 2 shown in partial phantom.
[0026] FIG. 5 is a diagrammatical view showing the in-liner
container portion of the composite bulk storage and transport
apparatus filled with atmosphere including oxygen prior to a
filling method of an embodiment.
[0027] FIG. 6 is a diagrammatical view showing the atmosphere
including the oxygen being removed from the in-liner container
portion of the composite bulk storage and transport apparatus
during the filling method of an embodiment.
[0028] FIG. 7 is a diagrammatical view showing product and nitrogen
being added into the in-liner container portion of the composite
bulk storage and transport apparatus during the filling method of
an embodiment.
[0029] FIG. 8 is a diagrammatical view showing nitrogen and the
product immobilized within the in-liner container portion of the
composite bulk storage and transport apparatus following the
filling method of an embodiment.
[0030] FIG. 9 is an assembly drawing showing the flexible
intermediate bulk container portion of the composite bulk storage
and transport apparatus in accordance with an embodiment.
[0031] FIG. 10 is an assembly drawing showing the in-liner
container portion of the composite bulk storage and transport
apparatus in accordance with an embodiment.
[0032] FIG. 11 is a flow chart showing a method of packing a
container with an associated product in accordance with an
embodiment.
DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS
[0033] With reference now to the drawing Figures, wherein the
showings are for purposes of describing the embodiments only and
not for purposes of limiting same, example embodiments herein
relate to a container 10 for receiving and holding associated
filled product, a composite bulk storage and transport apparatus
100 including a flexible intermediate bulk container (FIBC) device
110 and the container 10 operable as an in-liner container for
receiving and holding associated filled product, and to a method
150 of packing a container including a sealed 3/16'' to 1/4'' melt
seal 90 at a discharge spout with an associated product. It is to
be appreciated that the embodiments herein are applicable to many
different container schemes and to many different container shapes
and/or configurations having various sizes, and other
characteristics as may be necessary or desired.
[0034] As representative of the embodiments and with reference in
particular first to FIG. 1, a composite bulk storage and transport
apparatus 100 in accordance with an example embodiment is shown in
a perspective schematic view. The composite bulk storage and
transport apparatus 100 includes a FIBC device 110 and an in-liner
container 10 in accordance with the embodiments to be described in
detail below.
[0035] To reduce and substantially eliminate the risk of fire
and/or explosion, the embodiments of the bulk bag herein have been
uniquely engineered to provide a Modified Atmosphere Package (MAP).
In the embodiments herein, the atmospheric conditions inside of the
package are deliberately modified by special package and process
design to produce a specific environment beneficial to reducing the
chance of fire in the contents of the package.
[0036] In this regard, the embodiments of the subject bulk bag
apparatus in accordance with the present application provide many
benefits. These include, without limitation, at least the benefits
of the prevention of sparks during use of the bulk bag apparatus,
an inert atmosphere inside the package air tight barrier to keep
oxygen out through a removal of oxygen from the bag during the
product filling process in combination with a nitrogen flush, and
the prevention of ignition by friction (FIGS. 7 and 8) renders the
atmosphere inside the package inert owing to a technique of vacuum
sealing immobilization through vacuum compression, which holds the
product within the bag in a tight pack.
[0037] In an embodiment, the subject composite bulk storage and
transport apparatus 100 apparatus includes a FIBC device 110 and a
container 10. In its preferred form, the FIBC device is a Type "B"
dissipative shell shown in FIGS. 2 and 9, and the container 10 is
preferably an integral proprietary film liner shown in FIGS. 3 and
11 that prevents sparking and potential ignition of its contents.
The integral film liner 10 is shown inserted and sewn into the
shell of the FIBC device 110 in FIG. 4. Any type of outer shell
device may be used, but Type "B" dissipative shells manufactured by
Conitex/SONOCO of Charlotte, N.C. made from woven polypropylene
fibers with a static dissipative additive to help prevent static
sparking are particularly useful and advantageous.
[0038] The proprietary film liner 10 shown in FIGS. 3 and 10 also
creates an air tight barrier to keep oxygen out as shown in FIG. 8.
No oxygen results in less chance of fire or explosion. In
accordance with the of example embodiment, the container comprises
a multilayered composite film combination forming a bag defining a
product fill opening. The multilayered composite film combination
comprises a first polymer film having vacuum holding properties, a
second polymer film having vacuum holding properties, and a third
polymer film disposed between the first and second polymer films.
The first polymer film acts as an inner layer of the container, and
the second polymer film acts as an outer layer of the container.
Preferably, the third polymer film is impervious to a flow of
selected gasses such as for example oxygen and/or nitrogen.
[0039] As best shown in the cross-sectional view of FIG. 3A, the
film liner in accordance with a first embodiment is 3 mil
ldpe/eva/ldpe with a static dissipative additive added, to help
prevent static sparking, and with two layers of ldpe instead of a
single layer to provide a thicker, stronger, airtight vacuum seal.
The provision of two separate layers of low melt temperature ldpe
is unique to this bulk package design. Normal industry practice
uses a single layer of ldpe or other low melt temperature sealing
film; however, the need for absolutely air tight seals in the
subject bulk sack necessitates the provision of twice the sealing
material as standard industry practice. Also, standard industry
seals on a bulk package liner are 1/4'' wide. The subject bulk
package utilizes 3/8'' seals, to provide more strength and better
vapor barrier properties to the package. The specification and use
herein of the food grade EVA (ethylene vinyl acetate) barrier film
layer resulted from extensive testing and produces a layer with
outstanding barrier values to both O.sub.2 and H.sub.2O transfer.
This specific film liner structure, comprised of a double sealing
layer of ldpe, a static dissipative additive, and the unusual
provision of a superior EVA film vapor barrier, combined with the
Type B static dissipative shell, is unique to bulk package
construction at the current time.
[0040] Specifically in the example embodiment, the first and second
polymer films comprise low density polyethylene (LDPE) films, and
the third polymer film comprises an ethylene-vinyl acetate (EVA)
film. The first and second LDPE films provide an airtight vacuum
seal, and the EVA film is impervious to a flow of oxygen
therethrough. The EVA film is impervious to a flow of nitrogen
therethrough.
[0041] The ldpe/eva/ldpe film liner is preferably a tri-lamination
formed by a method of direct co-extrusion, a process in which hot
melted layers of different polymer films are extruded together to
form a single unit film structure with superior adhesion properties
between the layers, to prevent de-lamination. As shown in FIG. 3A
the layers are in intimate contact with each other. The
multilayered composite film combination is a co-extrusion of the
LDPE and EVA films arranged as illustrated. The LDPE and EVA films
are in intimate contact with each other, and are preferably fused
together as a single unitary film structure using for example the
co-extrusion process.
[0042] The specification of the food grade EVA barrier film layer
resulted from extensive testing and produces a layer with
outstanding barrier values to both O.sub.2 and H.sub.2O transfer.
The overall film structure of the subject bag is preferably
airtight, but at the same time, the subject bulk sack design is
preferably able to withstand the forces inherent to a 1,500 lb.
bulk sack. This is a unique requirement for a MAP package at the
present time. Most flexible MAP packages are designed for the food
industry and are, therefore, tiny, wherein much smaller packages,
from 1 oz. to 1 lb. are common. The strength of the typical MAP
film structure can therefore be much less. This specific film liner
structure, combined with the Type B static dissipative shell, is
unique to bulk package construction of the embodiments herein.
[0043] An alternate embodiment multilayered composite film
combination is shown in FIG. 3B. The composite film structure is
formed by adhesively laminating the three layers of polymer films
(LDPE and EVA) into a composite structure, with a layer of adhesive
(ADH) between each layer to hold the laminate together. The
multilayered composite film combination comprises a first polymer
film having vacuum holding properties, a second polymer film having
vacuum holding properties, and a third polymer film disposed
between the first and second polymer films. The first polymer film
acts as an inner layer of the container, and the second polymer
film acts as an outer layer of the container. Preferably, the third
polymer film is impervious to a flow of selected gasses such as for
example oxygen and/or nitrogen. As best shown in the
cross-sectional view of FIG. 3B, the film liner is 3 mil
ldpe/adh/eva/adh/ldpe with a static dissipative additive added, to
help prevent static sparking, and with two layers of ldpe instead
of a single layer to provide a thicker, stronger, airtight vacuum
seal. The provision of two separate layers of low melt temperature
ldpe is unique to this bulk package design. Normal industry
practice uses a single layer of ldpe or other low melt temperature
sealing film; however, the need for absolutely air tight seals in
the subject bulk sack necessitates the provision of twice the
sealing material as standard industry practice. Also, standard
industry seals on a bulk package liner are 1/4'' wide. The subject
bulk package utilizes 3/8'' seals, to provide more strength and
better vapor barrier properties to the package. The specification
and use herein of the food grade EVA (ethylene vinyl acetate)
barrier film layer resulted from extensive testing and produces a
layer with outstanding barrier values to both O.sub.2 and H.sub.2O
transfer. This specific film liner structure, comprised of a double
sealing layer of ldpe, a static dissipative additive, and the
unusual provision of a superior EVA film vapor barrier, combined
with the Type B static dissipative shell, is unique to bulk package
construction at the current time.
[0044] Specifically in the example embodiment, the first and second
polymer films comprise low density polyethylene (LDPE) films, and
the third polymer film comprises an ethylene-vinyl acetate (EVA)
film. The first and second LDPE films provide an airtight vacuum
seal, and the EVA film is impervious to a flow of oxygen
therethrough. The EVA film is impervious to a flow of nitrogen
therethrough. The ADH layers bind the LDPE layers with the EVA
layer.
[0045] The specification of the food grade EVA barrier film layer
resulted from extensive testing and produces a layer with
outstanding barrier values to both O.sub.2 and H.sub.2O transfer.
The overall film structure of the subject bag is preferably
airtight, but at the same time, the subject bulk sack design is
preferably able to withstand the forces inherent to a 1,500 lb.
bulk sack. This is a unique requirement for a MAP package at the
present time. Most flexible MAP packages are designed for the food
industry and are, therefore, tiny, wherein much smaller packages,
from 1 oz. to 1 lb. are common. The strength of the typical MAP
film structure can therefore be much less. This specific film liner
structure, combined with the Type B static dissipative shell, is
unique to bulk package construction of the embodiments herein.
[0046] A still further alternative embodiment is to substitute the
EVA film layer with nylon film, to provide H.sub.2O and O.sub.2
barrier properties. In any case, the preferred embodiment at the
time of this application is to co-extrude the alternating
LDPE/EVA/LDPE film structures, and the alternate embodiment is to
adhesive laminate the film structure using an adhesive resulting in
an overall LDPE/ADH/EVA/ADH/LDPE film structure.
[0047] While keeping oxygen out is important, removing oxygen as
illustrated in FIGS. 5 and 6 from the bag during the filling
process is also very important. Through a dual approach of nitrogen
flush as illustrated in FIGS. 7 and 8 and by vacuum sealing, which
removes and also displaces oxygen inside the bag, the oxygen
content is reduced, preferably to just 1%. Importantly, the
innovative N.sub.2 purge renders the atmosphere inside the package
inert.
[0048] Also, the torrefied particles are immobilized through vacuum
compression, which prevents ignition by friction. It has been
suggested that shaking and vibrating of the material particles
inside regular Type A woven polypropylene supersacks and not
immobilized through the novel and unique vacuum compression method,
system and structures in accordance with the embodiments, herein
could produce static sparking, or heat from friction caused by the
particles rubbing against each other, or against the walls of the
bulk bag. Both sparking and friction hot spots in prior systems are
possible sources of ignition to the highly flammable torrefied
biomass. In accordance with the embodiments herein, however,
compressing the particles immobilizes them, which prevents the
particles from rubbing against each other, or against the wall of
the bulk sack, thereby preventing the generation of a static
discharge or heat from friction.
[0049] To best help facilitate providing the inert atmosphere
within the subject bag as well as to help provide for the
immobilization of the product within the bag, the container 10 of
the example embodiment further includes a fill spout operatively
coupled with the bag at an opening thereof, and a flexible bladder
member carried on the fill spout adjacent to the second opening.
The fill spout has a generally cylindrical conformation defining a
first opening in fluid tight connection with the product fill
opening of the bag, and a second opening configured to receive the
associated filled product into the bag through the fill spout and
the product fill opening. In addition, the flexible bladder member
is configured to be selectively inflatable for selectively coupling
the fill spout with an associated fill tube communicating the
associated product. The bladder member is operative to couple the
fill spout with the associated fill tube when the bladder is in an
inflated condition and to decouple and release the fill spout from
the associated fill tube when the bladder member is in a deflated
condition
[0050] The unique structure of the subject bulk bag apparatus
simultaneously: substantially eliminates static sparking, removes
oxygen from inside the sack, replaces it with inert nitrogen, and
compresses the contents to prevent ignition by friction. No other
known bulk sack offers this degree of protection.
[0051] In accordance with an embodiment, in a bag filling process
as best shown in FIG. 11, the subject bulk bag apparatus is placed
into an associated form that can have, for example, a box shape,
and can, for example, be made of metal, plastic, wood or any other
material. This allows the bags to fill to a uniform shape to
minimize damage during handling, permit stacking, and to provide a
visual cue that the contents are under vacuum. It is to be
appreciated that the subject bulk bag apparatus in accordance with
the example embodiment comprises a fill spout which is fitted with
a rubber bladder. The fill spout is selectively inflatable with
compressed air to draw the neck tight around a fill tube of the
associated filling system, to eliminate combustible dust or
contaminants from being released during filling. After a vacuum is
drawn on the bag contents, the sack is removed from the form, but
retains the shape and dimensions of the form, because of the
vacuum. Also, preferably during the filling process, the subject
bulk bag apparatus is placed on or in an associated compaction
table of an associated filling system, wherein the associated
compaction table vibrates to settle and help compress the incoming
material and also move the oxygen out (FIGS. 7 and 8).
[0052] More particularly, the method 150 method of packing a
container with an associated product, the method comprises an
initial step 152 of coupling a fill spout of the container with a
fill tube of an associated filling apparatus. It is to be
appreciated that the bag is provided with a 3/16'' to 1/4'' melt
seal 90 at a discharge spout thereof, and that the melt seal 90 is
indeed sealed before coupling the fill spout of the container with
a fill tube of an associated filling apparatus. In any case, the
associated product is flowed at step 153 into the inner cavity
through the fill spout of the container. Next, at step 154 oxygen
(O.sub.2) is drawn from an inner cavity of the container. Nitrogen
(N.sub.2) is added at step 155 into the inner cavity through the
fill spout of the container to purge the bag of any remaining
oxygen. A negative pressure is drawn at step 156 within the inner
cavity relative to areas outside of the container. Lastly, the fill
spout of the container is sealed at step 157 while the bag is under
negative pressure.
[0053] Preferably, the drawing the negative pressure immobilizes
the associated product within the inner cavity by inward pressure
of a wall of the container on the associated product. The drawing
of the negative pressure beneficially immobilizes the associated
product within the inner cavity by inward pressure of a wall of the
container on the associated product. This helps to ensure that no
movement between the product pieces occurs due to product settling
and during handing of the bag such as during transport or the like.
Also preferably, the sealing comprises sealing the fill spout of
the container while the inner chamber is under a negative pressure
relative to the areas outside of the container. In that way, vacuum
sealing immobilization through vacuum compression holds the product
within the bag in a tight pack thereby minimizing the chance of
relative movement between the product pieces and therefore also
minimizing the chance for friction buildup between the product
pieces during handling and/or transport of the subject bulk
bag.
[0054] In a preferred embodiment, as the filling progresses, in a
vacuum process stage, the sealer measures the air pressure content
and once the desired PSI is achieved, preferably about 20'' Hg or,
equivalently, about 12 PSI, the vacuum portion of the associated
filling system automatically turns off. A vacuum of about 10 PSI
would work very well also. This vacuuming process takes
approximately 4 minutes. The fill and discharge spouts of the
associated filling system are designed to allow re-use and
re-filling of the subject bulk bag apparatus in accordance with the
example embodiment, resulting in greater cost efficiency.
[0055] In addition, while, for purposes of simplicity of
explanation, the methodology 150 of FIG. 11 is shown and described
as executing serially, it is to be understood and appreciated that
the example embodiment is not limited by the illustrated order, as
some aspects could occur in different orders and/or concurrently
with other aspects from that shown and described herein. Moreover,
not all illustrated features may be required to implement a
methodology in accordance with an aspect the example embodiment.
Example methodologies described herein are suitably adapted to be
implemented in any system, devices, hardware, or a combination
thereof.
[0056] In a further embodiment, the diameter of a bottom spout of
the subject bulk bag apparatus is increased from industry standard
diameter of 15,'' to a 20'' diameter to help prevent bridging and
rat-holing of the material contained within the bag, and to help
achieve free flow during discharge.
[0057] In one embodiment, the subject bulk bag apparatus in
accordance with the example embodiment has a 51 cubic foot
capacity. However, it is to be appreciated that the embodiments are
not limited to this size or to any other size, and may take on any
dimensions as may be necessary or desired. The subject bulk sack
dimensions are determined by the bulk density of the given
torrefied material (biochar, biocoal, plastic fillers, sorbents,
etc.). Therefore, subject bag size will vary to accommodate the
most efficient configuration for the subject material bulk density.
The objective in custom sizing the subject bulk sacks by the
material contents bulk density is to permit more efficient double
stacking of the sacks into a transport container. Stacking the
subject sacks into two layers, instead of one layer inside a
shipping container maximizes the weight per shipment of the
products, by as much as 40% per shipment over a single layer of
larger bulk sacks. The intentional smaller size and compressed,
preformed cube shape of each subject sack permits easier stacking
and improved handling characteristics, with less chance of damage
to the sack, because the subject sack conforms precisely with the
outside dimensions of the associated pallets and does not overhang.
The most common damage to bulk sacks occurs when forklift operators
puncture the bulk sack at a point where the filled bag overhangs
the pallet. The second most common damage to filled bulk sacks
occurs when the same bag overhang snags against a protuberance
inside the shipping container when loading the sacks by forklift.
The preformed cube shape of the subject bag does not overhang the
pallet dimensions, so the chance of damage during handling is much
reduced. The ability to make the subject bag conform to a
pre-formed shape is unique to the industry, and no other bulk sack
offers this solution.
[0058] In the embodiments herein, preferably, the liner of FIGS. 3
and 10 is located into and then sewn into the Type B dissipative
shell (FIGS. 2 and 9) as shown in FIG. 4. Production bulk bag
apparatus include dissipative shells that are form-fitted to the
liner to present a clean, cube like appearance. The cube shape
makes it less liable to damage during handling and facilitates
stacking.
[0059] The embodiments herein combine a vacuum sealing process,
static dissipative materials, vacuum compression, unusually strong,
airtight construction, N.sub.2 purge, with large bulk sacks having
liners to provide a unique bulk packaging solution for the emerging
torrefaction industry. In this regard, primarily though not
necessarily exclusively for purposes of scaling the packaging to a
1500 lb highly functional supersack, for example, the subject FIBC
package is specifically designed to help reduce the chance of fire
or explosion with torrefied materials or biochar, by removing one
or more legs of the Fire (Combustion) Triangle or Explosion
Pentagon. The subject bulk package helps to remove heat (ignition
sources) and oxygen, which comprise two of the legs of the
combustion triangle. Fire cannot occur unless all three legs are
present. If one or more legs are removed, then fire is impossible.
Potential sources of heat like friction or static sparking are also
limited in the design of the embodiments herein. Likewise with the
explosion pentagon; by removing one or more legs of the pentagon,
namely, oxygen and heat, an explosion cannot occur. The subject
bulk sack is designed to help eliminate two required conditions for
a fire or explosion to occur--oxygen and heat.
[0060] It is to be appreciated that the embodiments of the liner
shown in FIG. 2 and of the dissipative shell shown in FIG. 3 are
for purposes of illustrating the novel concepts of the subject bulk
bag apparatus and for explanation thereof. It is to be further
appreciated that the embodiments of the liner shown in FIG. 9 and
of the dissipative shell shown in FIG. 10 are preferred commercial
embodiments having the proportions and properties as specified in
FIGS. 10 and 12, respectively.
[0061] Some features of the bulk bag apparatus described herein
include, but are not necessarily limited to: Type B static
Dissipative Shell helps reduce static charge build up and prevent
sparking; proprietary ldpe/adh/eva/adh/ldpe film structure with
static dissipative additive also helps to eliminate static sparking
events; and the airtight, watertight, high barrier properties of
the proprietary film liner structure prevents oxygen from
transferring through the package walls, keeping oxygen away from
the contents during transport and storage.
[0062] Vacuum sealing removes oxygen from inside the subject bulk
sack to prevent contents from igniting. The N.sub.2 purge displaces
residual oxygen inside the subject bulk sack to prevent contents
from igniting, and surrounds the contents with inert gas. Vacuum
compresses and immobilizes the particles for shipment, and prevents
friction hot spots as a source of ignition. The cubed form of the
bag apparatus reduces chance of damage from handling (the cube does
not overhang the pallet). The discharge spout diameter has been
increased from the industry standard 15'' to 20'' diameter,
depending on the flow characteristics of the torrefied material to
be packaged. The increased spout diameter increases the angle of
repose of the packed material, reduces bridging and rat holing
during discharge, and facilitates free flow of the material out of
the subject bulk package.
[0063] All seals in the subject package have been increased from
industry standard 1/4'' width to 3/8'' width to provide sufficient
strength and reduce the chance of seam leakage.
[0064] Example embodiments of the subject bulk bag apparatus for
safe storage and transport of torrefied materials provide a unique
innovative vacuum packaging with N.sub.2 purge to prevent fire of
torrefied biomass. This is an emerging industry with new and unique
safety concerns, which require novel solutions such as are provided
by the embodiments of the subject bulk bag apparatus.
[0065] Described above are example embodiments. It is, of course,
not possible to describe every conceivable combination of
components or methodologies, but one of ordinary skill in the art
will recognize that many further combinations and permutations of
the example embodiments are possible. Accordingly, this application
is intended to embrace all such alterations, modifications and
variations that fall within the spirit and scope of the appended
claims interpreted in accordance with the breadth to which they are
fairly, legally and equitably entitled.
* * * * *